Material Track & Trace in pharmaceutical research

The project

Laboratory staff should no longer have to search for chemical-biological raw materials and sub-products
RFID-based Track&Trace of substances for the research department
Digitization of the laboratory material cycle (Material Track&Trace)

RFID Lösungen Digitalisierung Lager - RFID Konsortium

The solution

250 research workstations use RFID sample management for efficient and transparent material consumption
Automated booking of research chemicals at the table using RFID antennas
Quick retrieval of already opened (cooled) substances for all research teams

Key Facts – The Goals Achieved

100% transparency across all materials

Material Track & Trace

Digitization of the R & D laboratories

One-fits-all label: removable, permanent, -200 to +80 C°

WIFI First incl.
certificate management

Comprehensive monitoring functions

Project Requirements

360° project: consulting, software, plug & play hardware, one-fits-all label, data transfer to middleware, WIFI First incl.
certificate management, support
Combination of barcode, RFID and weighing system
Avoidance of cross reads at tables of four
Agile project approach
Self-sufficient in-house modification of the laboratory structure possible

Special features:

The proof-of-concept phase in May 2023 was already all about an agile approach: Within just 4 weeks, the hardware, software filters and data transfer were to be successfully simulated in a test lab. After this test, the implementation path was set. The complete Track & Trace project for the planned new building for the research department was realized in just under a year. The installation of the 250 RFID readers was rolled out in just 5 weeks using the WIFI-first approach, i.e. the data is transferred directly to the higher-level system via the WLAN. A certificate management system guarantees the secure authorization of all RFID readers at the access points. As all RFID readers are available preconfigured, the laboratory can be reconfigured for new research projects as required, as there is no need to pull network cables and the RFID antennas are immediately ready for use in plug’n play mode. When the scientists no longer need the lab samples, they can be tracked to the waste area to ensure that they are a) are no longer in the refrigerator and b) have been disposed of properly.
The comprehensive 360° implementation project was realized under great time pressure. This was only possible thanks to agile project management, in which the test, development and production systems were operated in parallel. Even last-minute changes before the go-live were part of the project challenge.

Implementation of key objectives:

1. digitalization of the laboratories for the new R&D department and as part of the Group's overall digitalization strategy.
2. establish material track & trace with RFID.
3. more cost-conscious handling of expensive raw materials.

Each researcher brings their ordered laboratory materials to their workstation, where these items are automatically booked in the WMS. A green light visually confirms that the materials have been recorded. If additional substances are required, an information system tells them whether they are on stock or where they are already in use. Search times, replacement costs and wastage of consumables are significantly reduced.

Head of Research Laboratories about the project

Sample management for medical research and development

With this project, we have realized research laboratory logistics 4.0. Between 500,000 and 1 million RFID labels identify powders, granules, liquids, containers, test tubes and packaging units - everything that is needed for laboratory work in medical research. The scientific staff trigger orders in the central warehouse.
An order picking system supplies the laboratories on the various floors, where they are booked in logistics zones with RFID and made available for collection.
When the employee then takes their order to their workstation, the RFID label is read by an RFID reader located under the desk and transferred to the system.

RF KonSys Modules

RFID Hardware

Only one type of RFID label was used for all items for labeling the laboratory objects to be tracked. The highly functional label is both removable and permanently adhesive and extremely temperature-resistant (-180 C° to +80 C°). Kathrein antennas were used for the automated detection of the RFID labels. At close range, they prevent accidental unwanted read processes from neighboring objects, so-called cross reads, and reliably detect only the objects to be read. Stationary RFID readers with circular antennas (cylindrical radiation) and RFID printers were used.

RF KonSys modules

Monitoring
Track & Trace
Replenishment control
Inventory
Storage
Quality assurance

Monitoring

Track & Trace

Replenishment control

Inventory

Storage

Quality assurance

RFID hardware

Only one type of RFID label was used for all items for labeling the laboratory objects to be tracked.
The highly functional label is both removable and permanently adhesive and extremely temperature-resistant (-180 C° to +80 C°).
Kathrein antennas were used for the automated detection of the RFID labels.
At close range, they prevent accidental unwanted read processes from neighboring objects, so-called cross reads, and reliably detect only the objects to be read.

Stationary RFID readers with circular antennas (cylindrical radiation characteristic)RFID Printer