Sensors at Work: Accelerating Accuracy and Speed in Lab Testing

Laboratory automation is transforming the landscape of scientific research, pharmaceutical development, and clinical diagnostics. Central to this shift is the use of sensors that convert physical or chemical properties into electrical signals. These sensors provide real-time feedback, enhance process reliability, and enable autonomous operation of complex workflows.

I recently experienced the benefits of this firsthand during a routine blood test – a complete blood count (CBC) with differential. In just one microliter of my blood, which is about the size of a pinhead, there were 4.83 million red blood cells and 6,700 white blood cells – all within normal range, I’m happy to report.

In the past (and still in some smaller labs or with older protocols), this type of test was performed manually. A drop of blood would be placed on a special microscope slide called a hemocytometer, which has finely etched grids measuring 0.1mm square each. A lab technician would count the cells one by one under a microscope. They’d then multiply that count by 10,000 to estimate the total number of cells. So, in my case, the technician would have counted 483 cells in that tiny square. But my test was performed by an automated hematology analyzer based on the Coulter Principle, which detects and counts each cell at a rate of 10,000 cells/second. Thanks to this automation, my test results were ready in just two days.

It’s often said that 70% of medical decisions are based on laboratory test results – a statistic that underscores the crucial role clinical labs play in helping doctors make informed choices. As demand grows for faster results, higher testing volumes, and fewer human errors, lab equipment manufacturers are turning to sensors to drive innovation.

The growing need for automation in laboratories

Facing the pressure to deliver fast, accurate results requires that clinical labs follow detailed protocols involving multiple steps, such as microplate handling, accurately measuring and moving fluids, and recording data. Lab automation equipment helps meet these challenges and streamlines all the workflows into one device. Within this automated setup, sensors serve as the system’s eyes and ears, enabling precise, real-time control and monitoring.

The integration of sensors into lab automation platforms brings multiple advantages:

• Real-time quality control. Sensors continuously monitor test conditions, ensuring that reagents stay within valid temperature ranges, sample volumes are accurate, and there are no clogs or leaks in the fluidic systems. This greatly reduces invalid results and saves critical time.

• Improved throughput. With real-time sensor feedback, systems can quickly detect and address issues such as misplaced samples or reagent depletion, thereby minimizing downtime. This helps laboratories meet tight deadlines and deliver results faster.

• Reduced human error. Automating tasks like barcode scanning, sample loading, and fluid handling eliminates many of the human errors and contamination that can occur during manual operations. This leads to more reliable diagnostic outcomes.

• Traceability and compliance. Sensors create detailed logs of temperature, pressure, and other operational parameters. These logs are vital for regulatory compliance (e.g., CLIA, CAP, ISO 15189) and help in audit trails and root cause analysis.

With 70% of medical decisions based on lab reports, the ripple effects of delayed or erroneous results can be significant. Sensor-enabled automation helps labs deliver high-quality, timely results, which directly translates to faster diagnosis and treatment initiation, reduced hospital stays and healthcare costs, and improved patient outcomes and satisfaction. 

Despite the many advantages, incorporating sensors has some challenges. These include integration with legacy systems, sensor drift and the need for periodic recalibration, and managing the large volumes of data sensors produce. However, advances in smart sensors, IoT integration, and AI-enhanced automation are addressing these hurdles. Future labs may feature self-calibrating sensors, predictive maintenance algorithms, and fully interconnected diagnostic ecosystems.

Sensors power precision in lab automation

Sensors are more than just components. They are the enablers of the precision, reliability, and speed that newer lab automation equipment promises. Lab equipment manufacturers rely on sensor suppliers who can meet their stringent specifications, offer global support, and can demonstrate many years of field-tested use. 

As lab diagnostics continues to evolve, sensors will remain a core technology driving the transformation of medical laboratories into high-performance, patient-centric diagnostic powerhouses.