74 MANUFACTURE


payback period and net present value (NPV) for the investment using straightforward financial modeling. A high-throughput rapid microbial screening


system for a mid-size personal care product manufacturing site can be purchased and installed for approximately $50,000 in capital expenditure, achieve payback in six to nine months, and realize an average five-year NPV in excess of $500,000. For larger manufacturing sites, the


investment may be closer to $100,000 but the NPV can reach well into the millions of dollars. These numbers are based on averages generated using a financial impact assessment developed by a global consumer products company in conjunction with a global management consultancy. This assessment is specifically designed


to evaluate the implementation of a rapid microbial screening system using specific manufacturing and testing data such as cost of capital and the value of average daily output of finished goods and current testing protocols. Proven accurate over years of use by many different companies, the analysis is routinely used to support capital equipment purchase requests.


Avoiding speed bumps Some rapid methods are perceived to have poor compatibility with personal care products, requiring labs to invest in several instruments or execute several methods. Choosing a rapid method requires the need to consider the range of raw materials, product bulk, and finished goods that can be tested with the selected system. The full economic benefits of rapid microbial


detection methods cannot be maximized if the method cannot be applied to the majority of a company’s products. The best rapid microbial detection methods


for your company should be able to test a wide range of product matrices commonly seen across the industry. Personal care products have a variety of viscosities, particulates, etc. – some of which cannot be filtered and cannot be tested on some platforms. A rapid microbial method with flexible


sample preparation can be used across your product lines and a variety of preservative systems, pH levels, etc. When switching to a rapid method, companies should not compromise the flexibility they have with traditional methods to make standard product accommodations. Additionally, the detection system itself


should not be subject to interference by particulate matter or product colour. A good system allows your company to assess the majority, if not all, of its products. Your company will benefit from using a standardized platform and maximize financial benefits through a broader application of rapid methods. Personal care product companies have


a diverse portfolio of products that include not only a variety of aesthetics but can also be classified as over the counter (OTC) drug products. When looking to change to a rapid microbial method, it is important to choose a system that has been used with OTCs and have


PERSONAL CARE June 2023


a history of accepted validation by regulators around the world. It is not just the method that matters, but the


vendor as well. Your choice of a rapid method vendor should include an assessment of the support capabilities that they can offer you and your team.


The best and most seamless transition to


implementing rapid methods requires vendors who are partners from pre-qualification proof- of-concept testing prior to purchase, to system implementation, training, change control/ preventative maintenance, reliable technical support, and steady supply of consumables/ reagents.


Making the switch Take a close look at your current product release method to see if there is any time due to micro holds that can be reduced. Those who do not understand the value a rapid system can bring to your company may be reluctant to take the lead on internal, multi-department conversations. Begin a conversation with your quality team to uncover a financial opportunity hidden by asking these questions.


What is the primary method we use for microbial testing? Traditional methods may be referred to as compendial or pour plating methods. If you are using traditional methods, find out how many nonvalue-adding waiting days are in your production cycle.


How many days do we usually hold our finished products while we wait for microbial testing results? This will vary, usually three to five days for non-sterile products, however a rapid method can give you a result in just 24 hours. You may also have a ‘micro hold’ on raw materials. Each micro hold confirms quality and reduces risk but adds several days to your production cycle. If you use a rapid method, it does not have to be this way.


Have we considered the cost saving that manufacturing would realize if we could shorten our microbial testing time? It will cost the quality department more per test for a rapid microbial detection system, but it will save your company much more in reduced inventory requirements, shortened lead times, and it will free up working capital. The financial benefits must be made clear to


all internal partners and leadership. Compliant, rigorous rapid detection matters to finance and operations; it reduces cycle times by eliminating days of waiting time, resulting in a more streamlined, cost-effective, and responsive manufacturing facility. When you can explain to your quality control


and/or operations leaders how micro testing wait times impact the bottom line, they will come to understand the importance of making the switch to a rapid microbial method is long past due.


The next step in efficiency Even if you are managing an efficient operation, most companies today have room for improvement. When it comes to lean manufacturing, taking days out of the production cycle translates into speed to market and quantifiable savings. Many companies feel as though they have streamlined production as much as possible, but one area that is frequently overlooked is microbiological testing. A rapid method is a proven, contemporary method that gives you actionable information at a critical decision point. Information that enables you to rapidly confirm the quality of your product, a reduction in production cycle times and work in process inventory and increase response time when there is a microbial contamination event. The realizable cost savings and reduction


in production cycle times and working capital requirements may enable your company to pursue more productive endeavors, like funding new projects, developing new products or simply conserving cash. The speed of rapid microbial methods can be game-changing across your company, now and for the future.


PC www.personalcaremagazine.com


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