Laboratory Automation Through Labware LIMS Batch Templates

A nig pharmaceutical and vaccine manufacturer located in south Germany sought to address the burdensome amount of paper-based documentation generated in their quality control (QC) laboratories. Each batch of product samples required detailed logging of devices, eluents, and various other parameters for regulatory compliance. These repetitive tasks produced a massive paper trail each month, often leading to inefficiency, errors, and significant storage challenges.

Challenges Faced

High Volume of Manual Paperwork: Repeatedly documenting items like used devices and reagents across multiple batches created a large administrative burden. Staff spent considerable time preparing and reviewing these paper documents, which could run into tens of thousands of pages.
Risk of Errors and Non-Compliance: Paper-heavy workflows increased the chance of transcription mistakes and missed details, putting the organization at risk during regulatory audits. Any inaccuracies could undermine product quality or raise questions around data integrity.
Inefficient Sample Processing: Handling multiple batches separately meant duplicating effort. Each time a new batch arrived, staff essentially repeated the same tasks and logs, leading to longer turnaround times and potential bottlenecks.
Need for Streamlined Data Management: The laboratory required a uniform platform to handle metadata, track samples, and securely store records while maintaining adherence to regulatory standards. A centralized digital environment was critical for alignment with good manufacturing practices and data integrity requirements.

Zamann Pharma Support’s Approach

Initial Evaluation: Experts from Zamann Pharma Support met with the laboratory team to review existing workflows and identify areas of duplication. This involved mapping out each phase in the QC process—from sample receipt to final reporting—and pinpointing the points where paper forms were being duplicated.
Template Development: A robust set of Labware LIMS Batch Templates was introduced to standardize data entry and handling. These templates were designed to capture all relevant metadata once, including instruments, reagents, and sampling details. This minimized the chance of overlooking key information and greatly reduced manual transcription.
Automation Strategy: By configuring the LIMS platform, the laboratory could group various batches of samples under a single analytical run. Metadata and procedural information were automatically pulled into each test sequence, ensuring consistent documentation. Repetitive tasks, such as documenting equipment usage, were streamlined into a digital format that could be quickly validated and reviewed.
Regulatory Alignment: All configurations adhered to regulatory expectations around data integrity, traceability, and security. Audit trail functionalities were integrated into the LIMS, providing clear visibility into any changes or updates. This approach helped assure regulators that all processes were properly monitored and controlled in a digital environment.
Training and Implementation: Zamann Pharma Support conducted hands-on workshops and practical demonstrations. Laboratory staff received guidance on setting up batches, running the new templates, and verifying output data. Comprehensive user manuals were created for ongoing reference, reducing the learning curve and fostering confidence in the updated workflow.

Results Achieved

Substantial Reduction in Paperwork: The team saved tens of thousands of pages every month by consolidating repetitive documentation requirements into a single digital process. This significantly lowered administrative overhead and freed staff to focus on more strategic tasks.
Enhanced Regulatory Compliance: The automated logs and audit trails built into the LIMS satisfied requirements from regulatory authorities. Data integrity was strengthened, and the new system allowed for quick retrieval of records during inspections or internal audits.
Faster Turnaround Times: Merging multiple batches into a single run removed redundant tasks and shortened the overall testing cycle. Staff could set up and process samples more quickly, delivering results to stakeholders in a timely manner.
Greater Traceability and Data Integrity: The digital environment offered a clear chain of custody for all data points. By centralizing information, the laboratory minimized the risk of transcription errors and maintained consistent, verifiable records.
Improved Resource Utilization: The lab’s new processes reduced the need for manual oversight and manual recordkeeping, enabling the organization to allocate resources more effectively.

Client Testimonial

“Zamann Pharma Support brought us a fresh perspective on how to handle our laboratory documentation. Their approach to setting up Labware LIMS Batch Templates gave us a more efficient workflow. We saw immediate improvements in both productivity and compliance readiness. The drastic reduction in paperwork has been a game-changer, and our team can now concentrate on higher-value activities instead of getting bogged down by repetitive manual tasks.”

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