The Race to Manufacture Ellume’s COVID-19 Rapid Diagnostic Tests

Ellume invested in new manufacturing lines for their facilities in Australia and the U.S.

In an Australian manufacturing success story, Ellume is in the process of automating the high-volume production of its rapid COVID-19 home test using the latest technologies from Bosch and Rockwell Automation. 

The COVID-19 pandemic has rapidly spread to all parts of the globe. There have been more than 395 million cases [1] around the world and this figure continues to rise rapidly. Healthcare systems are overwhelmed and continue to face a multitude of challenges as they work to manage demand while providing high-quality care.

Communities, governments and industry around the world are now recognising the importance of minimising the requirement for widespread lockdowns and travel restrictions, which have been the main line of defence against COVID-19 since the start of the pandemic.

As countries around the world move towards a new post-pandemic normal, rapid diagnostic testing has an integral role in reducing disease burden, managing outbreaks and community transmission, and reducing pressure on healthcare systems.

Ellume, a Brisbane-based digital diagnostic company, has recently developed a rapid COVID-19 home test which detects the SARS-CoV-2 antigen and complies with Centers for Disease Control and Prevention (CDC) reporting requirements. Accurate results are provided within 15 minutes, providing users with quick results, and helping communities to return to a ‘new normal.’ With a growing list of orders, predominantly from the United States, ensuring supply was a key priority for Ellume.

The project utilised more than 160 robots, 200-plus visions systems and more than 60 PLCs

Scaling up production

To meet the consumer demand for COVID-19 home tests, Ellume has invested in new manufacturing lines for their facilities in both Australia and the U.S.

“COVID-19 isn’t going away anytime soon and as communities and economies continue to open up there will be increased need for rapid antigen tests which is why automating our production is vital to meet a surge in consumer demand,” said Sean Parsons, founder and CEO, Ellume.

Ellume called on Bosch Australia Manufacturing Solutions (BAMS), a leading supplier of factory automation for the medical device industry, to automate the high-volume production of its COVID-19 diagnostic tests. This involves 27 new production lines in total – three new lines for Ellume’s facility in Brisbane, Australia and 24 production lines for their facility in Maryland, U.S.

“We are providing Ellume with 18 fully automated assembly lines for manufacturing the home COVID-19 analyser unit. This also includes an end-of-line test system which communicates to the analyser unit over Bluetooth and completes a functional check to ensure the quality of the part,” said Bradley Trewin, Programme Manager, BAMS.

“BAMS is also manufacturing nine lines for the production of the ‘dropper’ which will fully automate the assembly and packing of this product,” he added.

Once complete, the production capacity will be nine parts per second

Next generation technologies

The Bosch manufacturing experience and factory automation know-how has benefited this project immensely. The production lines are being manufactured at Bosch’s headquarters in Clayton, Victoria. More than 160 robots are being utilised on this project, there are also 200-plus vision systems which are cameras that inspect and evaluate the line, and more than 60 programmable logic controllers (PLCs). 

“We are delighted to bring the BAMS automation expertise to support Australian med-tech manufacturing for a global market – a real positive for local manufacturing, and a positive for the testing and medical diagnosis of COVID-19,” said Gavin Smith, President of Bosch Australia.

Ellume’s rapid COVID-19 home test provides accurate results within 15 minutes

An Australian manufacturing success story

Ellume’s technology addresses the unprecedented global demand for accurate and rapid diagnostics as accessible, reliable, and fast diagnostics become increasingly critical to the COVID-19 response.

Given the widespread supply shortages resulting from the pandemic, Rockwell Automation has prioritised their global supply chain to applications and machines that can help in the fight against COVID-19. “Our priority is to support local manufacturing, helping to ensure that we are able to provide much needed assistance to those requiring it urgently,” said Anthony Wong, regional director, Rockwell Automation. 

“By working with local innovative companies such as BAMS and Ellume, we can deliver next generation technologies to help mitigate the risks of COVID-19 while also strengthening the Australian manufacturing industry,” he said.

The new Ellume manufacturing facility will be one of the largest of its kind in the Southern Hemisphere. The production lines for Ellume’s Brisbane facility are undergoing final testing and likely to be operational by the end of February, whilst the first U.S. lines departed in November 2021.  The final lines for the US are expected to be installed and operational in mid-2022. Once complete, the production capacity across the whole Ellume project will be nine parts per second.

“We’ve spent the last decade perfecting our technology, and now, in the midst of the COVID-19 pandemic, the role of rapid, accurate diagnostics has never been more important. Ellume is pleased to be working with Bosch to bring their world-leading automation know-how to our manufacturing process. This will allow Ellume to manufacture best-in-class diagnostics that can be relied on in a health crisis,” said Dr Parsons.”