Netstal’s ultra-precise manufacturing solutions for research laboratories, pharmaceutical and clinical diagnostic companies

Hospitals, laboratories, and research institutions worldwide depend on Hamilton’s high-quality pipetting products to drive innovation in diagnostics, clinical applications, and life sciences. Since 2018, Hamilton Bonaduz AG has been producing CO-RE® II pipette tips at their advanced facility in Domat/Ems, Switzerland. To meet growing global demand, Hamilton partnered with Netstal, leveraging their precision injection moulding technology for scalable, efficient production. This case study explores how Hamilton has continued providing essential pipette tips during the COVID-19 pandemic and remains prepared to serve these critical industries in the future. 

About Hamilton: Hamilton Bonaduz AG, located in Bonaduz, Switzerland, develops automated pipetting robots for handling a wide variety of liquids. With their sensors, they are an innovation leader in the field of process analytics. Hamilton Storage GmbH, which belongs to Hamilton Bonaduz AG, is a leading provider of automated sample storage systems for research laboratories, pharmaceutical and clinical diagnostic companies and government institutions.

Hamilton’s products are known for advancing the life science, clinical diagnostics, forensics, biotechnology and biopharma industries, offering reliability, performance and flexibility. Hamilton utilises state-of-the-art manufacturing facilities in Reno, Nevada, and Bonaduz, Switzerland, as part of its ongoing commitment to quality and has achieved global ISO 9001 certification. Hamilton is privately held with headquarters in Reno, Nevada, Franklin, Massachusetts, and Bonaduz, Switzerland, and offices around the world. More about Hamilton Bonaduz AG

Challenge 

Hamilton faced the challenge of ensuring the production of highly precise and reliable pipette tips at a large scale to meet growing demands. Their CO-RE® II tips are vital components in life science research, diagnostics, and biotechnology applications, requiring precision in every aspect of their production. With the onset of the COVID-19 pandemic, Hamilton’s production facility in Domat/Ems was confronted with a threefold increase in global demand for consumables due to the surge in PCR testing. 

Ensuring continuous production at high precision, maintaining ISO standards, and scaling up operations became critical. Hamilton needed a partner who could deliver innovative injection moulding solutions and help increase production capacity without compromising on quality. The challenge was intensified by the disrupted global supply chains and the difficulties of procuring specialized equipment on short notice. 

Solution 

To address these challenges, Hamilton turned to Netstal, a trusted partner known for delivering high-performance injection moulding machines. Netstal’s Elion series all-electric machines were pivotal in meeting Hamilton’s stringent requirements. These machines offer the precision needed to produce Hamilton’s CO-RE® II pipette tips, which feature a thin, fine tip designed for the accurate dispensing of micro-volumes. 

The CO-RE® II tips utilise a robust, airtight lock-and-key mechanism to securely attach to independent pipetting channels, ensuring seamless and consistent liquid transfers. With their ability to perform in an ISO Class 8 cleanroom environment, Netstal’s injection moulding machines met Hamilton’s exacting standards, offering reliability, performance, and flexibility in large-scale production. 

Additionally, Netstal’s innovative machine program played a crucial role in enabling Hamilton to increase capacity at short notice. When global supply chains were under strain, Netstal quickly provided a used rental machine to bridge the delivery of a newly ordered unit. This allowed Hamilton to continue production without delays, eventually adding more machines to both their Swiss facility and their U.S. operations. 

Implementation 

The implementation process at Hamilton’s Domat/Ems facility was a showcase of seamless collaboration and technological excellence. The production of the CO-RE® II pipette tips was automated from the provision of raw materials to packaging and storage. Netstal’s all-electric Elion series machines were positioned directly behind the building’s striking glass façade, symbolising the high-tech nature of Hamilton’s operations. 

The pipette tips are produced and monitored in real-time for concentricity and the absence of burrs, ensuring flawless performance. The tips are further processed in Hamilton’s centrally located cleanroom and packaged into 96-well trays, sealed in blister racks, and coded for traceability. Hamilton’s fully automated packaging system ensures that the product is safely prepared for distribution while maintaining the strictest quality control standards. 

When demand for pipette tips surged in 2020, Hamilton tripled their production capacity by doubling their injection moulding lines and personnel. The new Netstal machines, in conjunction with the used rental unit, enabled Hamilton to run production 24/7 in four shifts, ensuring uninterrupted operations throughout the pandemic. As demand began to stabilise, the facility was able to reduce operations to weekday production, while maintaining the capacity to quickly scale up if needed. 

Results 

By partnering with Netstal, Hamilton was able to meet the surge in global demand for pipette tips during a critical time. The precision of the Netstal machines allowed Hamilton to produce high-quality tips at an increased capacity while adhering to the strictest ISO standards. The seamless integration of Netstal’s injection moulding technology into Hamilton’s automated processes ensured not only efficiency but also the safety and reliability of each pipette tip produced. 

The partnership between Hamilton and Netstal stands as a testament to the power of collaboration and innovation in meeting market demands without sacrificing quality. 

Do you manufacture specialised components for the medical diagnostics or pharmaceutical industry? 

Contact our injection moulding and Netstal experts to learn how we can provide advanced solutions tailored to your production needs, ensuring precision, efficiency, and scalability for your business.