To prevent device maintenance from becoming a cost trap: a special tool enables laboratory staff to perform manufacturer-independent and digitalized maintenance of their own equipment.

Chromatographic systems contain numerous components that need to be regularly checked and maintained to ensure the precise operation of the devices. (Source: AnaTox GmbH & Co. KG)

Chromatographic systems contain numerous components that must be regularly checked and maintained to ensure the precise operation of the devices. (Source: AnaTox GmbH & Co. KG)

Chromatographic systems contain numerous components that must be regularly checked and maintained to ensure the precise operation of the devices. (Source: AnaTox GmbH & Co. KG)

All parameters are continuously monitored and the recorded results – including all raw data and metadata – are stored in the company's own AIQ database, so they cannot be manipulated through external access. (Source: AnaTox GmbH & Co. KG)

As soon as a user connects to the desired device, the software automatically detects the condition of the chromatograph and lists the necessary maintenance steps. (Source: AnaTox GmbH & Co. KG)

Many laboratory areas across various industries use chromatographic systems for precise substance separation. (Source: AnaTox GmbH & Co. KG)

"With the AIQ tool, laboratories receive a 2-in-1 solution that allows them to perform maintenance and qualification fully automatically, in a legally compliant and user-friendly manner. This makes them less dependent on manufacturers and their technicians regarding maintenance, component care, and testing," reports Detlef Wilhelm, Managing Director of AnaTox GmbH & Co. KG. (Source: AnaTox GmbH & Co. KG)

The regular maintenance of chromatographic systems ensures that the devices operate at peak efficiency and meet the highest standards of substance separation. However, servicing chromatographs often entails significant financial costs for many laboratories, as it is typically performed by the device manufacturers. In addition to scheduling arrangements, a large amount of documentation and data must be exchanged between the user and the manufacturer – resulting in confusing paperwork and organizational efforts. To make maintenance more cost- and time-efficient, AnaTox GmbH & Co. KG has enhanced its proven AIQ tool with a new feature: The qualification software now also enables a standardized maintenance procedure for all system components, which offers clear cost advantages for device upkeep. The software automatically recognizes the system components and lists the corresponding maintenance steps along with related tests. The guided process subsequently minimizes downtime. It clearly documents the condition before and after maintenance and stores this digitally. Laboratories, with the AIQ tool, can independently and manufacturer-agnostically maintain and qualify their chromatographic environment through a single software solution.

Chromatographic systems are essential for many manufacturers of pharmaceutical products in quality control and laboratories in fields such as Life Science and Food. It is therefore crucial that the devices operate as efficiently, economically, and safely as possible. "Regular maintenance is not only essential as preparation for mandatory qualification. It also helps to extend operating times and prevent wear of certain components – downtime is an expensive luxury for laboratories," explains Wilhelm. However, maintenance is often unnecessarily complex, as technicians from the manufacturer are usually sent to the lab for service. This involves a sometimes confusing coordination process, where maintenance lists are handled and exchanged in paper form. Due to their quantity, long-term and clear documentation is difficult to manage. If a component needs to be replaced, the device cannot be used during the process until a technician has performed the swap – again, the lab depends on external specialists. Overall, this results in high costs for maintenance processes, most of which could be avoided.

The AIQ (Automatic Instrument Qualification) tool from AnaTox GmbH & Co. KG offers a solution. It is a user-friendly, intuitive qualification software for chromatographs, now expanded with a manufacturer-independent maintenance function. This allows laboratories to perform maintenance independently, resolve dependencies, facilitate maintenance, and ensure legal compliance. All tests can be carried out by laboratory personnel (even with training provided by AnaTox) – there is no longer a need to commission the device manufacturer.

Software guides users step-by-step through maintenance

As soon as a user connects to the device to be maintained, the software automatically determines the condition of the chromatograph and lists the necessary maintenance steps. These are manufacturer-compliant and meet applicable regulations and guidelines regarding the use of these laboratory devices. Depending on the type and configuration of the equipment, the required functional tests are then performed in modules. This may include leak testing or pump efficiency checks, as well as heating rates of thermostated ovens or detector performance. Users are guided step-by-step through the process, with the AIQ tool automatically handling the actual test execution and evaluation. "The program provides detailed instructions to the user when, for example, a component needs cleaning or replacement. The software automatically records which steps were performed, repeated, or skipped," explains Wilhelm. In the latter cases, the user can add comments explaining why. "The major advantage is that during maintenance, a seamless digital documentation is automatically created, which can be used later for comparison or qualification preparation," Wilhelm adds.

An additional benefit of the maintenance tool comes from tracking or reading out the wear counters of the chromatographs. "This data helps the customer understand how often the devices are used and how heavily certain components are stressed," says Wilhelm. This allows for quick identification of where wear has already occurred. The implemented tests can also be used individually for fault diagnosis. This way, it is possible to order and stock spare parts in a timely and cost-effective manner, enabling quick replacement without long waiting times for a technician. Since the lab has full control over the maintenance process, some costs—such as those incurred when a technician performs device testing and part replacement—can be saved. During AnaTox training sessions, which can also be conducted remotely, users gain an understanding of which maintenance steps and part replacements they can perform themselves.

2-in-1 solution increases the laboratory's independence from the manufacturer

The driver concept of the AIQ tool uses direct control of the connected instrument via network cable for data exchange. All parameters are continuously monitored, and the collected results – including all raw and metadata – are stored in the AIQ database, preventing manipulation by external access. Additionally, the detailed maintenance report includes information about the engineer performing the service and their certification, stored in the AIQ software database, ensuring complete traceability of maintenance activities at all times. The relevant module-specific counters are also updated or reset accordingly. This guarantees that subsequent qualification with the AIQ tool can be successfully performed by the user. The reporting contains all relevant information about the system’s condition. "With the AIQ tool, laboratories receive a 2-in-1 solution that allows them to perform both maintenance and qualification fully automatically, legally compliant, and user-friendly. This reduces their dependence on manufacturers and their technicians regarding maintenance, component care, and inspections. Maintenance costs can thus be significantly reduced," Wilhelm concludes.