How Automated Sampling Helps Dairy Labs Manage Staffing Pressure

Reduce hands-on sample preparation during busy shifts

Dairy processors are facing a structural labor challenge. According to Food Industry Executive, companies are now being forced to “amplify efficiency to do more with less.”¹ 

When a production run generates more samples than the dairy quality control (QC) team can prepare as they arrive, the queue can build quickly. Automated sampling can take repetitive transfers off the bench and help technicians manage peak workloads.

For compatible finished products, the Innovate™ Autosampler III automates sample transfer and microplate preparation. Reducing hands-on work at this stage can give technicians more time to review results, investigate unexpected findings and support release decisions.

Where Staffing Pressure Shows Up in Dairy Labs

Staffing pressure can become most apparent on a peak production day, when the lab needs to prepare more samples while keeping routine checks and investigations on schedule. This matters in facilities that handle high volumes of packaged dairy products, including ultra-high-temperature (UHT) and extended shelf life (ESL) products.

Repetitive preparation steps such as pipetting and plate setup add up across batches. If preparation takes longer than the time technicians have available, samples can queue before analysis and other quality control work can be pushed back.

Start by looking at where the team spends its time during a typical shift and a peak shift. That comparison helps show whether sample preparation is the step limiting laboratory capacity.

The Operational Cost of Staffing Gaps in Dairy QC

In a dairy quality control lab, staffing gaps can affect several parts of the operation.

• Time-to-result and release cycles
• Consistency across shifts
• Training burden for new technicians
• Overtime costs and burnout risk
• Audit readiness and documentation control

In high-throughput dairy labs, even incremental delays in microbial testing can compound across production runs.

When queues form regularly, track how long samples wait for preparation and how often technicians need overtime to clear the backlog. Those two measures can help show how staffing pressure affects the laboratory’s day-to-day workload.

How Automated Sampling Reduces Hands-On Workload

For compatible packaged products, samples are incubated according to the site’s testing procedure. The Innovate Autosampler III then transfers liquid from product containers into microplates and prepares the plates for analysis.

The prepared microplates move to the Innovate™ system for microbial ATP screening. Automating preparation can shorten the time samples spend in that part of the workflow. Overall time to result still depends on incubation, laboratory scheduling and analysis.

Automating preparation can help laboratories reduce manual work and handle peak sample volumes. The benefits depend on the setup and the number of samples the team processes.

• Reduce hands-on time spent on repetitive sample transfers.

• Standardize preparation steps across operators and shifts.

• Reduce opportunities for handling errors during manual transfers.

• Free technician time for other quality control work during peak shifts.

More Time for Specialist Work

Reducing repetitive preparation can give microbiologists and technicians more time for work that calls for their expertise.

• Method validation
• Data interpretation
• Root cause analysis
• Continuous improvement initiatives
• Regulatory readiness

If a screening result is unexpected, for example, the team can use that time to review the batch records, check for a pattern and plan the next steps in the investigation.

Consistent Sample Preparation Across Shifts

Running the same sample preparation steps across shifts can make that part of the workflow more consistent when different technicians handle different batches. Measure hands-on time and preparation queues before and after implementation to see how much the change helps.

Product release timing also depends on the required incubation period, how quickly the lab can run and review the analysis, and the site’s release criteria.

Assess the Fit for Your Dairy Lab

Follow a batch from the end of incubation to the start of analysis. Record how long technicians spend preparing it and how long it waits between steps. Use a typical shift and a peak shift to see how those times change with volume.

When comparing options, check the following.

• How many samples does the lab prepare on a typical shift and during peak periods?

• Which products and pack formats need to be supported.

• How much space is available and how samples will move into and out of the system.

• What installation, training and ongoing maintenance will involve.

See How Automation Could Impact Your Dairy Lab

The Innovate Autosampler III is designed for high-volume aseptic packaging and bottling operations. Applied Microbiology International named it its 2022 Product of the Year. Explore how the instrument fits into finished product screening and compare its workflow with your lab’s sample volumes and packaging formats.