Tissue Processor Robotic Handling for Independent Histological Processing
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Solution Overview
Problem
Existing tissue processors process multiple specimens in batches, leading to compromises in processing speed and quality, inability to prioritize urgent specimens, and unnecessary delays due to first-in-first-out queuing, which is economically unprofitable and hazardous due to the need for formalin-filled buffer containers.
Innovation Solution
A tissue processor with a robotic arm and control unit that allows independent processing of each tissue carrier, enabling tailored protocols and prioritization, eliminating the need for batch processing and reducing exposure to hazardous formalin through automated handling and processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If tissue specimens are processed in batches using traditional tissue processors, then multiple specimens can be processed simultaneously, but processing speed and quality are compromised due to first-in-first-out queuing and inability to prioritize urgent specimens
Solution Approach 1:
The batch processing system is segmented into individual processing channels, each capable of handling tissue carriers independently. The control unit divides the batch into multiple groups and assigns them to different containers/retorts, allowing parallel processing without FIFO queuing constraints. This segmentation enables urgent specimens to be prioritized in specific channels while maintaining overall high throughput.
Solution Approach 2:
The system dynamically adjusts processing parameters and container assignments based on specimen priority and processing requirements. The control unit can modify processing times, temperatures, and reagent volumes for different tissue carriers within the same batch, enabling optimized processing for urgent specimens while maintaining efficiency for routine cases.
2Productivity
If tissue specimens are processed in batches, then multiple specimens can be handled together, but the system cannot apply specific processes for each individual tissue carrier or specimen
Solution Approach 1:
The batch is segmented into multiple groups that can be assigned to different containers with different processing protocols. Each tissue carrier can be individually identified (e.g., via barcode) and assigned to a specific processing sequence, allowing customized processes for different specimen types, sizes, and urgencies while maintaining batch processing efficiency.
Solution Approach 2:
The tissue processor is designed with multiple retorts/containers that can each perform different histological processes (fixation, dehydration, clearing, impregnation, embedding). The control unit can configure any container for any process type, making the system universally adaptable to different processing requirements while maintaining batch processing capability.
3Adaptability or versatility
If continuous flow tissue processor is used with single-tissue batches, then specific processes can be applied to each specimen, but the number of tissues processed is limited to about 10-15 per two to three hours
Solution Approach 1:
The system merges the advantages of single-specimen customization with batch processing by combining multiple tissue carriers in the same container/retort for identical processing. The control unit coordinates processing across multiple containers simultaneously, achieving both individualized protocol application and high throughput (hundreds of specimens per batch) that continuous flow processors cannot match.
4Loss of time
If batch processing is used with formalin-filled buffer containers, then tissue specimens can be held before processing, but operator exposure to hazardous formalin increases
Solution Approach 1:
The system extracts the need for formalin-filled buffer containers by implementing a pull-based processing system. Tissue carriers are processed immediately upon availability through coordinated container scheduling, eliminating the push-based approach that requires holding specimens in formalin buffers. This removes the source of formalin vapor exposure while maintaining workflow efficiency.
Solution Approach 2:
The control unit acts as an intelligent intermediary that coordinates between specimen availability and processing container readiness. It schedules processing sequences to eliminate idle time and buffer requirements, using real-time monitoring and dynamic assignment to ensure continuous flow without formalin-based holding, thereby protecting operators from hazardous exposure.
Data Source
AI summary
The invention relates to a tissue processor (100) for automatically processing histological tissue specimens, the tissue processor (100) comprising a plurality of containers (1, 2, 3, 4, 5, 6, 7) each being provided for a respective histological process for processing at least one tissue carrier, a robotic arm (9) for handling a tissue carrier between the containers (1, 2, 3, 4, 5, 6, 7) for being processed in each of the containers (1, 2, 3, 4, 5, 6, 7), and a control unit for controlling the histological process in each of the containers (1, 2, 3, 4, 5, 6, 7) and for controlling the robotic arm (9), wherein the control unit is configured such that the robotic arm (9) handles a tissue carrier between the containers (1, 2, 3, 4, 5, 6, 7) while the histological process in each of the containers (1, 2, 3, 4, 5, 6, 7) continues in an uninterrupted fashion, so that the execution of the process for each tissue carrier is independent from the loading order and/or process duration of other tissue carriers being processed in the containers (1, 2, 3, 4, 5, 6, 7).