Innovative Development to Accelerate Swab Manufacturing
Revolutionizing swab production during COVID-19 with continuous infrared drying and automated sterile packaging.
10/15/20251 min read
Context:
During the COVID-19 pandemic, the demand for medical test swabs surged exponentially, creating an urgent need for rapid and scalable manufacturing solutions. Many producers across India struggled with traditional batch-based drying systems that were slow, space-consuming, and difficult to maintain in sterile environments. Packaging was another limiting factor, affecting both productivity and process hygiene.
Innovation:
Under the leadership of Mr. Sanjay Zacharias, an infrared-based continuous drying tunnel with humidity control was conceptualized and developed — replacing the old batch process with a continuous, automated operation. This innovation enabled faster drying, reduced cleanroom space requirements, and significantly improved energy efficiency.
To complement this, a customized pouch-sealing machine was engineered for sterilizable swab packaging, enhancing productivity and ensuring consistent quality at lower costs.
Outcome:
The new system allowed manufacturers to increase output, reduce operational costs, and maintain high hygiene standards, even under pandemic pressure. This innovation not only strengthened India’s medical supply ecosystem during a critical time but also set a new benchmark for efficiency and process design in swab production.