- However, when analyzing the entire laboratory operating cost, many companies realize that the real cost does not lie only in the price of the raw medium. Factors such as labor, equipment, energy, waste and the risk of errors also greatly affect the total testing cost.
- This article helps companies see more clearly the true cost picture between the two methods:
+ Self-preparing medium and pouring plates manually
+ Using pre-poured media plates such as Compact Dry
- This helps companies choose a suitable solution and optimize the operating costs of their microbiology testing laboratory.
The self-preparation method and pre-poured media plates
The traditional process in microbiological testing usually involves:
- Weighing out the dry medium
- Dissolving it in distilled water
- Adjusting the pH if necessary
- Sterilizing it in an autoclave
- Cooling the medium
- Pouring it into sterile petri dishes
- Pouring it into sterile petri dishes
This is a process familiar to many laboratory technicians. However, it carries many hidden costs that companies often do not take into account.
1. The cost of chemicals and culture media
If only the dry medium cost is considered, self-preparation is usually cheaper.
For example:
- PCA or Plate Count Agar in powder form can make many plates at low cost.
- Companies only need to buy the medium and empty petri dishes.
Meanwhile, pre-poured media plates such as Compact Dry cost more per plate because they have already been standardized and treated.
However, if you only look at the direct consumable price, companies may overlook other, more important costs.
2. The cost of laboratory equipment
The manual agar pouring method requires many pieces of equipment:
- An autoclave
- A heating stove or water bath
- A microbiology incubator
- Equipment for controlling the medium temperature
These devices require:
- Initial investment costs
- Regular maintenance costs
- Equipment qualification costs
In particular, the autoclave is an energy-consuming device that needs frequent safety checks.
Conversely, when using pre-poured media plates, companies can significantly reduce the use of equipment related to preparing and sterilizing the medium.
3. The cost of electricity and energy
A factor often overlooked in cost calculations is electricity consumption.
In the traditional process, energy is used for:
- Heating the medium
- Autoclave sterilization
- Keeping it warm
- Cooling
For laboratories with a high testing frequency, the electricity costs for the autoclave and heating equipment can increase significantly over time.
When using prepared plates such as Compact Dry, these steps are almost completely eliminated, significantly cutting energy costs.
4. The cost of labor
In the actual operation of a QC laboratory, labor is one of the biggest cost factors.
The self-preparation process requires the technician to perform many steps:
- Preparing the medium
- Cleaning the utensils
- Autoclave sterilization
- Pouring plates
- Storage
This whole process can take 1–2 hours every day, depending on the number of samples.
Meanwhile, with Compact Dry plates, the process is significantly shortened:
- Only drop the sample onto the plate
- Incubate at the specified temperature
This saves the technician time, letting them focus on other important testing activities.
5. Waste and loss of consumables
In the manual method, common forms of loss are:
- Excess medium that is not fully used
- Contaminated poured plates that must be discarded
- Mediium that does not set with acceptable quality
Pre-poured media plates are produced industrially under a strictly controlled quality process, significantly reducing waste.
This technology was developed by Shimadzu Diagnostics, a company with many years of experience in applied microbiology.
6. The cost of errors and result risks
Another important factor is the cost of testing errors.
When the medium is mixed at the wrong ratio or the plates become contaminated, the results may:
- Misstate the microbial density
- Require retesting
- Slow down production
In some serious cases, testing errors can affect:
- The export process
- Quality control documentation
- Brand reputation
Using standardized media plates significantly reduces these risks.
A total-cost analysis: the comprehensive view
If you only compare the price per media plate, the manual method may be cheaper.
However, when the total operating costs are calculated, including:
- Chemicals
- Equipment
- Electricity
- Labor
- Waste
- The risk of errors
The real cost may not differ much, and prepared plates can even be more economical in many cases, especially for:
- Small and medium QC laboratories
- Factories that need fast testing
- Companies that want to standardize their processes
Pacific company – a comprehensive microbiological testing solution
Choosing a testing method is not only a matter of consumable costs, but also a quality management strategy.
Pacific company provides a comprehensive solution for the microbiology testing laboratory, including:
- Advice on choosing a suitable testing method
- Supplying pre-poured media plates such as Compact Dry
- Guidance on building standard operating procedures (SOP)
- Training laboratory technicians
- Consulting on upgrading and optimizing the microbiology room
With experience working with companies in fields such as:
- Food
- Water
- Cosmetics
- Pharmaceuticals
- Feed
- Pacific company always aims to help companies control microorganisms effectively, stably and with low operating costs.
Conclusion
The mindset of "cheap means saving" is not always true in running a microbiology testing laboratory.
Looking at the total operating cost, companies need to consider many factors:
- Labor
- Equipment
- Energy
- The risk of errors
- The consistency of results
Modern solutions such as Compact Dry are helping many QC departments optimize their testing processes and improve the effectiveness of their quality management.
If your company wants to re-evaluate its microbiological testing system, a comprehensive cost analysis will be the first step towards making the right decision.