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Small UK business develops equipment for rapid production of Covid testing swabs
A small UK business, based in Hampshire, has been working flat out designing and building innovative production equipment capable of producing up to 10,000 Covid-19 medical testing swabs per hour.
Small and large versions of the equipment have already been purchased by eager customers in Israel, South Africa, Australia, Denmark and China.
In February this year, Andrew Campbell, managing director and owner of Campbell Coutts Ltd discovered that the delays in Covid testing all over the world were partly caused by a huge shortage of the particular “flocked” swabs required to collect biological specimens, with the demand far outstripping the production capacity of the 2 major manufacturers and no flocked swab production capability in the UK. Andrew’s business specialises in producing flocking equipment and he set about developing machines for the rapid production of flocked swabs, using his extensive knowledge of electrostatic flocking technology.
Andrew explains the complexity of the project: “Each small thin stick has to have thousands of tiny, synthetic fibres adhered to one end, with the finished products meeting strict criteria in terms of sterility and quality. We had to develop a unique system that included adhesive application, drying ovens, electrostatic flock fibre application, static removal air jets and cleaning stations. And, we had to design and build the equipment very quickly to help meet the growing global need for swab sticks.”
Andrew and his small team of just 3 colleagues worked long hours, within the social distancing constraints of lock-down and, by May a prototype had been successfully tested and orders were coming in from customers around the world.
When asked about some of the challenges he faced, Andrew said, “The equipment had to be suitable for use in a “clean room”, sterile environment, which was a particular challenge, especially when dealing with millions of minute, nylon fibres flying around. Another hurdle was the shortage of the polycarbonate sheeting needed to enclose parts of the equipment; the demand for protective, perspex screens being used in public environments had used up all the stock in the UK. I’m really delighted that all our hard work has paid off and that we are making a positive contribution to the global fight against Coronavirus”.
The company is the UK’s longest established and largest supplier of flocking equipment and consumables and one of just a handful of businesses worldwide with the expertise and capability to design and produce electrostatic flocking equipment for large-scale production of a variety of flocked products and components.
To assist with accelerating the design and development, the company applied for and were awarded a government grant via Innovate UK under the “Business-led innovation in response to global disruption” competition, that was launched in April to fast-track the development of innovations borne out of the coronavirus crisis and to build future resilience.
More Colours Added to Range
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- 1.0mm SUEDE EFFECT FLOCK in 11 COLOURS
- 0.5mm 1.5 decitex in 26 COLOURS !
- 0.7mm 1.5 decitex in 40 COLOURS !
- 1.0mm 3.3 decitex in 67 COLOURS !
- 2.0mm 22 decitex in 48 COLOURS
- 4.0mm 40 decitex in 25 COLOURS
- 6.0mm NYLON FLOCK in 25 COLOURS
- 8mm NYLON FLOCK in 9 COLOURS
- 10 mm NYLON FLOCK in 11 Colours
- TRILOBAL NYLON FLOCK in 7 Colours
- COLOURED TRILOBAL FLOCK NOW IN STOCK
> Our range of adhesive pigments have been added to the site
Flocking Booths Now Available (single booth)
- The single booth is available as a flocking booth or as a glue spray booth.
- Noise level - 72db @ 1m from booth face
- Opening size – 1110W x 1070T
- Twin double fluorescent light units with spray shield film clamps
- Variable speed 315mm extraction fan.
- Earth connection points
- Product hanging bar
Flocking Booths Now Available (double booth)
- The double booth is available as a flocking booth or as a glue spray booth.
- Provides containment for free flock fibres
- Allows recycling of excess flock fibres
- Noise level - 72db @ 1m from booth face
- Opening size – 2220W x 1070T
- Four double fluorescent light units with spray shield film clamps
- Two Variable speed 315mm extraction fan.
- Earth connection points
- Product hanging bar
1.0mm FLOCK SELECTION BOX NOW AVAILABLE
Selection of colours of 1.0mm 3.3 decitex nylon flock
40 x 100gm bags - £140
50 x 100gm bags - £175
Aeroflocker™
The Aeroflocker™ is our newest product. It is a blown flocking system that is easily controlled and is great for the flocking of 3D items with internal surfaces and undercuts. The hopper holds a reservoir of flock which provides a continuous flow of flock to the applicator gun. The base unit can also be used to power standard pure electrostatic applicator assemblies or tray systems.