The display screen of a -80°C freezer

Credit: iStock.com/ Pornpak Khunatorn

A sustainable approach to cold sample storage

An innovative sample storage system enables efficient, eco-friendly biorepository management. 
| 5 min read

As global sustainability efforts intensify, innovative solutions in biorepository management have become crucial, particularly with the rising pressure to reduce carbon emissions from the tens of thousands of -80°C freezers. In response, Azenta has introduced the BioArc™ Ultra High Density -80°C Automated Sample Storage System, designed to address environmental concerns and operational inefficiencies while maximizing storage capacity. This system also utilizes advanced robotics and imaging technology to enhance sample traceability, facilitating easier management of valuable specimens. 

Dean Montano, a Senior Product Manager at Azenta, plays a key role in the development of these automated storage solutions by collaborating with engineers and researchers on complex, long-term projects. Driven by a commitment to expedite the delivery of new cures through innovative storage technologies, Montano's team has integrated trusted automated solutions alongside air cooling technology originally developed for aviation into the BioArc Ultra. These innovations enhance research workflows and streamline drug discovery processes, while also representing a crucial step toward a more sustainable future in scientific research.

What sparked the idea to create the BioArc Ultra?

The idea for the BioArc Ultra originated about three years ago. Each year, tens of thousands of -80°C freezers are sold, consuming considerable space. In Azenta’s biorepositories worldwide, where we manage samples for clients, we operate facilities housing hundreds of these freezers. The operation of -80°C freezers involves significant labor, as staff must locate and manually retrieve samples, and contributes to an associated carbon footprint. Additionally, many national and governmental agencies are tightening environmental regulations. In Europe, for instance, there are stringent targets for certain refrigerants by 2030, which are used in many -80°C refrigeration systems. As these factors converged, we began brainstorming solutions to the challenges of cold storage, leading to the creation of the BioArc Ultra. We designed it not only to support our customers but also to enhance our own biorepositories.

What are some of the challenges of automating storage at minus 80°C?

The variety of tube types used by researchers has mushroomed over the past two decades. Fridges and freezers hold everything from boxes of all shapes and sizes to vials, bottles, pouches, sachets, and more. Automating solutions to handle hundreds, thousands, or even millions of these diverse sample types, while efficiently picking them up and delivering them to researchers using robotics, presents a significant challenge. 

The BioArc Ultra allows for the storage of a range of different sample types and includes an imaging module that accurately counts the tubes in a rack and reads data matrix codes to identify each sample's exact location. Azenta also supplies many modern tubes, vials, and plates under the Fluid X brand. Each tube features a 2D data matrix code on its base, a 1D code along its side in addition to a Human Readable Code, making them tri-coded. This is ideal for automation, allowing researchers to easily locate samples. 

How does the user interact with the storage system?

The system has an input/output module, where users put samples in or pull samples out. Our imaging module tracks the number of tubes in each rack, so we can monitor if a sample is moved within the storage area. This provides a full traceability audit trail. If a user needs a specific tube, they can place an order by selecting the desired barcode, similar to an Amazon shopping cart. The freezer’s robotics then retrieve the appropriate tray, pick out the requested tube, and place it in an output tray. Users simply open the door to collect their sample. 

Who can benefit from this ultra storage technology? 

Biorepository teams can get rid of bulky manual freezers and consolidate their collection in one system. These systems are now helping in clinical trial studies. We've also got customers that use our systems for putting scientific kits together, which previously was a laborious manual process. Now, they can store various sample types and create the kit, which can be retrieved on a tray. All they need to do is lift the kit, place it in a cryo box with dry ice, and ship it. For biobanking, researchers may possess tissue samples stored for many years, and this system facilitates long term archival and research studies. The BioArc Ultra can store cryo vials, tubes, cryo boxes, plates, syringes and much more. While our automation technologies are consistent across our systems, the BioArc Ultra offers the highest density available on the market.

How do you mitigate the risk of a freezer failure?

Sample integrity is always the number one concern. We have two long storage banks on the BioArc Ultra, each with its own refrigeration unit. Should one of those refrigeration units fail, there is a secondary refrigeration unit per bank. Altogether, there are four refrigeration units: two primaries and two backups. These units will periodically change over, so they don’t just sit there doing nothing for years. In the extremely rare case that all four fail, then the tertiary backup is liquid nitrogen.

How does the system work differently than a typical -80°C freezer that makes it more sustainable? 

Conventional -80°C refrigeration systems rely on special blends of refrigerants to remove heat, many of which are harmful to the environment and have high global warming potential (GWP). Regulations around these refrigerants have tightened significantly, with some now banned and quotas limiting their use. The BioArc Ultra, however, operates without any refrigerant, using fresh air instead, resulting in a GWP of zero and no environmental impact. Many biopharmaceutical companies have sustainability targets, and by using our sophisticated return on investment calculator, we can assess each team’s specific situation and provide insights into potential reductions in space, electricity costs, carbon footprint, and time savings.

This is not new technology. Can you tell us more about that?

The underlying technology has been around since the late 1960s, originally developed by Boeing for aviation applications. Mitsubishi created the first compressor for refrigeration systems utilizing this technology. About ten years ago, our partner Mirai commercialized it for ultra-low temperature applications, successfully selling several hundred units. The same technology used in the BioArc Ultra is already employed in the biopharmaceutical industry for vaccine storage, cold chain logistics, and cold rooms. While not new, this is the first time the industry has integrated this technology into an automated storage solution, based on reliable, time-tested technology.

How are these large, automated solutions really transforming drug discovery?

Large, automated solutions expedite research across all levels by saving researchers’ time. With reliable storage, researchers can avoid starting experiments over due to sample loss. Automation enhances workflow efficiency, reducing human error and freeing researchers to focus on their work instead of tracking sample movements or managing paperwork. It’s not just about storage; it encompasses the entire workflow, including other products and services. When researchers combine all this technology and automation, they can reduce the time to market and accelerate their research.

Sponsored by

  • Azenta Life Sciences

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