{"id":19159,"date":"2025-10-01T19:11:31","date_gmt":"2025-10-01T19:11:31","guid":{"rendered":"https:\/\/www.thermofisher.com\/blog\/behindthebench\/?p=19159"},"modified":"2025-10-25T16:34:11","modified_gmt":"2025-10-25T16:34:11","slug":"scalable-molecular-testing-workflows","status":"publish","type":"post","link":"https:\/\/www.thermofisher.com\/blog\/behindthebench\/scalable-molecular-testing-workflows\/","title":{"rendered":"From Bottlenecks to Breakthroughs: Scaling Molecular Testing with OpenArray"},"content":{"rendered":"\n<p>At Livingston Med Lab in central Texas, the team has long prided itself on doing quality molecular medicine work including qPCR, array cards, and infectious disease panels, and always pushing to offer more to its community. But a roadblock emerged when they asked: how do we scale more efficiently without sacrificing cost or quality?<\/p>\n\n\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"864\" height=\"513\" src=\"https:\/\/admin.acceleratingscience.com\/behindthebench\/wp-content\/uploads\/sites\/9\/2025\/10\/Sean-Villasana-is-molecular-lab-supervisor-technical-respresentative-at-Livingston-Med-Lab-1.png\" alt=\"Sean Villasana is molecular lab supervisor technical respresentative at Livingston Med Lab\" class=\"wp-image-19161\" srcset=\"https:\/\/admin.acceleratingscience.com\/behindthebench\/wp-content\/uploads\/sites\/9\/2025\/10\/Sean-Villasana-is-molecular-lab-supervisor-technical-respresentative-at-Livingston-Med-Lab-1.png 864w, https:\/\/admin.acceleratingscience.com\/behindthebench\/wp-content\/uploads\/sites\/9\/2025\/10\/Sean-Villasana-is-molecular-lab-supervisor-technical-respresentative-at-Livingston-Med-Lab-1-300x178.png 300w, https:\/\/admin.acceleratingscience.com\/behindthebench\/wp-content\/uploads\/sites\/9\/2025\/10\/Sean-Villasana-is-molecular-lab-supervisor-technical-respresentative-at-Livingston-Med-Lab-1-768x456.png 768w\" sizes=\"auto, (max-width: 864px) 100vw, 864px\" \/><figcaption class=\"wp-element-caption\">Sean Villasana is molecular lab supervisor technical respresentative at Livingston Med Lab<\/figcaption><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-the-challenge-maximizing-throughput\">The Challenge: Maximizing Throughput<\/h2>\n\n\n\n<p>Livingston Med Lab runs moderate to high complexity testing in molecular medicine, immunology, hematology, chemistry, allergies and plans to grow into next\u2011generation sequencing and full toxicology. One key challenge: figuring out which technology to use when, especially given variable sample volumes.<\/p>\n\n\n\n<p>They\u2019d used array cards in the past, but array cards have limits: lower throughput, certain workflow constraints, and sometimes cost inefficiencies when sample numbers increase. When looking at OpenArray technology on the QuantStudio\u2122 12K Flex system, questions arose:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>When is OpenArray better than array cards?<\/li>\n\n\n\n<li>What throughput can realistically be achieved?<\/li>\n\n\n\n<li>What are the cost trade\u2011offs, and when does the extra investment in reagent and &nbsp;consumables pay off?<\/li>\n<\/ul>\n\n\n\n<p>These are questions many labs face when balancing precision, speed, and cost.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-bringing-in-the-field-application-scientist-fas\">Bringing in the Field Application Scientist (FAS)<\/h2>\n\n\n\n<p>Enter John Pfeifer, Thermo Fisher\u2019s Field Application Scientist. Livingston\u2019s molecular lab supervisor, Sean Villasana, describes the FAS\u2019s role as crucial:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>First, John helped break down when each technology makes sense, not just the \u201chow.\u201d<\/li>\n\n\n\n<li>He walked through the methods for OpenArray-how to set it up, run it, get good data, what pitfalls to avoid.<\/li>\n\n\n\n<li>Importantly, the help was remote (and sometimes onsite) but always hands\u2011on: step by step guidance, including tips &amp; tricks.<\/li>\n<\/ul>\n\n\n\n<p>The remote support made a big difference-not just for speed of resolution but for cost. For example, eliminating the need for outside contractors to fix or set up certain workflows saved Livingston Med Lab an estimated $60,000\u2013$80,000 in one year just for their HIV testing workflow.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-the-turning-point-from-modest-to-massive-throughput\">The Turning Point: From Modest to Massive Throughput<\/h2>\n\n\n\n<p>With guidance from the FAS, Livingston recalibrated how they use OpenArray vs array cards. The results were dramatic:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>By switching from array cards (low volume panels) to OpenArray for high\u2011volume infectious disease panels, they could run 4 OpenArray plates simultaneously, drastically increasing daily sample throughput.<\/li>\n\n\n\n<li>Where they once were handling small numbers (e.g. 7 samples on a card), they now manage ~23 in a similar timeframe using OpenArray.<\/li>\n<\/ul>\n\n\n\n<p>Overall, this contributed to nearly <strong>900% scale\u2011up in daily production.<\/strong><\/p>\n\n\n\n<figure class=\"wp-block-image aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"864\" height=\"407\" src=\"https:\/\/admin.acceleratingscience.com\/behindthebench\/wp-content\/uploads\/sites\/9\/2025\/10\/Figure-1-table-showing-OpenArray-technology.png\" alt=\"Figure . by improving their use of OpenArray technology, Livingston Med Lab has been able to maximize their sample throughput daily, resulting in an increase in production of ~900%, since 4 open array plates can re run at a time.\" class=\"wp-image-19162\" srcset=\"https:\/\/admin.acceleratingscience.com\/behindthebench\/wp-content\/uploads\/sites\/9\/2025\/10\/Figure-1-table-showing-OpenArray-technology.png 864w, https:\/\/admin.acceleratingscience.com\/behindthebench\/wp-content\/uploads\/sites\/9\/2025\/10\/Figure-1-table-showing-OpenArray-technology-300x141.png 300w, https:\/\/admin.acceleratingscience.com\/behindthebench\/wp-content\/uploads\/sites\/9\/2025\/10\/Figure-1-table-showing-OpenArray-technology-768x362.png 768w\" sizes=\"auto, (max-width: 864px) 100vw, 864px\" \/><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-strategy-lessons-matching-the-right-tool-to-the-right-job\">Strategy Lessons: Matching the Right Tool to the Right Job<\/h2>\n\n\n\n<p>The key to success wasn\u2019t simply adopting a new technology-it was leveraging it strategically. Livingston implemented a blended approach:<\/p>\n\n\n\n<figure class=\"wp-block-table\"><table class=\"has-fixed-layout\"><tbody><tr><td><strong>Panel Type<\/strong><\/td><td><strong>When To Use Array Cards<\/strong><\/td><td><strong>When To Use OpenArray<\/strong><\/td><\/tr><tr><td>Low sample volume \/ smaller panels &nbsp;<\/td><td>Use array cards (lower upfront consumable cost)<\/td><td>Not cost-effective to use OpenArray<\/td><\/tr><tr><td>High sample volume \/ high throughput panels<\/td><td>Array cards too slow, less scalable<\/td><td>OpenArray is faster, more samples, better throughput<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n<p>By knowing clearly which panel to route to which platform, and by leveraging the training and support from their FAS, they avoided waste and maximized production where it counts.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-the-impact-what-this-means-for-labs-like-yours\">The Impact: What This Means for Labs Like Yours<\/h2>\n\n\n\n<p>If you run molecular diagnostics, this case has some key takeaways:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Don\u2019t assume \u201cfaster tech = always better<\/strong>.\u201d It depends on your sample load and your panel type.<\/li>\n\n\n\n<li><strong>Training and support matter<\/strong>. Having a partner who understands both your lab\u2019s constraints and the biology behind the methods accelerates learning and pays off.<\/li>\n\n\n\n<li><strong>Remote support can give big savings in both time and money<\/strong>. Especially when dealing with unfamiliar technologies or optimizing workflows.<\/li>\n\n\n\n<li><strong>Scalability isn\u2019t just buying expensive instruments<\/strong>. It\u2019s about process: choosing when to switch platforms, optimizing reagent use, and running multiple plates efficiently.<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-resources\"><strong>Resources:<\/strong><\/h2>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Read the full customer <a href=\"https:\/\/assets.thermofisher.com\/TFS-Assets\/LSG\/Reference-Materials\/fas-solved-mystery-openarray-technology-case-study.pdf\" target=\"_blank\" rel=\"noreferrer noopener\">case study<\/a><\/strong><\/li>\n\n\n\n<li><strong>Learn more about our <a href=\"https:\/\/www.thermofisher.com\/us\/en\/home\/products-and-services\/services\/services-support-life-sciences-instruments.html\" target=\"_blank\" rel=\"noreferrer noopener\">services and support<\/a><\/strong><\/li>\n\n\n\n<li><strong>Have a question? <a href=\"https:\/\/forms.office.com\/Pages\/ResponsePage.aspx?id=LXJ9toqqd0ehaevremo7Z0zrIyJDHR9HmsCNlM2ER2pUNVpaSEFITDZRSTdZUVQyQlI0QU1aQU9SNy4u\" target=\"_blank\" rel=\"noreferrer noopener\">Ask our team of experts<\/a><\/strong><\/li>\n<\/ul>\n\n\n\n<p><\/p>\n","protected":false},"excerpt":{"rendered":"<p>At Livingston Med Lab in central Texas, the team has long prided itself on doing quality molecular medicine work including qPCR, array cards, and infectious disease panels, and always pushing to offer more to its community. But a roadblock emerged when they asked: how do we scale more efficiently without sacrificing cost or quality? The<\/p>\n","protected":false},"author":1793,"featured_media":19161,"comment_status":"open","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"_kad_blocks_custom_css":"","_kad_blocks_head_custom_js":"","_kad_blocks_body_custom_js":"","_kad_blocks_footer_custom_js":"","_monsterinsights_skip_tracking":false,"_genesis_hide_title":false,"_genesis_hide_breadcrumbs":false,"_genesis_hide_singular_image":false,"_genesis_hide_footer_widgets":false,"_genesis_custom_body_class":"","_genesis_custom_post_class":"","_genesis_layout":"","_jetpack_newsletter_access":"","_jetpack_dont_email_post_to_subs":false,"_jetpack_newsletter_tier_id":0,"_jetpack_memberships_contains_paywalled_content":false,"_jetpack_memberships_contains_paid_content":false,"footnotes":""},"categories":[67,2259],"tags":[2524,2523,2521,2522,20],"division":[],"class_list":{"0":"post-19159","1":"post","2":"type-post","3":"status-publish","4":"format-standard","5":"has-post-thumbnail","7":"category-infectious-diseases","8":"category-molecular-diagnostics","9":"tag-infectious-disease","10":"tag-molecular-medicine","11":"tag-molecular-testing","12":"tag-open-array","13":"tag-qpcr","14":"entry"},"_selected_authors":[1100],"_selected_reviewers":[],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v27.8 (Yoast SEO v27.8) - https:\/\/yoast.com\/product\/yoast-seo-premium-wordpress\/ -->\n<title>Scalable Molecular Testing Workflows for Clinical Labs<\/title>\n<meta name=\"description\" content=\"Learn how labs can scale molecular testing throughput by balancing array cards and OpenArray. 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Her research centers on downy mildew of grape (Plasmopara viticola) and\u2026","rel":"","context":"In &quot;Animal Health and AgriGenomics&quot;","block_context":{"text":"Animal Health and AgriGenomics","link":"https:\/\/admin.acceleratingscience.com\/behindthebench\/animal-health-and-agrigenomics\/"},"img":{"alt_text":"Portrait of a smiling plant pathology researcher standing outdoors beside grapevine leaves.","src":"https:\/\/i0.wp.com\/admin.acceleratingscience.com\/behindthebench\/wp-content\/uploads\/sites\/9\/2026\/02\/Heger-headshot-1_Jordan-Ruggieri-scaled.jpeg?resize=350%2C200&ssl=1","width":350,"height":200,"srcset":"https:\/\/i0.wp.com\/admin.acceleratingscience.com\/behindthebench\/wp-content\/uploads\/sites\/9\/2026\/02\/Heger-headshot-1_Jordan-Ruggieri-scaled.jpeg?resize=350%2C200&ssl=1 1x, https:\/\/i0.wp.com\/admin.acceleratingscience.com\/behindthebench\/wp-content\/uploads\/sites\/9\/2026\/02\/Heger-headshot-1_Jordan-Ruggieri-scaled.jpeg?resize=525%2C300&ssl=1 1.5x, https:\/\/i0.wp.com\/admin.acceleratingscience.com\/behindthebench\/wp-content\/uploads\/sites\/9\/2026\/02\/Heger-headshot-1_Jordan-Ruggieri-scaled.jpeg?resize=700%2C400&ssl=1 2x, https:\/\/i0.wp.com\/admin.acceleratingscience.com\/behindthebench\/wp-content\/uploads\/sites\/9\/2026\/02\/Heger-headshot-1_Jordan-Ruggieri-scaled.jpeg?resize=1050%2C600&ssl=1 3x, https:\/\/i0.wp.com\/admin.acceleratingscience.com\/behindthebench\/wp-content\/uploads\/sites\/9\/2026\/02\/Heger-headshot-1_Jordan-Ruggieri-scaled.jpeg?resize=1400%2C800&ssl=1 4x"},"classes":[]},{"id":19828,"url":"https:\/\/www.thermofisher.com\/blog\/behindthebench\/cyclospora-molecular-testing-gi-pathogens\/","url_meta":{"origin":19159,"position":3},"title":"Cyclospora Outbreak in the United States: Why Rapid Molecular Testing Matters for Gastrointestinal Pathogens","author":"Ashleigh Barlow","date":"July 17, 2026","format":false,"excerpt":"Fresh produce is one of the most common sources of Cyclospora outbreaks. 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She explains why children can act as asymptomatic reservoirs, why tracking bacterial serotypes matters, and\u2026","rel":"","context":"In &quot;Infectious Diseases&quot;","block_context":{"text":"Infectious Diseases","link":"https:\/\/admin.acceleratingscience.com\/behindthebench\/infectious-diseases\/"},"img":{"alt_text":"Donna Paznar discussing molecular methods for identifying Streptococcus pneumoniae serotypes.","src":"https:\/\/i0.wp.com\/admin.acceleratingscience.com\/behindthebench\/wp-content\/uploads\/sites\/9\/2026\/08\/Paznar_Headshot_Jordan-Ruggieri-scaled.jpg?resize=350%2C200&ssl=1","width":350,"height":200,"srcset":"https:\/\/i0.wp.com\/admin.acceleratingscience.com\/behindthebench\/wp-content\/uploads\/sites\/9\/2026\/08\/Paznar_Headshot_Jordan-Ruggieri-scaled.jpg?resize=350%2C200&ssl=1 1x, https:\/\/i0.wp.com\/admin.acceleratingscience.com\/behindthebench\/wp-content\/uploads\/sites\/9\/2026\/08\/Paznar_Headshot_Jordan-Ruggieri-scaled.jpg?resize=525%2C300&ssl=1 1.5x, https:\/\/i0.wp.com\/admin.acceleratingscience.com\/behindthebench\/wp-content\/uploads\/sites\/9\/2026\/08\/Paznar_Headshot_Jordan-Ruggieri-scaled.jpg?resize=700%2C400&ssl=1 2x, https:\/\/i0.wp.com\/admin.acceleratingscience.com\/behindthebench\/wp-content\/uploads\/sites\/9\/2026\/08\/Paznar_Headshot_Jordan-Ruggieri-scaled.jpg?resize=1050%2C600&ssl=1 3x, https:\/\/i0.wp.com\/admin.acceleratingscience.com\/behindthebench\/wp-content\/uploads\/sites\/9\/2026\/08\/Paznar_Headshot_Jordan-Ruggieri-scaled.jpg?resize=1400%2C800&ssl=1 4x"},"classes":[]},{"id":19235,"url":"https:\/\/www.thermofisher.com\/blog\/behindthebench\/crispr-digital-pcr-gene-editing-workflow\/","url_meta":{"origin":19159,"position":5},"title":"Revolutionizing Gene Editing with CRISPR and Digital PCR &#8211; A Conversation with Dr. Dustin Rubinstein","author":"Behind The Bench Staff","date":"November 11, 2025","format":false,"excerpt":"In a recent Absolute Gene-ius podcast episode titled \u201cCRISPR, dPCR, and pigs - a cut above the rest\u201d, Dr. Dustin Rubinstein, Director of the Advanced Genome Editing Laboratory at the University of Wisconsin-Madison, shared his insights on how CRISPR and digital PCR (dPCR) are revolutionizing gene editing workflows. 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