A fast-growing food safety technology company sought to transform the way foodborne pathogens are identified in agricultural environments — replacing slow, manual processes with an integrated, automated platform capable of delivering results weeks ahead of conventional methods. Ascential delivered full-scale engineering, design, and manufacturing services to bring this complex system from prototype to commercial readiness.
Identifying foodborne pathogens in agricultural environments has long been one of the most critical — and most cumbersome — processes in food safety management. Existing methods were manual, error-prone, and slow. Delays in detection translated directly into delayed intervention, increasing the risk of contamination events with significant public health and operational consequences.
The client recognized an opportunity to fundamentally change this paradigm. Their vision was to build a platform that could combine cell transport technology with molecular techniques to rapidly identify and quantify pathogens in food production settings — detecting them weeks ahead of current practices. But translating that scientific concept into a commercial-scale product required deep engineering expertise, systems integration capability, and proven manufacturing rigor.
Their goals were clear:
Compress Time-to-Result
Reduce pathogen detection turnaround by weeks compared to conventional methods, enabling faster intervention decisions.
Enable High-Volume Sample Processing
Build a system capable of processing large sample sizes at scale without sacrificing cell viability or detection accuracy.
Unify Complex Technologies in a Single System
Combine cell transport technology with molecular identification techniques in a single, automated platform.
Accelerate Time-to-Market
Partner with a full-service engineering and manufacturing provider to bring the platform to market quickly and at scale.
Ascential engaged as a full development partner, taking ownership of the engineering, design, and manufacturing lifecycle from the outset. Rather than inheriting a partially developed system and working in isolation, our cross-functional team — spanning mechanical, fluidic, optical, software, and systems engineering — worked in parallel across all phases of development to accelerate timelines without compromising quality.
By engaging early and owning the full development lifecycle, Ascential was able to refine the core technologies and integrate them into a unified automated system — one that could be manufactured consistently at scale while maintaining the performance standards the client required.
The platform Ascential engineered and brought to production is the first of its kind to combine cell transport technology with molecular techniques for food production applications. Designed to keep cells viable while rapidly identifying and quantifying pathogens in complex samples, the system delivers results 6–10 weeks ahead of current conventional practices. Key elements of Ascential’s solution included:
The platform integrates a sophisticated combination of subsystems, all designed, validated, and documented in-house by Ascential’s engineering team:
| Capability | What Ascential Built |
|---|---|
| Cell Transport Integration | Engineered the cell transport subsystem to maintain cell viability throughout the detection workflow, preserving sample integrity from intake through analysis. |
| Molecular Identification | Integrated molecular techniques for rapid, accurate pathogen identification and quantification within a single automated platform. |
| Automation & Controls | Designed high-throughput automated processing with custom control system electronics, integrated sensors, and safety interlocks. |
| Fluidic Handling | Precision fluidic systems for accurate reagent and sample dispensing throughout the detection workflow. |
| Software & Firmware | Complex workflow scheduling, firmware, and user interface software to support seamless, reliable operation. |
| Scalable Manufacturing | Contract manufacturing processes established to produce units consistently at scale with validated quality controls. |
| Supply Chain Management | End-to-end supply chain oversight to ensure production timelines were met and component quality was maintained. |
From prototype refinement through commercial-scale manufacturing, Ascential served as a full-service technical program management partner. The completed platform exceeded performance targets across every key dimension:
Foodborne illness remains a persistent and costly public health challenge worldwide. The ability to detect pathogens weeks earlier than current practices gives food producers, processors, and regulators a meaningful window to act — reducing contamination risk, protecting consumers, and limiting the operational and reputational consequences of an outbreak.
For the client, this platform represents a commercially ready, scalable product that brings a genuinely differentiated capability to market. For the food industry more broadly, it sets a new standard for what rapid, automated pathogen detection can achieve.
Ascential’s contribution extended well beyond engineering execution. By owning the full development and manufacturing lifecycle — and integrating supply chain management from the outset — we ensured that speed to market and product performance advanced together, rather than in tension.
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