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Medtech

Al Fahim Manufacturing: Setting the Standard in Microbiology Culture Media Production

Al Fahim Manufacturing, located in Dubai, UAE, is certified by the Dubai municipality and adheres to ISO 13485 and GMP standards. Our state-of-the-art facility specializes in producing Ready-to-Use Microbiology Culture Media. Utilizing fully automated production lines within our validated ISO 7/Class 10,000 Cleanroom, all products undergo rigorous quality testing based on CLSI M22 A3 and ISO 11133 Guidelines.

Al Fahim Manufacturing stands as one of the most esteemed manufacturers in the UAE, offering a comprehensive selection of ready-to-use microbiological culture media. Our products cater to various industries, including Clinical, Food & Dairy, Pharmaceutical, and Veterinary labs, both in the United Arab Emirates and the wider GCC region.

Al Fahim Manufacturing adheres to stringent protocols to oversee every aspect of the manufacturing process. We maintain meticulous in-process control and uphold rigorous standards of quality assurance, validation, and calibration. Additionally, we operate a fully equipped on-site microbiological and water testing quality control laboratory, ensuring compliance with current international guidelines.

Al Fahim Manufacturing boasts a dedicated Class 10,000 clean room measuring 15 meters by 9 meters, exclusively for petri dish filling. Our facility features a state-of-the-art filling machine capable of processing 2,000 plates per hour, complemented by fully automated packaging and labeling equipment.

A cleanroom is a specialized zone within a laboratory or manufacturing facility engineered for the meticulous preparation and packaging of culture media under controlled and sterile conditions. This dedicated space can accommodate a filling machine capable of processing up to 4,000 plates per hour, seamlessly integrated with existing fully automated packaging and labeling machinery.

At Al Fahim Manufacturing, we utilize a heat-sealable coating on both sides of cellophane, enhancing stiffness in chilled conditions while controlling moisture permeability. Presently, our production capacity stands at 20,000 agar media plates, with plans to increase it to 60,000 plates per day upon the incorporation of additional media preparators and filling machines.

Our petri dish filling machines are specialized for 55mm, 90mm, and 140mm sizes, achieving speeds of up to 2,000 dishes per hour for 90mm and 55mm types, and 800 plates per hour for 140mm plates. Production rates are determined based on a three-minute drying time.

The petri dish filling machines are equipped with standard modules that include: an enclosed HEPA drying environment, additional HEPA filtration at the receiving end, an open lid drying system to eliminate excess moisture and reduce condensation during transport and storage, adjustable dry time for customizable drying durations, two cavities for simultaneous pouring, an additive pump for online mixing of fresh sheep blood during pouring, and meniscus generation for achieving an even surface. Overall, these automatic filling machines offer enhanced efficiency, accuracy, and consistency compared to manual filling methods, making them the preferred choice for large-scale production of culture media plates.

In addition to its current setup, Al Fahim Manufacturing’s clean room has extra space available to accommodate additional filling machines, capable of processing 4,000 plates per hour. These machines can seamlessly integrate with the existing packaging system and label print station.

It also features a dedicated Class 10,000 area for tube filling, bottle filling, and inkjet printing. Additionally, there are personal entry and media preparation rooms classified as Class 100,000, serving as airlock areas. Inkjet printing of plates occurs online, where the final product is automatically printed. Additionally, a separate inkjet printer is exclusively dedicated to tubes and bottles. A shrink-wrapping machine is kept on standby for use during maintenance of the automated packaging machine. Additionally, it can be utilized for packaging very low volume agar media.

Al Fahim Manufacturing features walk-in cold rooms maintained at temperatures ranging from 2°C to 8°C for storing finished products, along with dedicated space for raw materials and other consumables. Additionally, there is a refrigerator set at 2°C to 8°C, equipped with a backup battery, for storing growth and antibiotic supplements.

The water plant features a reverse osmosis (RO) system capable of producing 5000 liters in 24 hours. The RO membrane has a shelf life of 2-3 years and is supplemented with in-line UV treatment, in-line filtration (0.2um), and additional vent filters. The deionization cylinder is equipped with standard (strong) mixed bed resin, eliminating the need for regeneration with alkali or acid. The mixed bed resin is replaced once a year. The media preparators represent cutting-edge systems equipped with fully automated control panels. Available in both 30 L and 50 L capacities, these automatic media preparators can handle volumes ranging from 2.5 Liters to 30 Liters and 5 Liters to 50 Liters, respectively. Featuring a patented large stirring system, these preparators ensure thorough mixing of the media throughout the entire cycle. The stirrer speed is adjusted according to the type of media being prepared. The stirrer is engineered to eliminate any bubble formation. The 30 L model can produce a maximum of 1,500 plates per cycle, while the 50 L model can yield up to 2,500 plates in a single cycle. With the option to repeat the cycle 2 or 3 times per day, achieving the target production quantity is feasible. Safety features include a lid that locks automatically when the temperature reaches 80°C. Utilizing various locking mechanisms, along with visible and audible alarms, and housed in an anti-shock casing, the risk is significantly minimized compared to traditional mechanical media preparation methods. Complete traceability and easy data export via a USB interface streamline work processes and optimize workflow. Cleaning is effortless, facilitated by a drain mechanism located underneath the bowl. Real-time data monitoring is enabled through Wi-Fi and Ethernet connections to your PC, smartphone, or tablet. Each cycle is meticulously recorded and stored locally, with the option to export data (in PDF or CSV format) via the USB drive. Approximately 45% of agar media produced by Al Fahim Manufacturing necessitates defibrinated sheep blood. To meet this requirement, we collaborate with a meticulously managed sheep farm under veterinary supervision in Scotland. Specially designed collection bags and custom-made instruments are employed to extract sheep blood. Prior to pooling for batch production, blood from each individual animal undergoes thorough testing. Every donor animal is tagged for identification and traceability purposes. Rigorous microbiological quality control procedures are conducted before approving each batch of sheep blood for use in production.

A specialized breed of sheep with high packed cell volume is exclusively maintained for this purpose. The shelf life of defibrinated sheep blood is 56 days, and orders are rotated every 20 days to ensure an adequate stock for agar plate media production at Al Fahim Manufacturing. Dehydrated culture media, growth supplements, and antibiotic supplements are sourced from Oxoid, Ltd, UK, a prominent supplier of raw materials. To maintain sufficient stock levels, inventory rotation occurs every 4 months at our Dubai warehouse. Oxoid products undergo rigorous testing before release, and Al Fahim Manufacturing adheres to established ISO/GMP protocols by routinely testing incoming raw materials.

Al Fahim Manufacturing operates a fully equipped Quality Control Laboratory to conduct thorough testing on each batch. Our laboratory features essential instruments such as deep freezers for storing ATCC cultures, bacteriological and CO2 incubators, a Biosafety cabinet, pH, TDS, and conductivity meters, laboratory refrigerators, microscopes, and more. Quality control certificates are provided with every batch delivered to ensure product integrity.  Al Fahim Manufacturing transports the final product to customers in refrigerated trucks maintained at temperatures of 2°C to 8°C. Our deliveries extend to customers in the UAE, neighboring GCC countries, and to certain international destinations via air freight. Dubai International Airport serves as a central hub in the Middle East, facilitating efficient transportation. Our commitment to innovation extends beyond production, with essential instruments and stringent testing protocols in place, we deliver nothing short of excellence. We are proud to be at the forefront of microbiology culture media production in the UAE and beyond.

Factory address: AL Fahim Manufacturing LLC, 597-4217 Dubai Investment Park 2. 

Opposite to Gulf Rice Factory. Dubai, UAE Tel: +971 4 3483277 Mobile / WhatsApp: +971 50 539 9422 

Email: info@alfahimhealth.com Website: www.alfahimhealth.com

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