Eco-Flo
Designing plastic out of diagnostics
Brief
To design the world's first plastic-free lateral flow test.
Narrative
Removing single-use plastic from diagnostics, from pregnancy to pandemics.
Outcome
What started as a conceptual project from the Morrama Lab, gained traction and investment and is now being scaled up for production.
Eco-Flo was born from an internal Morrama Lab project exploring how we could create a biodegradable and recyclable COVID-19 testing kit concept in response to increased use of the tests during the COVID pandemic.
Despite the pandemic coming to an end, the market for immunoassays is growing with over 2 billion plastic cassettes produced annually to test everything from plant health to pregnancy. Our concept proposed replacing this component with a paper moulded design.
After a hugely successful PR campaign we drew the attention of UK diagnostics leader Abingdon Health, forming a joint venture to develop the test ready for market and accelerating the shift toward a truly plastic-free lateral flow immunoassays, without compromising performance.
‘Plastic lateral flow cassettes may be cost-effective and robust, but they’re a clear material mismatch. Dry-moulded fibre offers a viable alternative, durable, affordable, and far more sustainable. Single-use plastics must be phased out, and credible replacements must step forward. Eco-Flo is exactly that: a tailored, high-performing test housing that matches, if not exceeds, its plastic counterpart, without using a single gram of virgin plastic.’
- Ben Melvin, Senior Lead
The Eco-flo plastic free cassette will be manufactured in the UK using a novel renewable plant fibre dry-moulding technology that reduces CO2 emissions by up to 80% compared and plastic use across the full test kit by 62% This dry-moulding production process is highly efficient and at scale is cost parable to plastic, making it easier for brands to make the switch.
Testing
Development and lab testing are ongoing, but initial pilot production has delivered promising results. Under controlled conditions, batches of Eco-Flo cassettes were integrated into existing semi-automated assembly lines, assembling smoothly and without the need for significant machinery adjustments.
To assess performance, cassette assemblies were tested using two different lateral flow strips and benchmarked against standard plastic housings. Tests ran without issue or lab team intervention, consistently producing clear, strong test lines across both positive and negative samples. Notably, Eco-Flo outperformed its plastic counterparts in testing speed, delivering strip readings in less time.
Interested?
If you are interested in finding out more about this project, email ecoflo@morrama.com.
Design rights property of Morrama. Patented design.
