Meet us at AIRTAC in Augsburg on October 22, 2025 - make an appointment on site now!

Cleanroom QDL for large daily quantities

How Zettl tested up to 50,000 medical masks every day and ensured full delivery capability for the manufacturer

A person wearing protective clothing, gloves, and a face shield inspects a blue mask in a clean room environment.

Initial situation

A medical technology manufacturer needed support at short notice in the quality inspection of large daily quantities. Up to 50,000 masks had to be tested in order to meet regulatory requirements and ensure delivery capability.

The challenge

Automated testing was not feasible due to the tight time window. What was needed was an immediately available, manual and highly sensitive quality inspection that could detect even the smallest material and processing defects.

Solution

We set up a clean room within a very short space of time, provided qualified personnel and carried out a manual visual and functional inspection in accordance with the customer-specific test plan. Each mask was individually assessed and documented.

Result

The manual inspection resulted in high sorting quality, stable supply chains and absolute process reliability for the manufacturer. The tested masks were released and delivered on a daily basis.

Conclusion

Daily inspection of large quantities without automation

High sorting quality thanks to sensitive manual inspection

37 % cost reduction through rapid external capacity expansion

Similar projects

Rapid scaling through medical assembly
Quality assurance for safety vehicle modules