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PLOS ONE logoLink to PLOS ONE
. 2021 Jul 14;16(7):e0252509. doi: 10.1371/journal.pone.0252509

Implementation of an open-source robotic platform for SARS-CoV-2 testing by real-time RT-PCR

José Luis Villanueva-Cañas 1,*, Eva Gonzalez-Roca 1,2, Aitor Gastaminza Unanue 3, Esther Titos 1,4,5, Miguel Julián Martínez Yoldi 1,6, Andrea Vergara Gómez 1,6, Joan Anton Puig-Butillé 1
Editor: Ruslan Kalendar7
PMCID: PMC8279358  PMID: 34260637

Abstract

The current global pandemic due to the SARS-CoV-2 has pushed the limits of global health systems across all aspects of clinical care, including laboratory diagnostics. Supply chain disruptions and rapidly-shifting markets have resulted in flash-scarcity of commercial laboratory reagents; this has motivated health care providers to search for alternative workflows to cope with the international increase in demand for SARS-CoV-2 testing. The aim of this study is to present a reproducible workflow for real time RT-PCR SARS-CoV-2 testing using OT-2 open-source liquid-handling robots (Opentrons, NY). We have developed a framework that includes a code template which is helpful for building different stand-alone robotic stations, capable of performing specific protocols. Such stations can be combined together to create a complex multi-stage workflow, from sample setup to real time RT-PCR. Using our open-source code, it is easy to create new stations or workflows from scratch, adapt existing templates to update the experimental protocols, or to fine-tune the code to fit specific needs.

Using this framework, we developed the code for two different workflows and evaluated them using external quality assessment (EQA) samples from the European Molecular Genetics Quality Network (EMQN). The affordability of this platform makes automated SARS-CoV-2 PCR testing accessible for most laboratories and hospitals with qualified bioinformatics personnel. This platform also allows for flexibility, as it is not dependent on any specific commercial kit, and thus it can be quickly adapted to protocol changes, reagent, consumable shortages, or any other temporary material constraints.

Introduction

The coronavirus disease 2019 (COVID-19) pandemic, caused by the severe acute respiratory syndrome coronavirus (SARS-CoV-2) [1], continues to have a devastating impact worldwide. Testing for COVID-19 is essential to control and monitor the virus transmission, and to manage health resources [2]. Although other COVID-19 testing methods are available, the real time Reverse Transcription Polymerase Chain Reaction (RT-PCR) remains the gold-standard and the main molecular approach [3]. However, in the hardest-hit countries, the shortage of laboratory supplies and limited testing capacity during the first months of the pandemic resulted in a restriction in the use of RT-PCR to few population groups (e.g. patients with severe symptoms, high-risk patients, or healthcare workers) [4, 5]. Hospitals and laboratories were forced to incorporate automated solutions, and simultaneously, to increase the throughput of existing ones [6].

There are several commercial platforms for automated high-throughput testing, such as the Cobas 6800 system from Roche [7] or the Panther Fusion system from Hologic [8]. These solutions usually work with proprietary reagent cartridges specifically tailored to each platform and process, using little or no generic components or consumables. This limits the utility of such platforms if the supply chains of a specific labware or reagent fail. Other platforms, such as liquid handling automated workstations from companies such as TECAN or Hamilton are high throughput platforms that can accommodate different protocols. In response to COVID-19, these companies adapted extraction, qPCR, and ELISA protocols to run on their platforms [9, 10]. These platforms are programmed through their proprietary software, and users are able to create their own scripts to some extent. Although they are relatively flexible, their high price is still a barrier to many laboratories.

The advent of affordable open-source liquid handling robots, such as the OT-2 developed by Opentrons, opened the door to low-cost automated solutions [11]. Despite their limitations, multiple OT-2 units can be used together to produce more complex workflows which would otherwise be impossible to do with a single OT-2 robot. Furthermore, as they are relatively affordable and open-source at both hardware and software levels, this makes them an attractive alternative for many laboratories due to the fluctuating demands of the health care market during a pandemic [12]. The “open-everything” approach allows these machines to circumvent supply chains disruptions of specific laboratory equipment vendors, as OT-2 robots can be easily configured to work with a wide variety of components and consumables. Open software is another advantage, as new protocols and features can be quickly be shared with other users. In addition, OT-2 robots are programmed using Python, which is the third most used programming language worldwide with an estimated community of 8.5 million developers [13].

In April 2020, the Hospital Clínic de Barcelona, a tertiary hospital in Spain, incorporated a set of OT-2 robots to increase the RT-PCR SARS-CoV-2 testing capacity.

In this work, we first describe the framework we developed to implement RT-PCR SARS-CoV-2 testing using the OT-2 robots at our center. This framework includes a structured code template with built-in functions that help to overcome some of the robots’ limitations.

Secondly, using our framework, we designed a “circuit” for SARS-CoV-2 RT-PCR testing, by combining several OT-2 robots which each perform a different stage of the test protocol. Finally, we evaluated our circuit using samples from an external quality assessment (EQA) and compared it to other routine automated diagnostic platforms.

Methods

Developing the framework

The OT-2 robots were initially created to perform simple pipetting tasks in research laboratories, and have a limited number of actions compared to other commercial liquid handlers due to their small size. After deploying, calibrating, and testing the robots, we detected some limitations with regard to incorporating the robots into a clinical setting. First, we realized that we needed to develop a framework to ameliorate hardware limitations but which could also help us cope with changes in labware, number of samples, or reactive volumes. We also needed to simplify the process of creating or modifying stations, and automate the circuit as much as possible.

We developed code that provides features to improve the base capabilities of the OT-2 robots and can be used as a starting point to develop individual stations and complete circuits. The Python code (functions and classes) is documented in our GitHub wiki:

https://github.com/CDB-coreBM/covid19clinic/wiki. It includes general descriptions of the functions and examples.

We also created a general template that includes all the functions developed and that can be used to facilitate the development of new stations as well as the automation of some tasks. The template has been designed to work with a variable number of samples and includes the features described below. Furthermore, the template is structured in distinct steps, making the code easier to understand and repurpose. This structure allows the user to execute selected steps, which can be useful for testing or resuming a run after encountering a problem. Some improvements and functions include:

Reagent classes

The liquids used in a protocol might have distinct physical properties. We developed a system that defines liquids as python objects with predefined properties at the beginning of a protocol. With this system, it is only necessary to specify which liquid is being used in a step to apply all the adjustments for that liquid automatically. For example, when dispensing alcohol-based substances, a coating of the liquid is left on the tip; in these scenarios, the attribute “rinse” can be enabled. Pre-rinse is a technique to increase pipetting accuracy through the pre-conditioning of tips by aspirating a certain volume prior to using the tip. A more detailed description of this function is available on GitHub.

Height adjustments (function)

The reagent classes store the total volumes, location, and remaining volumes of all liquids defined. By using this information, combined with the geometrical measures of the containers, we used a simple formula to calculate the optimal aspiration height when pipetting that liquid.

Pickupheight=Totalheightaspiratedheight
Totalheight=x(Containervolumeconevolume)containercrosssectionarea+3xconevolume*conebasearea
aspiratedheight=aspiratedvolumecontainercrosssectionarea

*Formula for a container with cone-shaped bottom. The formula should be adjusted for different shapes. We include a thorough description and simulations in S1 File.

Other enhanced functions. These include a highly customizable liquid transfer function, which makes use of the reagent classes to adjust different parameters, a multi-dispensing function for one to many transfers or a reagent mixing function, among others.

Log system

Currently, every run generates a time report, registering the duration of each step and the number of pipette tips used.

Automation

An essential aspect of implementing a circuit in clinical diagnostics is the traceability of samples. Sample tracking is very context-dependent, as each laboratory has its own protocols, laboratory information management systems (LIMS), and databases. We provide several scripts that can be adapted to different working environments; for example, a template for sample barcode scanning that tracks sample placement in the different possible dispositions (i.e. 4 racks with 24 samples each or qPCR with 96 wells), or the automatic generation of templates with sample names and well positions for the ABI 7500 qPCR system (Thermo Fisher Scientific) or the LightCycler 480 II system (Roche life science).

Custom labware

Definitions of commonly used plasticware from popular vendors are available for download from our repository. These are available as.json files, with the measures and their description, and can be imported into the OT-2 app.

Circuit design and evaluation

Using our framework, we build two circuits for SARS-CoV-2 RT-PCR testing using OT-2 robots. A full description of these circuits is provided in the Results section. The difference between both circuits relies on the kit used for RNA extraction: MagMax™ Pathogen RNA/DNA kit or MagMax™ Viral Pathogen II RNA/DNA kit. Both circuits use TaqPath™ COVID-19 CE-IVD RT-PCR reagents for the RT-PCR reaction.

The first circuit was named OT-2KF pathogen, after the extraction kit used (MagMax™ Pathogen RNA/DNA kit). We externally evaluated this circuit using eight inactivated samples with unknown content (at the time of processing) provided by the European Molecular Genetics Quality Network (EMQN). These samples were analyzed using the KF pathogen circuit and three additional platforms used in routine at our laboratory: Flow Solution (Roche), Cobas 6800 (Roche), and a Hamilton-Seegene combination (see S1 File). Samples were mixed 1:1 with Cobas omni Lysis Reagent (Roche) before being processed to allow comparisons.

Due to shortages in MagMax™ Pathogen RNA/DNA kit, we had to build a second circuit (OT2-KF viral pathogen II) using MagMax™ Viral Pathogen II RNA/DNA extraction kit. To evaluate our second circuit, we compared it to the OT-2-KF pathogen circuit using 15 previously collected nasopharyngeal swab samples (with known outcome) from our center. These samples were collected for routine diagnostics and immediately placed into a sterile tube, containing 2 mL of lysis buffer (2 M guanidinium thiocyanate, 2 mM dithiothreitol, 30 mM sodium citrate, and 1% Triton X-100). Samples were vortexed and mixed 1:1 with Cobas omni Lysis Reagent (Roche, Basel, Switzerland) for inactivation.

Nucleic acid extraction and SARS-CoV-2 qPCR set up

Viral RNA was extracted from inactivated samples using either the MagMax™ Pathogen RNA/DNA kit or the MagMax™ Viral/Pathogen II kit on the Kingfisher™ Flex Purification System (Thermo Fisher Scientific, Waltham, MA) according to manufacturer’s instructions with some modifications. Specifically, when we used the MagMax™ Pathogen RNA/DNA kit protocol, no addition of MagMax™ Pathogen RNA/DNA Lysis Solution Master Mix was applied to the inactivated samples, and 460 μl of lysates were directly transferred to the King Fisher™ deep-well sample plate. Subsequently, 260 μl of MagMax™ Pathogen RNA/DNA Bead Master Mix and 5 μl of the MS2 Phage Control (Thermo Fisher Scientific, Waltham, MA) were added to each well, including a negative control sample containing 460 μl of PBS located at A1 position of the 96 deep-well plate. The sample plate was then loaded onto the KingFisher™ instrument, and automated RNA extraction was performed using the BindIt™ protocol “MagMax_Pathogen_High_Volume”.

Viral RNA extraction using the MagMax™ Viral/Pathogen II kit was performed according to the protocol for “400 μl sample input with two wash steps” recently published by Thermo Fisher Scientific as a “Sample Prep Application Note” on its website with some modifications. To summarize the protocol, no addition of proteinase K was applied to the inactivated samples and 400 μl of sample were directly transferred to the King Fisher™ deep-well sample plate. Subsequently, 550 μl of Binding Bead Mix and 10 μl of the MS2 Phage Control (Thermo Fisher Scientific, Waltham, MA) were added to each well including a negative control sample containing 400 μl of PBS located at A1 position of the 96 deep-well plate. Sample plate was then loaded onto the KingFisher™ instrument and, automated RNA extraction was performed using the BindIt™ protocol “MVP_2Wash_400_Flex” provided in Thermo Fisher’s website with minor modifications. Specifically, the proteinase K digestion step was removed and plastic configuration was used as follows: three King Fisher™ deep-well plates (samples, wash1 and wash2), 2 King Fisher™ Standard plates (elution and Tip Comb plate) and one Tip Comb. See Availability Section for more information.

RT-PCR in OT-2/Kingfisher circuits

To summarize the protocol, 5 μl of nucleic acid eluate was used for multiplex real-time RT-PCR test intended for the qualitative detection of nucleic acid for SARS-CoV-2 using the TaqPath™ COVID-19 CE-IVD RT-PCR kit (ThermoFisher Scientific, Waltham, MA).

Interpretation of SARS-CoV-2 qPCR results

Results from the ABI 7500 qPCR system, generated by the 7500 software v2.3.3 (Thermo Fisher Scientific), are transformed into a user-friendly table using an Rmarkdown script, which includes an automatic interpretation of results. A sample is considered positive when two or more targets are amplified, negative when the internal control is amplified but the viral targets are not, or invalid when there is no amplification of any targets (including internal control). Other cases are marked as “revise” and evaluated individually by a microbiologist prior to automatically transferring the results to the laboratory information system.

Results

Building circuits with OT-2 robots

We have built and tested two different functional circuits for SARS-CoV-2 RT PCR testing using our code framework in the OT-2 stations. Both circuits work with equipment and reagents from Thermo Fisher Scientific, which are routinely used for SARS-CoV-2 testing in our laboratory and are already validated. Each circuit is composed of six stations: four OT-2 stations, a Kingfisher™ Flex Purification System, and one ABI 7500 Fast Real-time PCR instrument. As previously mentioned, the difference between both circuits relies on the kit used for RNA extraction (see Methods).

In both cases, the circuit workflow (Fig 1A) is as follows:

Fig 1. Diagram of the OT2-KF circuit.

Fig 1

Note that station A and station B1 can be run simultaneously. The full configuration of labware for OT2 stations is available as S2 File.

1. Initial sample setup (OT-2 station A), 2. sample preparation (OT-2 station B1), 3. plate filling for Kingfisher Flex (OT-2 station B2), 4. RNA extraction step (Kingfisher Flex station), 5. RT-PCR preparation (OT-2 station C), and the 6. RT-PCR (ABI 7500 Fast thermocycler).

Each OT-2 station can have two pipettes simultaneously installed. The OT-2 pipettes have three different capacities (20, 300, 1000 μl) and can be either single-channel or multi-channel. A combination of these pipettes defines letters in the OT-2 station nomenclature; therefore stations B1 and B2 can be run on the same robot. A complete description of every station with its required list of components is available as S2 File.

The complete process for testing 96 samples takes about 4h (Table 1), and a single laboratory technician can operate it. RT-PCR amplification and detection using ABI 7500 Fast thermocycler is the longest step. Theoretically, a new run could start every 70 minutes. A summary of the steps carried out in each station and their executing time is indicated in Fig 2.

Table 1. Number of steps and running times in minutes for a full run with 96 samples across the different stations.

Station A and B1 can be run simultaneously.

Station Steps Total time (minutes)
A: sample setup 1 54
B1: plate filling 5 41
B2: sample prep 3 59
C: RT-PCR preparation 2 20
KF: extraction 1 30
Thermocycler: RT-PCR 1 70
Total 234

Fig 2. Run times in minutes for the different steps classified by station in the Kingfisher pathogen circuit using the MagMax™ Pathogen RNA/DNA kit.

Fig 2

Evaluation of OT-2-KF pathogen circuit within a clinical setting

We analyzed the samples (N = 8) from the Coronavirus Outbreak Preparedness EQA Pilot study from EQMN using the OT-KF pathogen circuit. We found that, out of eight samples, five were positive for SARS-CoV-2, and three were negative. The results obtained by the OT-KF pathogen circuit were consistent with those obtained by three commercial platforms, even though the target regions were different (Table 2). The internal control was correctly amplified for all samples and platforms.

Table 2. Comparison of four different platforms used for SARS-CoV-2 detection from external quality control samples, including our OT2-KF circuit.

Every platform has its own targets and primers.

Flow Solution Cobas 6800 Hamilton-Seegene OT2-KF pathogen
Sample ID E E ORF1 E N RdRP N ORF1ab S
CVOP2052-01 29,57 30,43 29,74 28.19 30.81 31.26 28,07 27,3 28,15
CVOP2052-02 Undetectable Undetectable Undetectable Undetectable Undetectable Undetectable Undetectable Undetectable Undetectable
CVOP2052-03 32,15 33,8 32,7 31.73 33.39 34.43 31,08 30,35 31,16
CVOP2052-04 Undetectable Undetectable Undetectable Undetectable Undetectable Undetectable Undetectable Undetectable Undetectable
CVOP2052-05 Undetectable Undetectable Undetectable Undetectable Undetectable Undetectable Undetectable Undetectable Undetectable
CVOP2052-06 29,06 31,14 30,23 28.93 30.94 31.31 27,3 26,92 27,81
CVOP2052-07 25,8 27,16 26,63 25.47 27.72 27.73 24,64 23,66 24,46
CVOP2052-08 35,25 35,82 35,27 34.49 35.98 36.91 34,42 34,42 38,02

Ct levels are inversely proportional to the amount of target nucleic acid in a sample. The range of Ct was 25.8–35.25 for Flow Solution platform, 25.47–35.82 for Cobas 6800, and 27.72–36.91 for Hamilton-Seegene. The range of Ct for the platform OT2-KF pathogen was 23.66–38.02, with consistently lower values except for the S gene in sample CVOP2052-08.

According to the EMQN sample content, we identified all the SARS-CoV-2 strains correctly (Table 3) with all platforms. The other coronaviruses (NL63 and OC43) were not detected, showing that the tests have specificity for SARS-CoV-2.

Table 3. Sample content of the EQA Pilot study.

Sample code: QCMD panel sample codes for the samples distributed to laboratories. Sample content: Content of the individual panel samples and, where applicable, the subtype or stain of the pathogen. Expected result: Expected outcome when testing for SARS-CoV-2. Log10 dPCR Copies/ml: The value obtained using a digital droplet PCR assay (modified from [14]). Samples CVOP20S2-07, 01, 03, 08, are in a calibrated dilution series. CVOP20S2-06 is a duplicate sample of CVOP20S2-01.

Sample code Sample content Expected result Log10 dPCR Copies/ml
CVOP20S2-01 Novel Coronavirus SARS-CoV-2 Positive 4.30
CVOP20S2-02 Coronavirus NL63 Negative 4.64
CVOP20S2-03 Novel Coronavirus SARS-CoV-2 Positive 3.30
CVOP20S2-04 Coronavirus OC43 Negative 4.03
CVOP20S2-05 CV Negative Negative -
CVOP20S2-06 Novel Coronavirus SARS-CoV-2 Positive 4.30
CVOP20S2-07 Novel Coronavirus SARS-CoV-2 Positive 5.30
CVOP20S2-08 Novel Coronavirus SARS-CoV-2 Borderline Positive 2.30

Comparison of OT-2-KF pathogen circuit with OT2-KF viral pathogen II

Fifteen previously frozen samples with known outcome were run across the two KF circuits in two separate batches. We obtained identical qualitative results for all samples in both circuits (Table 4). Sample S8 had one amplified target (N–nucleocapsid gene) with a very high Ct value (37.9), compatible with a patient after infection with some remnants of the virus.

Table 4. Comparison of fifteen samples using the two automated circuits implemented in our lab using Thermo Fisher kits: OT2-KF pathogen and OT2-KF Viral Pathogen II.

  Kit Pathogen Kit Viral Pathogen II
Sample N ORF S MS2 N ORF S MS2
S1 Undetectable Undetectable Undetectable 26,4 Undetectable Undetectable Undetectable 26,5
S2 22,9 23,1 22,7 22,9 23,9 23,4 22,8 27,1
S3 27,3 27,9 27,8 26,7 29,2 29,2 28,7 27,5
S4 31,4 31,3 31,6 26,4 32,5 34,5 33,0 27,4
S5 28,9 30 29 26,7 32,7 34,7 34,1 25,6
S6 Undetectable Undetectable Undetectable 26,3 Undetectable Undetectable Undetectable 27,5
S7 31,9 31,4 29,7 26,8 33,4 33,3 32,3 28,7
S8 Undetectable Undetectable Undetectable 25,9 37,9 Undetectable Undetectable 28,2
S9 17,9 18,5 18,6 26,3 20,0 20,2 19,8 28,0
S10 26,3 26,8 24,8 26,7 27,0 27,2 26,9 27,0
S11 21,8 21,9 21,9 26,9 22,5 22,7 22,3 25,1
S12 25,7 26,2 24,9 27,3 26,9 26,8 26,2 27,8
S13 23,4 23,4 23,2 26,5 25,0 25,1 24,8 27,1
S14 27,8 27,9 27,5 25,7 29,3 28,7 28,4 26,8
S15 Undetectable Undetectable Undetectable 25,9 Undetectable Undetectable Undetectable 27,0

The Ct values for the OT-2-KF viral pathogen II were 1.6 higher on average. One possible explanation for this difference is that the samples had an additional round of freezing-unfreezing as they were processed in the second batch.

Discussion

We have successfully prototyped and implemented an automated robotic workflow for performing SARS-CoV-2 RT-PCR tests using OT-2 robots and other commercial systems, as well as validating its viability at the production level. We obtained results which were equivalent to other commercial automated solutions, valid results according to the Coronavirus Outbreak Preparedness EQA Pilot study EMQN scheme, indicating that our custom framework can be routinely used in a clinical setting. So far, we have processed over 40,000 samples in more than 500 runs, and our code has been used as a starting point to develop SARS-CoV-2 OT-2 circuits in several other hospitals in Spain.

The framework includes classes and functions that facilitate the use of OT-2 liquid handling robots. For example, by creating a new class for different types of liquids, we have added a functionality that matches the more expensive commercial liquid handler robots available on the market. All attributes that depend exclusively on liquid properties are described in the code, and can be modified in the object definition section.

An advantage of establishing circuits based on independent modules is that some processes can be run in parallel, resulting in an increased turnaround and increased testing capacity. Taking into account the station times in the OT-2-KF circuit (Fig 1), the longest step is the RT-PCR amplification and detection using ABI 7500 Fast thermocycler. Therefore, while a run could theoretically start every 70 minutes, the inactivation of samples remains the main bottleneck. Inactivation of samples is a non-automated procedure that requires specialized facilities and microbiology laboratory technicians.

OT-2-based circuits are a promising solution to increase SARS-CoV-2 testing capability since it is an affordable open-source platform for liquid handling. The cost of the robots is much lower than other solutions, and the cost of reagents can be significantly reduced by using in-house protocols [15]. However, other associated costs (personnel, labware, etc.) are similar. Open-source platforms are also versatile, as it is easy to incorporate new protocols, adjust existing protocols to compensate for fluctuations in consumable availability, and benefit from code shared and maintained by the open-source research community. Although working with these platforms can be challenging at first, further improvements made by members of the community can be quickly shared and implemented across laboratories worldwide. Currently, the OT-2 community is still growing, and the available code is not always easy to repurpose; however, our work contributes code to the community that is flexible and scalable, and mimics the advanced capabilities available in more expensive proprietary platforms.

As previously mentioned, OT-2 circuits also have limitations. For instance, some protocols like RNA extraction are difficult or impossible to perform on the OT-2 platform. To date, most extraction protocols use magnetic beads and these protocols require some shaking steps. While OT-2 systems have a magnetic module, they currently do not incorporate an agitator. Despite this deficiency, we tested different RNA extraction protocols using OT-2 robots with partial success (data not shown). Therefore, in the design of our circuits where test accuracy and sensitivity were key, RNA extraction was carried out by a KingFisher™ instrument which incorporates an agitator module. However, advances and improvements to the OT-2 platform’s capabilities continue, as evidenced by a new in-house extraction protocol which has been recently implemented using OT-2 robots in a hospital [15].

Another limitation to the OT-2 is that there is currently no hardware or software which performs sample tracking, which is essential in a clinical setting. We used external barcode readers before starting a run to associate individual samples to a pre-defined position on each plate, with a series of scripts for technicians that help to automate the process. Thirdly, OT-2 robots lack hardware to control if samples are correctly aspirated and/or detect clot formations. To minimize the clinical of impact of that limitation, OT-2 robots are monitored by a technician who visually inspects the plates between each station. By visually inspecting samples before testing, the majority of issues regarding clots or low volume sample are quickly detected. Problematic samples can be then separated from the rest and addressed on an individual basis. Additionally, pipetting is adapted to each liquid type by using reagent classes, as mentioned previously. For example, slow aspiration and dispense speed is set when pipetting SARS-CoV-2 samples to compensate for their high density and prevent clotting.

Another issue is that developing these circuits from scratch requires both in-house programming and molecular biology expertise. Even if general templates and working code are available, it will still be necessary to make changes, adjustments, and to understand the biological context. In that sense, the role of bioinformatics professionals in molecular diagnostics laboratories is fundamental when implementing such circuits.

In conclusion, this work can help to increase SARS-CoV-2 testing capacity of established laboratories and provide an alternative to proprietary protocols and during acute consumable shortages [15, 16]. These open-source solutions might also be a good fit for laboratories that currently do not have the resources for other automated platforms. Finally, we have developed a framework that can be used to adapt the OT-2 robots to other uses.

Availability

Code, documentation, and station diagram and descriptions are available in the CDB GitHub repository: https://github.com/CDB-coreBM/covid19clinic

Codes for Kingfisher robot are available in Thermo Fisher’s website:

Pathogen. https://www.thermofisher.com/order/catalog/product/4462359#/4462359

Viral Pathogen II. https://www.thermofisher.com/order/catalog/product/A48383#/A48383

Supporting information

S1 File. Supplementary methods.

Expanded methodology for the height calculation function and description of the platforms used in the EMQN comparison.

(DOCX)

S2 File. Supplementary material.

Description of OT-2 stations including the labware placement for every circuit described in this manuscript.

(PDF)

S1 Fig

(TIF)

Acknowledgments

We thank M.D. Jiménez, Anabel Martínez, Mar López, Marta Parera, Núria Palau, Víctor Pastor, and Paula Sánchez for laboratory support and advice. Elena Roel, Katie Miller, and William Blevins for insightful comments. Ojas Patel for technical support. The authors thank the NGO COVIDWarriors for donating the Opentrons OT-2 stations to the Hospital Clínic de Barcelona (Spain).

Data Availability

Code developed is available at https://github.com/CDB-coreBM/covid19clinic.

Funding Statement

The author(s) received no specific funding for this work.

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Decision Letter 0

Ruslan Kalendar

Transfer Alert

This paper was transferred from another journal. As a result, its full editorial history (including decision letters, peer reviews and author responses) may not be present.

2 Mar 2021

PONE-D-21-03093

ROBOCOV: An affordable open-source robotic platform for SARS-CoV-2 testing by RT-qPCR

PLOS ONE

Dear Dr. Villanueva-Cañas,

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PLOS ONE

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This work was supported by the Hospital Clínic Barcelona'

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Reviewers' comments:

Reviewer's Responses to Questions

Comments to the Author

1. Is the manuscript technically sound, and do the data support the conclusions?

Reviewer #1: Partly

Reviewer #2: No

**********

2. Has the statistical analysis been performed appropriately and rigorously?

Reviewer #1: No

Reviewer #2: No

**********

3. Have the authors made all data underlying the findings in their manuscript fully available?

Reviewer #1: Yes

Reviewer #2: Yes

**********

4. Is the manuscript presented in an intelligible fashion and written in standard English?

Reviewer #1: No

Reviewer #2: No

**********

5. Review Comments to the Author

Reviewer #1: 

The title of the manuscript should be revised to be more informative, and, unless used with permission, to avoid the use of the name ROBOCOV, which is the name of a pre-existing statistical package – see https://github.com/kkdey/Robocov

As noted by the authors, the COVID-19 pandemic has highlighted the disastrous impact of supply chain disruptions on global response. Identification of cost-effective alternatives to increase diagnostic capabilities is critical. The authors describe integration of a potentially interesting robotic platform from a relatively new vendor, that has the advantage of utilizing open-source software, and compare its performance to several better-known systems that have FDA emergency use authorization for SARS-CoV-2 diagnostic testing. However, the manuscript can be shortened and would benefit from being more focused. In addition, the use of advertising jargon, eg. "Hit the ground running", or descriptions of system advantages that are not referenced or specifically supported by data in the manuscript may appear promotional and detract from the authors’ message, and should be deleted.

The authors’ stated aim is to describe use of the Opentrons OT system to set-up a reproducible workflow for diagnostic testing. It should be more clearly stated that the authors are describing a potential workflow incorporating the OT robot and the authors’ COVID-19 protocol for the Opentrons robot/author’s modifications to the COVID-19 protocol from the Opentrons Protocol Library, rather than a pilot study or an implementation in a clinical diagnostic setting, which would require testing of additional performance parameters and a larger sample size.

Additionally, since the authors are proposing this system as an affordable system for clinical diagnosis when resources may be limited, it would be helpful to discuss further:

System Affordability

- When the authors describe the system as affordable relative to other systems, are they considering only the cost of the robot itself? If so, it should be clearly stated that other major set-up costs, maintenance, consumables, personnel costs for operation etc. needed to obtain an interpretable diagnostic result for clinical purposes have not been addressed or compared to other systems

Consumables supply chain

- The authors raise concerns regarding global supply chain problems as a reason for using this open-source software platform. Please clarify why availability of the proprietary components and supplies listed on the Opentrons website, including heating blocks, pipette tips, racks & adapters, would not be an issue for this vendor.

Potential clinical impact of system limitations

- The authors note that there is no hardware or software in the robots to enable sample tracking. The value of robotics comes when large numbers of samples are being tested, and manual front and back end specimen tracking becomes burdensome and more prone to error. What are the work-arounds the authors propose, and what are the costs? How does that affect cost compared to other vendors that incorporate specimen and reagent recognition?

- Another limitation noted is the inability of the robot to detect specimen aspiration failures or clots, and presumably also short specimen volumes (a reality in the diagnostic laboratory). How do the authors propose this be addressed to minimize negative clinical impact of delayed or failed recognition of an invalid or (clinically)inaccurate test result?

Reviewer #2: 

The paper presents an affordable open-source robotic platform for SARS-CoV-2 testing by RT-qPCR using OT-2 open-source liquid-handling robots. The potential impact and need for this work is high. However, lack of rigor in each section of the paper diminishes the importance of this paper.

General comments to be addressed:

1. Abstract:

a. Bad grammar starting with the first sentence. The pandemic has struggled?? Please revise.

b. The abstract should summarize the need, methods, and results of the paper. After reading the paper it is very unclear what has been accomplished in the study. Please revise.

2. Introduction:

a. The advantages and disadvantages of different testing methods is not described.

b. The scale of testing is not well described.

c. Not clear what the contributions of this work is. A template and complete circuits??

d. Authors need to justify that the proposed method would provide an “optimal” solution or delete “optimal”.

3. Methods:

a. Very poor organization: It would be advised to start with a workflow picture describing the different elements of the proposed system. The section headers don’t follow a clear logic.

b. Not reproducible: The methods are not well enough described to reproduce your results. Showing your pseudo-code would help.

4. Results:

a. Poor organization

b. Figures need to be improved

c. Unclear study design and statistical evaluation

5. Conclusion is missing

6. General: The grammar and writing is very poor and needs to be improved.

**********

6. PLOS authors have the option to publish the peer review history of their article (what does this mean?). If published, this will include your full peer review and any attached files.

Reviewer #1: Yes: Emilia Mia Sordillo, MD, PhD

Reviewer #2: No

PLoS One. 2021 Jul 14;16(7):e0252509. doi: 10.1371/journal.pone.0252509.r002

Author response to Decision Letter 0


23 Apr 2021

Response to reviewers. Also available as .docx in the submission.

Reviewer #1:

The title of the manuscript should be revised to be more informative, and, unless used with permission, to avoid the use of the name ROBOCOV, which is the name of a pre-existing statistical package – see https://github.com/kkdey/Robocov

R: We appreciate the insightful comment. Following the reviewer's suggestion we have removed the name ROBOCOV from the manuscript to avoid confusions and changed the title to make it more informative.

As noted by the authors, the COVID-19 pandemic has highlighted the disastrous impact of supply chain disruptions on global response. Identification of cost-effective alternatives to increase diagnostic capabilities is critical. The authors describe integration of a potentially interesting robotic platform from a relatively new vendor, that has the advantage of utilizing open-source software, and compare its performance to several better-known systems that have FDA emergency use authorization for SARS-CoV-2 diagnostic testing. However, the manuscript can be shortened and would benefit from being more focused. In addition, the use of advertising jargon, eg. "Hit the ground running", or descriptions of system advantages that are not referenced or specifically supported by data in the manuscript may appear promotional and detract from the authors’ message, and should be deleted.

R: We appreciate the succinct summary of our work and fully agree with the reviewer. Following these suggestions, we have shortened the manuscript and removed unnecessary parts and superfluous descriptions. We have also rewritten several parts of the manuscript to better reflect the objectives, the work we did, and its usefulness. The comments of the reviewer were particularly useful to focus the manuscript and enhance the discussion.

The authors’ stated aim is to describe use of the Opentrons OT system to set-up a reproducible workflow for diagnostic testing. It should be more clearly stated that the authors are describing a potential workflow incorporating the OT robot and the authors’ COVID-19 protocol for the Opentrons robot/author’s modifications to the COVID-19 protocol from the Opentrons Protocol Library, rather than a pilot study or an implementation in a clinical diagnostic setting, which would require testing of additional performance parameters and a larger sample size.

R: We apologize for the confusion and want to clarify our position. The CDB (Biomedical Diagnostic Center) works in a clinical setting (we are a part of the Hospital Clínic Barcelona). We have processed more than 40.000 samples (~500 runs) using the circuit described in the paper since the implementation of the platform. We do have other platforms/circuits in routine that we use in parallel.

The samples we use for comparing and validating the different platforms come from the EMQN (https://www.emqn.org/about-emqn/) which is the standard external quality assessment in Europe for molecular diagnostics.

We also want to stress that we have not used any protocol (code) available from the Opentrons Protocol Library, as we considered that the code was not good enough and difficult to generalize and/or re-adapt to changes. We have written all the necessary code from scratch, including several functions that enhance the current capabilities of the robots, as well as a template that is useful to build stations that conduct different steps from scratch. All the code has been made available through GitHub: https://github.com/CDB-coreBM/covid19clinic

We have included a setting section in Methods to better explain our context and the content we developed.

Finally, what we are validating is the adaptation of already validated kits (Thermo VP and VPII) into the OT-2 robotic platforms.

Additionally, since the authors are proposing this system as an affordable system for clinical diagnosis when resources may be limited, it would be helpful to discuss further:

System Affordability

- When the authors describe the system as affordable relative to other systems, are they considering only the cost of the robot itself? If so, it should be clearly stated that other major set-up costs, maintenance, consumables, personnel costs for operation etc. needed to obtain an interpretable diagnostic result for clinical purposes have not been addressed or compared to other systems

R: We certainly agree with the reviewer that would be of the utmost interest to have a thorough comparison. But such comparison belongs in the field of health economics and would constitute an entire paper. Nonetheless, we have incorporated this limitation into the discussion section

The OT-2 stations are a promising solution to increase the SARS-CoV-2 testing capability since it is an affordable open-source platform for liquid handling. The cost of the robot is much lower than other solutions, however other costs associated (personnel, consumables, etc) are similar. Other hospitals have compared the cost of using in-house protocols compared to commercial kits in OT-2 platforms12.

Consumables supply chain

- The authors raise concerns regarding global supply chain problems as a reason for using this open-source software platform. Please clarify why availability of the proprietary components and supplies listed on the Opentrons website, including heating blocks, pipette tips, racks & adapters, would not be an issue for this vendor.

R: We agree that supply chain problems should affect more or less uniformly the different vendors and Opentrons is clearly not an exception. What we tried to convey here:

Their openness confers them the ability to avoid limited supply chains for certain laboratory equipment, as it takes little time to define and test new laboratory equipment and include it in an already working protocol

The clear advantage of this system is that it is very easy to substitute equivalent labware from different vendors interchangeably simply by modeling the components and defining it in the configuration files of the system. We have clarified this point in the paper. We actually only use the pipette tips from the company Opentrons (and have found a replacement if it was necessary); all the other labware was sourced from other vendors. In addition, racks, adapters, and other reusable parts can be obtained with 3D printing. We built some of them for some custom protocols, but as they were not included in this methodology they are not included in the manuscript.

Potential clinical impact of system limitations

- The authors note that there is no hardware or software in the robots to enable sample tracking. The value of robotics comes when large numbers of samples are being tested, and manual front and back end specimen tracking becomes burdensome and more prone to error. What are the work-arounds the authors propose, and what are the costs? How does that affect cost compared to other vendors that incorporate specimen and reagent recognition?

R: We thank the reviewer for the comment. The workaround that we propose is based on manually scanning each sample in the different numbered sample racks (1 to 4) and storing that information in a file that is passed automatically throughout the circuit across the different scripts. Therefore, a sample is always associated with a well position, that is the same in the different plates used. The plates are also tagged with the run name before the beginning of a process.

Additionally, other users are actively developing solutions to incorporate barcode scanning hardware which could allow this type of sample tracking with a minimal investment (100$):

code: https://github.com/theosanderson/tube_checkout

demonstration: https://twitter.com/theosanderson/status/1286798512483708937

- Another limitation noted is the inability of the robot to detect specimen aspiration failures or clots, and presumably also short specimen volumes (a reality in the diagnostic laboratory). How do the authors propose this be addressed to minimize negative clinical impact of delayed or failed recognition of an invalid or (clinically)inaccurate test result?

R: This is clearly one of the main limitations. However, because the robots are modular and work in a chain, we have an assigned technician that prepares and supervises the whole run. He/she makes sure that there are no problems between stations by visually inspecting the plates and monitoring the behavior of the robots.

Reviewer #2:

The paper presents an affordable open-source robotic platform for SARS-CoV-2 testing by RT-qPCR using OT-2 open-source liquid-handling robots. The potential impact and need for this work is high. However, lack of rigor in each section of the paper diminishes the importance of this paper.

R: We thank the reviewer for the comments in our manuscript and agree that the potential impact of this work is high. Following the reviewer’s suggestions, we have included some new sections to better explain the objectives and logic behind our work. We believe that the code we have developed will not only be useful for SARS-CoV-2 testing, but will also facilitate the use of this platform in diverse research environments in the future.

General comments to be addressed:

1. Abstract:

a. Bad grammar starting with the first sentence. The pandemic has struggled?? Please revise.

R: We have thoroughly revised the manuscript for grammar errors and re-written most parts, including the abstract.

b. The abstract should summarize the need, methods, and results of the paper. After reading the paper it is very unclear what has been accomplished in the study. Please revise.

R: We have re-written the abstract and introduction and have included more specific objectives to clarify what has been accomplished and its usefulness.

2. Introduction:

a. The advantages and disadvantages of different testing methods is not described.

R: There is abundant literature comparing different testing methods. We feel that raising this point here would not add relevant context to our manuscript, as we already focus on the implementation of RT-qPCR.

b. The scale of testing is not well described.

R: Unfortunately, it is unclear to us what the reviewer is referring to with this comment. This could refer to the scale of testing needed globally (which is an open public health question), the number of samples we process in our implementation, or the theoretical capacity of a chain of such robots.

We have been using the platform regularly for a year approximately and have processed more than 40.000 samples so far. We did not run our setup at full capacity however, as we have access to several other robotic platforms.

As for the last question, one single chain of robots (4) can increment the throughput of a laboratory significantly.

The complete process for testing 96 samples takes about 4h (Table 1), and a single laboratory technician can operate it. The longest step is the RT-qPCR amplification and detection using the ABI 7500 Fast thermocycler. Theoretically, a new run could start every 70 minutes; however, the inactivation of samples becomes the real bottleneck.

c. Not clear what the contributions of this work is. A template and complete circuits??

R: We agree that the contributions were not clear enough. We have re-written the introduction for clarity. We have indeed developed a framework that includes several functions and a proposed template (that includes all the functions) to construct stations from scratch. We also developed a circuit for SARS-CoV-2 RT-PCR testing with the framework developed.

d. Authors need to justify that the proposed method would provide an “optimal” solution or delete “optimal”.

We agree with the reviewer and have removed the word “optimal”

3. Methods:

a. Very poor organization: It would be advised to start with a workflow picture describing the different elements of the proposed system. The section headers don’t follow a clear logic.

We thank the reviewer for their comment. We agree that the organization was not clear enough, and we have re-ordered the manuscript to clarify the context and what we did.

b. Not reproducible: The methods are not well enough described to reproduce your results. Showing your pseudo-code would help.

We have improved the code legibility on our GitHub repo and wiki (https://github.com/CDB-coreBM/covid19clinic/wiki ) with more detailed explanations of how the template is structured. We also include descriptions and examples of every individual function (included in the template) so it is easier to understand the logic behind them and its usefulness in different scenarios.

We would like to stress that the code provided is fully reproducible (it has been implemented in other hospitals) when using the same labware and settings. However it can be fully customized once the user understands the code (hence the wiki page).

4. Results:

a. Poor organization

b. Figures need to be improved

c. Unclear study design and statistical evaluation

R: Thanks for the comments. We have re-organized the results so they follow a clear logic after explaining the methodology and moved figure 1 to supplementary material because we believe it distracted from the main message.

About the validation, the samples we use for comparing and validating the different platforms come from the EMQN (https://www.emqn.org/about-emqn/) which is the standard external quality assessment in Europe for molecular diagnostics. Specifically we use the Coronavirus Outbreak Preparedness EQA Pilot study.

5. Conclusion is missing

R: We have improved the final message of the manuscript that acts as a conclusion.

6. General: The grammar and writing is very poor and needs to be improved.

R: As mentioned above we have revised the grammar and writing.

Decision Letter 1

Ruslan Kalendar

18 May 2021

Implementation of an open-source robotic platform for SARS-CoV-2 testing by real-time RT-PCR

PONE-D-21-03093R1

Dear Dr. Villanueva-Cañas,

We’re pleased to inform you that your manuscript has been judged scientifically suitable for publication and will be formally accepted for publication once it meets all outstanding technical requirements.

Within one week, you’ll receive an e-mail detailing the required amendments. When these have been addressed, you’ll receive a formal acceptance letter and your manuscript will be scheduled for publication.

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Kind regards,

Ruslan Kalendar, PhD

Academic Editor

PLOS ONE

Additional Editor Comments (optional):

To authors, minor comment from reviewer:

Figure S1 (simulations for pipette height adjustment to ensure correct reagent aliquots ) referenced in the S1 File Supplementary methods appears to be missing from the materials available for review.

Reviewers' comments:

Reviewer's Responses to Questions

Comments to the Author

1. If the authors have adequately addressed your comments raised in a previous round of review and you feel that this manuscript is now acceptable for publication, you may indicate that here to bypass the “Comments to the Author” section, enter your conflict of interest statement in the “Confidential to Editor” section, and submit your "Accept" recommendation.

Reviewer #1: (No Response)

Reviewer #2: All comments have been addressed

**********

2. Is the manuscript technically sound, and do the data support the conclusions?

The manuscript must describe a technically sound piece of scientific research with data that supports the conclusions. Experiments must have been conducted rigorously, with appropriate controls, replication, and sample sizes. The conclusions must be drawn appropriately based on the data presented.

Reviewer #1: Yes

Reviewer #2: Yes

**********

3. Has the statistical analysis been performed appropriately and rigorously?

Reviewer #1: (No Response)

Reviewer #2: Yes

**********

4. Have the authors made all data underlying the findings in their manuscript fully available?

The PLOS Data policy requires authors to make all data underlying the findings described in their manuscript fully available without restriction, with rare exception (please refer to the Data Availability Statement in the manuscript PDF file). The data should be provided as part of the manuscript or its supporting information, or deposited to a public repository. For example, in addition to summary statistics, the data points behind means, medians and variance measures should be available. If there are restrictions on publicly sharing data—e.g. participant privacy or use of data from a third party—those must be specified.

Reviewer #1: Yes

Reviewer #2: Yes

**********

5. Is the manuscript presented in an intelligible fashion and written in standard English?

PLOS ONE does not copyedit accepted manuscripts, so the language in submitted articles must be clear, correct, and unambiguous. Any typographical or grammatical errors should be corrected at revision, so please note any specific errors here.

Reviewer #1: Yes

Reviewer #2: Yes

**********

6. Review Comments to the Author

Reviewer #1: 

The authors have revised the manuscript and it is now more focused.

One concern - Figure S1 (simulations for pipette height adjustment to ensure correct reagent aliquots ) referenced in the S1 File Supplementary methods appears to be missing from the materials available for review

Reviewer #2: 

The paper presents an affordable open-source robotic platform for SARS-CoV-2 testing by RT-qPCR using OT-2 open-source liquid-handling robots. The potential impact and need for this work is high. The authors addressed all the previous comments and significantly improved the paper.

**********

7. PLOS authors have the option to publish the peer review history of their article (what does this mean?). If published, this will include your full peer review and any attached files.

If you choose “no”, your identity will remain anonymous but your review may still be made public.

Do you want your identity to be public for this peer review? For information about this choice, including consent withdrawal, please see our Privacy Policy.

Reviewer #1: Yes: Emilia Mia Sordillo, MD, PhD

Reviewer #2: No

Acceptance letter

Ruslan Kalendar

30 Jun 2021

PONE-D-21-03093R1

Implementation of an open-source robotic platform for SARS-CoV-2 testing by real-time RT-PCR.

Dear Dr. Villanueva-Cañas:

I'm pleased to inform you that your manuscript has been deemed suitable for publication in PLOS ONE. Congratulations! Your manuscript is now with our production department.

If your institution or institutions have a press office, please let them know about your upcoming paper now to help maximize its impact. If they'll be preparing press materials, please inform our press team within the next 48 hours. Your manuscript will remain under strict press embargo until 2 pm Eastern Time on the date of publication. For more information please contact onepress@plos.org.

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on behalf of

Prof. Ruslan Kalendar

Academic Editor

PLOS ONE

Associated Data

    This section collects any data citations, data availability statements, or supplementary materials included in this article.

    Supplementary Materials

    S1 File. Supplementary methods.

    Expanded methodology for the height calculation function and description of the platforms used in the EMQN comparison.

    (DOCX)

    S2 File. Supplementary material.

    Description of OT-2 stations including the labware placement for every circuit described in this manuscript.

    (PDF)

    S1 Fig

    (TIF)

    Data Availability Statement

    Code developed is available at https://github.com/CDB-coreBM/covid19clinic.


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