In an August survey conducted by TDA, product shortages and delays in delivery were at the top of the list of market trends scientific researchers were experiencing. The blame for this lies in more than one way in the COVID-19 pandemic. Beginning in March 2020, the scarcity of personal protective equipment (PPE) among health care workers made headlines. This was soon followed by a paucity of lab consumables, which has continued to present, as testing for the virus ramped up. According to one academic researcher, “It is becoming difficult to obtain specific plasticware, tips, or other consumables commonly used for COVID-19 testing.”
The paucity of pipette tips has received particular attention in the media. In January 2020, the FDA added pipette tips and micropipettes to its list of device shortages, estimating them to be in short supply for the “duration of the COVID-19 Public Health Emergency.” In an article published in January of this year, health care improvement company Premier reported that, since May 2020, hospitals’ daily use of pipette tips has grown more than 50%. In addition, average lead time for pipette tips had lengthened to more than 25 days. And the need for pipette tips is not shrinking. NPR reported that the average COVID-19 test requires four tips, and, with the spread of the Delta variant, the Johns Hopkins Coronavirus Resource Center shows the number of daily tests administered to be at about the same level as in January and February of this year on most days exceeding 1 million (and on a few, surpassing 2 million). So-called nonessential labs are also experiencing the delays and product scarcity as they resume activity, even at reduced capacity. Researchers have resorted to washing and reusing pipette tips, running tests in batches, and strategically planning experiments and tests to reduce tip consumptionΓÇöall measures that trade off factors such as time and contamination risk.
To help alleviate the scarcity of pipette tips, the US Department of Defense and Department of Health and Human Services (HHS) has awarded tens of millions of dollars in contracts to companies such as Corning, Tecan, and Thermo Fisher Scientific to step up their production of tips and other lab supplies. However, fulfilling these contracts is dependent on the availability of plastics, which are, in turn, dependent on supply chains and manufacturing ability.
The pandemic has disrupted supply chains around the world. The shutdown of borders has led to customs delays, and container ships are backed up at ports owing to reduced workforce or, in some cases, closure resulting from workers testing positive for COVID-19. After many countries ceased manufacturing and exporting goods early in the pandemic, activity has resumed, only to be faced with shortages of available shipping containers. The addition of stochastic events, such as the Suez Canal blockage in March, or hurricanes and winter storms, has compounded the problem.
The production of plastics, including polyethylene (PE) and polypropylene (PP), has hit some additional snags. Hurricane Laura in 2020 caused several petrochemical plants in Texas and Louisiana to shut down, reducing production in a market already experiencing shortages in PE and PP. According to Plastics Today, facilities forced to close by winter storms in Texas in February of this year accounted for 80%–85% of PE and PP production in the US. Factory fires and force majeure declarations of several plastics manufacturers in Europe and the US have also hampered plastics production.
For an industry already contending with an inefficient supply chain (as reported in SupplyChainBrain), the combination of the surge in demand for, decreased production of, and disruptions receiving lab products, including pipette tips, can have dire consequences. As reported in STAT News, scientists from labs screening newborns for genetic health conditions have spoken out about how the shortage of pipette tips has threatened to shut down parts of some screening programs, putting the health of infants at risk. In a win for these programs, in April, they received higher priority by HHS when ordering pipette tips.
Providers of lab products have been making strides in improving their supply chains. However, despite the resilience and even thriving of some labs, among some researchers, the short-term outlook is grim. “Supply shortages have greatly impacted operations and changed what we can offer to students and how quickly research can be accomplished,” commented one survey respondent. “Students are going to be leaving college with a lot less hands-on skills than what they were before the pandemic.” Asked how the pandemic and resulting economic conditions have affected lab operations, another researcher stated, “Badly. We are almost closed.”