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In-office lens casting systems may offer savings, solutions
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Optometrists who use in-office lens molding systems say once the practitioner determines the technology will meet practice and patient needs, it can help advance an already successful practice.
“It allows me to grow my practice better than anything else I’ve done,” Duane L. Wires, OD, told Primary Care Optometry News in an interview. “I can go out and buy a $30,000 piece of equipment that may make me a better doctor, but I’m always trying to figure out how to pay for the thing.”
Practitioners with these systems advise other optometrists to consider patient demographics and demands as well as staffing and office space before signing on the dotted line.
Dr. Wires practices in two Ohio locations and has been using the OptiCast II system manufactured by OptiCast Inc. of Findlay, Ohio, for 5 years. He makes up to six pairs of progressive lenses each day.
Another major player in the lens casting market, Optical Dynamics, based in Louisville, Ky., manufactures the Q-2100R in-office lens casting system.
Steve Croce, OD, who co-owns two practices in Rhode Island, said a possible $2,000 to $3,000 savings on his lab bill each month led him to consider making his own lenses in-house. He settled on the Optical Dynamics system and makes about 75 pairs of lenses every month.
“Our bill was becoming unmanageable and we needed to reduce our costs,” Dr. Croce told PCON. “However, you need to have a certain volume, or else it isn’t worth it. We sat down and crunched the numbers with the sales representative and it made sense for us. But it’s not for everybody.”
The OptiCast II
The OptiCast II is the latest version of the company’s in-office lens molding system. “Our claim to fame is our material that is poly-like in characteristics,” said Chip Myers, president of OptiCast USA, in an interview with PCON. “It also has an bayer value equal to a tintable hard-coated lens, only it doesn’t have a coating. It’s inherently very abrasion resistant – the only material in existence like this.”
Mr. Myers said the system works by setting “the front and back mold that is held together a specific distance apart with gaskets, and the cavity between the mold is filled up with the liquid resin.
“Our particular material is cured with light, resulting in a lens in six minutes” he continued.
The company boasts that the OptiCast can make about 92% of all prescriptions, ranging from a +4 D to a -4 D and out to a -2 D cylinder and a +1 D to +3 D add.
The company offers a total system or a la carte molds. The company sells the monomers separately on an as-needed basis, a policy that Dr. Wires said he appreciates. “There’s no forced utilization,” he said.
The Q-2100R
Optical Dynamics’ Q-2100R is a tabletop digital lens system with a computerized mold and gasket selection, according to the company Web site.
The machine can cast aspheric single vision, bifocal or multifocal lenses in clear or photochromic material with scratch coat. Aspheric single vision or multifocal lenses can be cast in clear or photochromic material with in-office nanoClear AR. The Q-2100R makes lenses in a power range of +4 D to -6 D spheres and -0.25 D to -2.50 D cylinder and an add power of +1 D to +3 D, all in 0.25-D steps.
 Optical Dynamics: The Q-2100R Digital Lens Systems with nanoCLEAR AR allows practitioners to make lenses that are antireflective, anti-scratch and anti-UV. Source: Optical Dynamics. |
The system can be purchased, leased or financed, the company said.
As for how the lenses are crafted, “liquid monomer is polymerized, via an automated, microprocessor-controlled process utilizing ultraviolet light, and cast into either clear or photochromic material,” Joseph B. Studebaker, OD, FAAO, explained to PCON. “The process uses proprietary lens molds and gaskets to cast lenses with scratch coating or, if required, in-mold antireflective lenses that are also anti-scratch and anti-UV.”
Dr. Studebaker, a clinical assistant professor at the Ohio State University College of Optometry, practices at Northwest Optometry in Englewood, Ohio. He licenses the Q-2100R under a 5-year lease agreement and produces about 40 pairs of lenses per week using the system.
Practice, patient savings
 OptiCast II: This system can make lenses ranging from a +4 D to a -4 D and out to a -2 D cylinder and a +1 D to +3 D add. Source: OptiCast. |
Both companies say their systems will result in reduced inventory and production costs for practitioners, many of whom previously used stock houses and wholesale labs for their lenses.
“They are still casting a premium quality progressive and they can cast it in-house for about $11 a pair vs. $25 to $75 for progressives from a wholesaler,” Mr. Myers said.
Dr. Studebaker said he saves about 40% using the in-office casting system. But several variables may mean savings will vary from practice to practice, he said.
“Factors such as lens spoilage, technician skill level and existing material cost schedules for outside laboratory work must be carefully considered,” he said. “For some practices, savings may approach 40% to 50%; however, in other practices, the ultimate savings will likely be reduced significantly if the system operators are not as skilled (higher rates of lens spoilage) or if pre-existing laboratory cost schedules were more favorable.”
Mr. Myers said OptiCast has a lens yield guarantee program to combat spoilage.
Dr. Wires said his system is profitable, and he is able to pass the savings on to his patients. He sells one pair of spectacles at full price and gives customers a second pair for $20, plus the cost of the frame.
“It costs me the same to make a bifocal as it does to make a progressive, so we offer a huge savings on second pairs that you just can’t afford if you’re going to buy (lenses) from a lab,” he said. “As long as they’re paying full price for the frame, we are making our profit on the frame side, which is really good. And yet we’re still more than breaking even on the cost of our lenses.”
He said he still inventories single-vision lenses because he can purchase them for less than it costs to make them.
Advice from users
Practitioners who spoke to PCON were happy with their decisions to make their own lenses. But they cautioned against investing in the technology without first conducting extensive research. “Carefully analyze and be certain that you understand your patient demographics and the associated demand for in-office lens production,” Dr. Studebaker said.
“Keep in mind that some insurers will not allow you to produce ophthalmic lenses in an in-office laboratory,” he continued. “Also, understand that, despite product automation, lens casting is still a technology that demands considerable operator skill. You will need staff members who are willing to develop this capability.”
Dr. Croce agreed.
“It is not for everybody, because it is labor intensive,” he said. “You have to have someone who can work in the lab with it.”
Dr. Croce said he sat down with a company representative to determine whether he would make enough lenses to make the investment worth it. “They were very close, within 10%,” he said about the representative’s estimation.
Also, although the companies tout their compact designs, practitioners will want to make sure they have enough lab space, Dr. Studebaker said.
“Any practitioner contemplating the addition of this technology in their practice will need to allocate adequate space for the associated equipment,” he said. “While the equipment is relatively self-contained and the space required will not have to be ‘clean-room’ quality, you will need a clean, dust-free environment to assure good product quality.”
For your information:
- Duane L. Wires, OD, can be reached at Village Vision Center, 107 S. Main St., Ada, Ohio, 45810; (419) 634-2921; fax: (419) 634-9858; e-mail: villagevisioncenter@mac.com or eyesonmain@mac.com; eyesonmainvisioncenter.com. Dr. Wires is an investor in OptiCast.
- Steve Croce, OD, can be reached at Croce and Pugliese Vision Care, 622 George Washington Highway, Lincoln, RI 02865; (401) 333-0550; fax: (401) 312-0083.e-mail: flyfishereyedoc@yahoo.com. Dr. Croce does not have any financial interest in any products mentioned in this article nor is he a paid consultant for any companies mentioned.
- Chip Myers is president of Opticast USA. He can be reached at at 12042-R Tiffin Ave., Findlay, OH 45840; (888) 893-2278; fax: (419) 425-2250; e-mail: chipmyers@opticastusa.com; Web site: www.opticastusa.com.
- Joseph B. Studebaker, OD, FAAO, is a clinical assistant professor at the Ohio State University College of Optometry and practices at Northwest Optometry, LLC, 639 West National Road, Englewood, OH, 45322; (937) 836-3041; fax: (937) 836-1937; e-mail: jbstudebaker@hotmail.com; www.visionsource-nwoptometry.com. Dr. Studebaker does not have any financial interest in any products mentioned in this article nor is he a paid consultant for any companies mentioned.
- Optical Dynamics is located at 10106 Bluegrass Parkway, Louisville, KY 40299; (800) 797-2743; fax: (502) 213-0742; www.OpticalDynamics.com.