Aseptic Production Cell Layout for Personalized Pharma Batches

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Solution Overview

Problem

Conventional production systems for pharmaceuticals, particularly in personalized therapeutics, face high costs, quality variations, and production rejects due to manual interventions, limiting scalability and industrial application of individual and ultrasmall batch sizes, with a need for secure and manipulation-protected manufacturing.

Innovation Solution

A production system comprising multiple processing units, a clean room area, airlock devices, handling and storage units, and workpiece carriers, designed to accommodate and treat educts efficiently and securely, enabling automated and aseptic processing of biological-pharmaceutical products.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If manual interventions are used in production systems for personalized therapeutics, then high-level personalization and customization are achieved, but costs increase significantly and quality variations occur

Engineering Contradiction:

Improvepersonalization levelVSAvoidquality consistency

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent replaces manual mechanical operations with automated robotic systems. Robots perform picking, placing, and processing operations on workpieces, eliminating manual interventions while maintaining high personalization capability through programmable control. This substitution ensures consistent quality execution without human variability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables automated self-service through intelligent workpiece carriers that autonomously navigate to processing stations, self-identify through recognition systems, and trigger appropriate processing operations. The carriers manage their own positioning and coordination with the control system, reducing manual oversight while maintaining customization.

Inventive Principle:

Principle #25Self-service

2Adaptability or versatility

If manual interventions are used for individual and ultrasmall batch production, then high-level customization is achieved, but production rejects and bad parts increase

Engineering Contradiction:

Improvecustomization capabilityVSAvoidproduction efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

Automated robotic systems replace manual operations to eliminate human error and variability. The robots execute precise, repeatable motions for handling and processing workpieces, ensuring consistent quality outcomes and reducing rejects while maintaining the ability to handle individual and small batch productions.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system incorporates sensors and recognition systems that continuously monitor workpiece characteristics and provide feedback to the control system. This real-time feedback enables dynamic adjustment of processing parameters, ensuring high quality outcomes for customized products while maintaining production efficiency through automated correction of deviations.

Inventive Principle:

Principle #23Feedback

3Ease of operation

If manual operations are performed in production, then flexible handling of individual items is possible, but manipulation protection and security are compromised

Engineering Contradiction:

Improvehandling flexibilityVSAvoidmanipulation risk

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

Robotic systems replace human operators in handling and processing workpieces, eliminating risks associated with manual manipulation such as contamination, damage, or unauthorized access. The automated systems maintain flexibility through programmable control while providing inherent protection against manipulation errors and security breaches.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

Intelligent workpiece carriers act as intermediaries between storage and processing stations. These carriers encapsulate workpieces, providing physical protection and controlled transport. The carriers interface with automated handling systems, enabling flexible routing and processing while minimizing direct exposure to potential manipulation risks.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Ease of operation

If conventional production systems are used for pharmaceutical manufacturing, then manual flexibility is maintained, but scalability to large-scale production is limited

Engineering Contradiction:

Improvemanual flexibilityVSAvoidscalability

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The production system is divided into modular functional units including multiple processing stations, independent robotic systems, and interchangeable workpiece carriers. This segmentation allows the system to be scaled by adding or removing modules without redesigning the entire system, enabling transition from individual to large-scale production while maintaining operational flexibility.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The robotic systems and processing stations are designed with universal capabilities to handle multiple workpiece types and perform various operations. The same robotic platform can be reconfigured through software to produce different pharmaceutical products, enabling scalable production across multiple product lines without sacrificing flexibility.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS20250298044A1Production system for the manufacture of a product

Publication Date: 2025.09.25 KYOOBE TECH GMBH

AI summary

A production system (10) for manufacturing a product (20), in particular a biological-pharmaceutical product, which comprises multiple processing units (30, 50, 702, 704) for accommodating and/or treating an educt (40), and/or to a method for this purpose.