Bioprocess Solution Mixing With Sensor-Controlled Fluid Flow
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Solution Overview
Problem
Existing methods for reconstituting bioprocess solutions from dry ingredients are time-consuming, labor-intensive, and prone to errors, particularly for large-scale preparations, and require significant manpower and storage space, with prepackaged liquid solutions being costly and light-sensitive.
Innovation Solution
An automated method and apparatus using a mixing apparatus with a mixing chamber, tubing, valves, and sensors to control fluid flow, allowing for the reconstitution of dry ingredients into liquid bioprocess solutions in a controlled and repeatable manner, minimizing physical contact and ensuring consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated mixing apparatus is used to reconstitute dry ingredients into liquid bioprocess solutions, then preparation time and labor are reduced, but device complexity increases
Solution Approach 1:
The automated mixing apparatus is divided into distinct functional modules: a mixing chamber for reconstitution, an array of tubing for fluid transport, multiple valves for flow control, and sensors for monitoring. This segmentation allows each component to perform a specific function efficiently, reducing overall preparation time while making the complex system manageable through modular design
Solution Approach 2:
The system incorporates sensors that automatically detect when dry ingredients have been fully reconstituted into liquid solutions, triggering the mixing process to stop. This self-service capability eliminates the need for continuous manual monitoring, significantly reducing labor requirements while maintaining precise control over the mixing process
2Reliability
If prepackaged liquid solutions are used, then consistency and reliability are improved, but cost and storage requirements increase
Solution Approach 1:
Dry ingredients are pre-packaged in stable, space-efficient forms before use. The automated mixing apparatus then reconstitutes these dry ingredients into liquid bioprocess solutions immediately before use, ensuring solution consistency and reliability while minimizing storage space requirements and reducing the need for refrigeration
Solution Approach 2:
The system transforms the physical state of ingredients from dry powder to liquid solution through controlled mixing with water. This parameter change allows the same material to be stored in a compact dry form and converted to liquid form only when needed, optimizing both storage efficiency and solution quality
3Device complexity
If manual reconstitution methods are used, then device complexity is reduced, but preparation time and labor requirements increase
Solution Approach 1:
The system replaces manual mechanical mixing operations with an automated mixing apparatus that uses controlled fluid flow through tubing and valves to reconstitute dry ingredients. This substitution eliminates time-consuming manual steps while the modular design keeps device complexity manageable
4Productivity
If large volumes of bioprocess solutions are prepared manually, then labor costs increase, but risk of contamination remains constant
Solution Approach 1:
Sensors automatically detect when the reconstitution process is complete and trigger the mixing apparatus to stop, eliminating the need for manual intervention during the critical mixing phase. This automation maintains contamination risk at constant levels while dramatically improving preparation efficiency for large volumes
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The automated system reduces preparation time, labor, and risk of contamination while improving reliability and consistency, making large-scale bioprocess solution preparation efficient and cost-effective.
Implementation Method 1
an automated system including at least one mixing chamber, an array of tubing for fluid flow within the system, and a plurality of valves provided within the tubing, to automatically prepare the liquid bioprocess solution
Data Source
AI summary
An automated bioprocess solution preparation apparatus includes a first mixing chamber containing at least one ingredient for a bioprocess solution, a first port and a second port for a fluid to enter the mixing chamber, and a third port for a liquid bioprocess solution to exit the mixing chamber. The apparatus further includes an array of tubing for fluid flow within the apparatus, a sensor arranged to measure a property of the liquid bioprocess solution exiting the mixing chamber, a first valve associated with the first port, and a second valve associated with the second port. When the property meets or exceeds a threshold value, the apparatus is operable to perform at least one of: closing the first valve to block the fluid from entering the mixing chamber through the first port, and opening the second valve for the fluid to enter the mixing chamber through the second port.