Bioprocessing Fluid Sensor Arrangement with Bypass and Conditioning Paths
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Solution Overview
Problem
Conventional bioprocessing systems face challenges in maintaining aseptic conditions during sensor calibration, cleaning, and replacement, leading to potential contamination and increased costs due to the need for sterile environments and time-consuming validation processes.
Innovation Solution
A bioprocessing fluid sensor arrangement that allows aseptic connection and separation of sensors from the process fluid path, utilizing a bypass and conditioning fluid path with flow controls to manage fluid flow, reducing the risk of contamination and simplifying the maintenance process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are placed directly in the process fluid path for monitoring, then measurement capability is improved, but sensor replacement and maintenance becomes time-consuming and costly with contamination risk
Solution Approach 1:
The system is divided into separate functional modules: a sensor unit that can be detached from the process fluid path, a bypass line with flow controls, and a conditioning fluid path. This segmentation allows the sensor to be removed and replaced without disrupting the process fluid flow, enabling quick maintenance while maintaining continuous monitoring capability.
Solution Approach 2:
A bypass line with flow controls acts as an intermediary between the sensor unit and the process fluid path. This intermediary allows process fluid to flow through the bypass when the sensor is being replaced or conditioned, eliminating the need to stop the process or breach sterile conditions during sensor maintenance.
2Productivity
If sensors are placed directly in the process fluid path, then real-time monitoring is achieved, but contamination risk increases during sensor maintenance activities
Solution Approach 1:
The sensor unit is extracted from the process fluid path and placed in a separate, easily accessible location. This extraction allows sensor maintenance (cleaning, calibration, replacement) to be performed outside the sterile process environment, eliminating the risk of contamination to the process fluid while maintaining real-time monitoring capability through the bypass line.
Solution Approach 2:
The sensor unit is designed as a disposable or easily replaceable component that can be quickly swapped out without requiring complex sterilization or validation procedures. This approach reduces contamination risk by allowing frequent replacement of potentially contaminated sensors with pre-sterilized units, eliminating the need for time-consuming sterile maintenance procedures.
3Reliability
If clean room environments are used to maintain aseptic conditions during sensor connections, then sterility is preserved, but operational complexity and cost increase
Solution Approach 1:
The system incorporates self-contained sterilization and conditioning capabilities within the sensor unit and fluid paths. The sensor unit can be sterilized independently and then connected to the process fluid path through a bypass line that maintains sterile conditions without requiring a clean room environment. This self-service approach preserves aseptic conditions while eliminating the need for complex clean room infrastructure.
4Productivity
If sensors are integrated into the process fluid path for continuous monitoring, then process control is improved, but maintenance costs and validation requirements increase
Solution Approach 1:
The system employs dynamic flow control through the bypass line and flow control valves, allowing flexible switching between sensor monitoring mode and bypass mode. This dynamic configuration enables continuous process control when the sensor is operational, while allowing quick transition to bypass mode during sensor maintenance, reducing maintenance costs and validation requirements compared to fixed integrated sensor designs.
Data Source
AI summary
The present invention relates to a bioprocessing fluid sensor arrangement (100) for sensing fluidic properties in a process fluid path with a sensor (S), configured for aseptically connecting the sensor with at least one conditioning fluid while separating said sensor from the process fluid to at least one conditioning fluid e.g. for calibration, cleaning, regenerating and/or storing the sensor, the arrangement comprising a process fluid path (PF) having a process fluid inlet (PI) and a process fluid outlet (PO); a sensor (S) arranged in the process fluid path (PF); a bypass fluid path (BF) in the process fluid path (PF), for bypassing the sensor (S); a conditioning or cleaning fluid path (CF) having an inlet (CI) and an outlet (CO) each aseptically and fluidically connected to the process fluid path (PF), one on each side of the sensor (S); and flow controls (FC) for controlling the flow of fluids, whereby fluids can be controlled to flow either in the process fluid path (PF) via the sensor (S), or in the bypass fluid path (BF) omitting the sensor from the fluid path (PF), or in the conditioning or cleaning fluid path (CF) including the sensor in said flow but omitting the remaining process fluid path (PF) and bypass fluid path (BF).