Continuous Bioprocessing Centrifuge Rotor for Controlled Liquid Removal
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Solution Overview
Problem
Conventional centrifugation processes face challenges in increasing throughput while minimizing operator effort and preventing remixing of separated components, particularly with large containers or multiple containers in a centrifuge.
Innovation Solution
A rotor assembly with a compression ring, retaining bolts, and baffles that securely hold bioprocess bags, along with a decanting and feed assembly, allows for continuous processing and efficient removal of liquid media without disturbing settled components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the size of the container is increased to hold as much suspension as possible, then the throughput is improved, but it becomes more difficult for an operator to place containers in and remove containers from the centrifuge
Solution Approach 1:
The container system is segmented into a bag portion and a cap portion that can be assembled together. The bag portion can be pre-filled and sealed, then attached to the cap portion which interfaces with the rotor. This segmentation allows operators to handle smaller, more manageable components rather than large rigid containers, improving ease of operation while maintaining throughput capacity.
Solution Approach 2:
The bag portion is designed to fit inside or nest with the cap portion, creating a compact assembled unit. The radially-aligned skirt of the bag portion fits within the rotor assembly, and the compression ring compresses the bag into the available space. This nesting approach allows large volume containers to be configured in a space-efficient manner that simplifies loading and unloading.
2Productivity
If the number of containers loaded into the centrifuge is increased to increase throughput, then the throughput is improved, but the amount of time it takes the operator to load and unload each batch of containers increases
Solution Approach 1:
Multiple bag portions can be pre-assembled with cap portions and held together in a stack or cluster configuration. The compression ring and holder assembly allow multiple bags to be secured simultaneously in the rotor, enabling operators to load multiple containers in a single operation rather than individually, thus increasing throughput without proportionally increasing loading time.
Solution Approach 2:
The bag portions can be pre-filled, sealed, and prepared outside the centrifuge before loading. The radially-aligned skirts and compression mechanisms are pre-configured in the rotor assembly. This preliminary preparation reduces the time required during the actual loading operation, allowing faster batch loading and unloading while maintaining high throughput.
3Productivity
If large containers are used to increase throughput, then the throughput is improved, but the jostling of the container increases which can cause remixing of the separated components
Solution Approach 1:
The bag portion is made of flexible material that can deform and conform during centrifugation. This flexibility allows the bag to absorb and dampen mechanical stresses and jostling forces, preventing the transmitted vibrations from disturbing the separated components. The flexible membrane maintains separation integrity while allowing the use of larger container volumes for increased throughput.
Solution Approach 2:
The compression ring applies pre-compression force to the bag portion, creating a cushioning effect that stabilizes the bag during rotation. The holder assembly and radially-aligned skirts provide structural support that cushions against jostling forces before they can cause remixing. This beforehand cushioning protects the separation integrity while enabling larger container sizes.
4Productivity
If conventional centrifugation methods are used with multiple containers, then throughput can be increased, but the complexity of securely holding and managing multiple containers increases
Solution Approach 1:
The holder assembly and compression ring are designed as universal components that can accommodate multiple bag portions of the same size specification. The radially-aligned skirts and compression mechanism provide a standardized interface for securing containers. This universality simplifies the management of multiple containers by providing a consistent, repeatable securing process rather than requiring different mechanisms for each container.
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 rotor assembly enables efficient, continuous centrifugation with reduced operator effort, minimizing remixing and optimizing the separation process by allowing for secure containment and controlled removal of liquid media.
Implementation Method 1
The centrifugal force created by spinning a rotor in the centrifuge causes the solids in the suspension to settle out and form a generally solid pellet toward the bottom of the container. A supernatant comprising liquid that is less dense than the pellet collects in the container above the pellet.
Data Source
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AI summary
A rotor assembly (10, 150, 270, 310) and method of using the rotor assembly (10, 150, 270, 310). The rotor assembly (10, 150, 270, 310) includes a bio-process bag (48), a drum (46) that receives a lower portion of the bag (48), and a pressure ring (50). A holder (54, 182) couples an upper portion of the bag (48) to the pressure ring (50). The pressure ring (50) is coupled to the drum (46) to define an interior space that contains the bag (48). A liquid transport assembly (35, 178, 272) passes through an opening in the holder (54, 182) so that liquids can be added to, and removed from, the bag (48) without removing the rotor (16, 154) from the centrifuge. A bearing assembly (190) in the holder (54, 182) couples the liquid transport assembly (35, 178, 272) to the rotor (16, 154), and enables the liquid transport assembly (35, 178, 272) to remain stationary while the rotor (16, 154) rotates around it. One or more seal assemblies (276, 312) provide a fluid-tight seal against the outer portion of the liquid transport assembly (35, 178, 272), and prevent fluids from leaking from the bag (48) during centrifugation.