Continuous Membrane Processing for Uniform Microparticle Production
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing batch processes for manufacturing microparticles and nanoparticles are limited by scale, labor intensity, and quality variability, with fed batch processes leading to inconsistent residence times and product differences.
Innovation Solution
A continuous process using membrane emulsification techniques, involving controlled provision of liquid phases through membranes with apertures, pH buffer adjustments, and optional concentration and microfiltration steps to produce uniform microparticles and nanoparticles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If batch process is used for manufacturing microparticles and nanoparticles, then flexibility and ease of operation are maintained, but productivity is limited and quality variability increases
Solution Approach 1:
The patent implements a continuous manufacturing process where liquid phases are continuously fed through membranes with controlled flow rates, eliminating batch interruptions. The system maintains continuous operation through multiple membranes arranged in series, with each membrane performing a specific function (emulsification, stabilization, concentration, filtration) without stopping the process, thereby significantly increasing productivity while maintaining operational control
2Device complexity
If batch process is used for manufacturing microparticles and nanoparticles, then equipment simplicity is maintained, but manufacturing scale is limited and labor intensity increases
Solution Approach 1:
The continuous manufacturing process is divided into distinct functional segments, each performed by a separate membrane module. The first membrane performs emulsification, the second stabilizes particles with pH buffer, the third concentrates the suspension, and the fourth filters the final product. This segmentation allows each component to remain relatively simple while the integrated system achieves large-scale manufacturing capability
Solution Approach 2:
Multiple membrane modules are combined in series to create an integrated continuous processing system. Each membrane unit handles a specific aspect of particle formation and processing, and their combination enables continuous operation at scale without requiring complex individual components, thus increasing manufacturing capacity while maintaining equipment simplicity
3Adaptability or versatility
If fed batch process is used, then flexibility in product formulation is maintained, but residence time variability increases leading to quality inconsistency
Solution Approach 1:
The continuous process ensures all particles experience the same residence time through the system, as materials flow continuously through each membrane stage without the variable accumulation and discharge periods inherent in fed-batch processes. This eliminates residence time variability and ensures consistent quality while maintaining formulation flexibility through controlled flow rates and membrane selection
4Productivity
If continuous process with multiple membranes is used, then productivity and quality consistency are improved, but device complexity increases
Solution Approach 1:
The complex continuous processing requirements are divided into simpler functional segments, each handled by a dedicated membrane module. This segmentation allows the use of standard, well-understood membrane technologies for each specific function (emulsification, stabilization, concentration, filtration) rather than requiring a single complex integrated system, thus managing overall device complexity while achieving high productivity and quality consistency
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
Enables large-scale, reproducible production of uniform microparticles and nanoparticles with reduced labor and quality variations, allowing for efficient encapsulation of active agents and adherence to industry standards.
Implementation Method 1
a first membrane defining a first plurality of apertures; controlling provision of a second liquid phase to the first membrane via the first plurality of apertures to form a mixture
Implementation Method 2
a second membrane defining a second plurality of apertures; controlling provision of a pH buffer liquid phase to the second membrane via the second plurality of apertures to form a stabilised suspension of particles
Implementation Method 3
controlling provision of the concentrated suspension phase to a third membrane, the third membrane defining a third plurality of apertures; controlling provision of a concentrated suspension phase to the third membrane via the third plurality of apertures to remove solvent, and exchange the particles into an excipient buffer
Implementation Method 4
a fourth membrane for microfiltration, to isolate the microscopic particles; controlling provision of the stabilised mixture to a fourth membrane for microfiltration, to isolate the microscopic particles
Data Source
AI summary
There is described a continuous process for the preparation of microscopic particles. e.g. nanoparticles or microparticles, said process comprising the steps of: (i) controlling provision of a first liquid phase to a first membrane, the first membrane defining a first plurality of apertures: (ii) controlling provision of a second liquid phase to the first membrane via the first plurality of apertures to form a mixture; and controlling provision of the mixture to a second membrane to form a stabilised suspension of particles; concentrating the suspension of particles and controlling provision of a pH buffer to a third membrane; and controlling provision of the stabilised mixture to a fourth membrane for microfiltration, to isolate the microscopic particles.