Disposable Bioreactor Bag for Continuous Perfusion
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Solution Overview
Problem
Conventional bioreactor systems face inefficiencies in continuous perfusion processes due to the need for cleaning and sterilization of equipment, which increases complexity and costs, and limits the use of disposable components that could simplify operations.
Innovation Solution
The development of systems and methods utilizing disposable, collapsible bags and reusable support structures for bioreactors, allowing for continuous perfusion and recycling of liquids while eliminating the need for cleaning and sterilization, and enabling the use of disposable components such as filtration elements and sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional bioreactor systems use reusable equipment requiring cleaning and sterilization, then equipment reliability is maintained, but device complexity and operational costs increase
Solution Approach 1:
The patent employs disposable bioreactor bags that are discarded after single use, eliminating the need for cleaning and sterilization of reusable equipment. This disposable approach maintains reliability by ensuring each bag is sterile upon use while reducing device complexity by removing cleaning and sterilization systems from the bioreactor design.
2Reliability
If conventional bioreactor systems use reusable equipment requiring cleaning and sterilization, then equipment reliability is maintained, but manufacturing costs increase
Solution Approach 1:
The disposable bioreactor bags eliminate expensive cleaning and sterilization infrastructure, reducing manufacturing costs while maintaining reliability through factory-sealed sterile packaging. The low cost of disposable bags compared to reusable equipment and their associated maintenance systems makes this economically advantageous.
3Productivity
If continuous perfusion is implemented in conventional bioreactors, then productivity increases, but device complexity increases due to additional components
Solution Approach 1:
The disposable bioreactor bag integrates all necessary components for continuous perfusion including built-in filters and recirculation pathways, enabling high productivity through continuous operation without the complexity of external cleaning and sterilization systems that would be required for reusable equipment.
4Ease of operation
If disposable components are used in bioreactor systems, then ease of operation improves by eliminating cleaning steps, but device complexity increases due to disposable component integration
Solution Approach 1:
The disposable bioreactor bags are designed as complete, ready-to-use units that eliminate all cleaning and sterilization steps, dramatically improving ease of operation. While the bags themselves are integrated components, they simplify overall system operation by removing the need for complex cleaning protocols and sterilization cycles associated with reusable equipment.
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
This approach simplifies and cost-reduces bioreactor operations by allowing for quick setup and operation without the need for cleaning, reducing equipment complexity, and enhancing the efficiency of product formation through continuous perfusion and recycling of cells and products.
Implementation Method 1
The first apparatus includes an impeller configured to rotate about a vertical axis of rotation and a drive system configured to rotate the impeller
Implementation Method 2
The first apparatus includes an impeller configured to rotate about a vertical axis of rotation and a drive system configured to rotate the impeller
Data Source
AI summary
Systems and methods for containing and manipulating liquids, including vessels and unit operations or components of cell culture, cell containment, bioreactor, and/or pharmaceutical manufacturing systems. In certain embodiments, such vessels and unit operations are directed to continuous perfusion reactor or bioreactor systems and may include one or more disposable components. In one aspect, a system includes an apparatus in the form of a bioreactor for harvesting cells. The apparatus may include a disposable, collapsible bag for containing a liquid, the collapsible bag in fluid communication with a liquid-solids separation device. An outlet of the collapsible bag may be connected to an inlet of the separation device, and an outlet of the separation device may be connected to an inlet of the collapsible bag. After separating the cells from the liquid in the separation device, the cells can flow back into the collapsible bag for re-harvesting.