Disposable Spray Drying Head for Aseptic Plasma Powdering
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Solution Overview
Problem
Existing spray drying systems are impractical for use by untrained operators and fail to provide aseptic manufacturing of dried plasma for medical applications, particularly in remote or emergency settings, and current methods do not allow for rapid availability and rehydration of plasma.
Innovation Solution
A spray drying apparatus with a disposable device that includes a spray drying head, plasma drying chamber, and gas outlet, utilizing a vortex generator and baffle plate to atomize plasma into dried particles, with a capture filter and exhaust system, allowing for aseptic operation and rapid rehydration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex spray drying systems are used for plasma drying, then plasma can be dried into powder form, but the systems become difficult to operate and require highly skilled operators
Solution Approach 1:
The system is divided into a permanent spray drying apparatus and a disposable device that contains the plasma chamber, filter, and nozzle assembly. The disposable device is pre-configured and sealed, requiring no assembly or adjustment by operators. This segmentation allows complex drying functionality to be maintained while simplifying operation to merely inserting the pre-prepared disposable unit.
Solution Approach 2:
The disposable device is prepared in advance with all necessary components (chamber, filter, nozzle) sealed and positioned correctly before use. The plasma chamber is pre-assembled with the capture filter and nozzle in their exact positions, eliminating the need for operators to perform complex setup or alignment procedures during operation.
2Reliability
If traditional spray drying systems are used, then plasma can be processed, but the systems are not suitable for aseptic manufacturing in remote or emergency settings
Solution Approach 1:
The plasma chamber, filter, and nozzle are integrated into a single-use disposable device that is sealed and sterile-packaged. This disposable unit can be stored at ambient temperature and deployed in any setting without requiring sterile infrastructure. After one use, the entire disposable unit is discarded, ensuring aseptic processing without complex sterilization infrastructure.
Solution Approach 2:
The disposable device uses sealed chambers and membrane filters that maintain sterility through physical barriers rather than active sterilization systems. The plasma chamber is hermetically sealed until use, and the capture filter uses microporous membranes that prevent contamination while allowing plasma passage, enabling aseptic operation in remote locations.
3Reliability
If plasma is stored frozen for long periods, then plasma availability is ensured, but rapid availability in emergencies is compromised due to thawing time
Solution Approach 1:
The system uses spray drying to transition plasma from liquid to dried powder form, which can then be rapidly rehydrated. The dried plasma powder is stable at ambient temperature and can be quickly reconstituted by adding liquid, providing rapid plasma availability in emergencies without the 30-45 minute thawing time required for frozen plasma.
4Object-affected harmful factors
If the plasma drying chamber is maintained with high integrity, then plasma safety is improved, but the device complexity increases
Solution Approach 1:
The plasma chamber is part of a disposable device that is sealed and sterile-packaged before use. The chamber maintains integrity through its sealed construction and is discarded after one use, eliminating the need for complex sterilization, validation, or maintenance procedures that would be required for a permanent chamber.
Solution Approach 2:
The capture filter acts as an intermediary barrier between the plasma and the external environment. The filter with its microporous structure allows plasma to pass through while blocking pathogens and contaminants, maintaining plasma safety without requiring the entire chamber to be hermetically sealed and maintained under controlled conditions.
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 aseptic manufacture of dried plasma by minimally trained operators, providing rapid availability and rehydration, overcoming the limitations of previous systems and ensuring plasma integrity and safety.
Implementation Method 1
spray dry nozzle assembly in fluid communication with the plasma source and the pressurized aerosol gas source, the pressurized aerosol gas atomizes the plasma entering the drying chamber to thereby obtain atomized plasma droplets
Implementation Method 2
atomized plasma droplets evaporate when coming into contact with the drying gas emitted from the one or more drying gas jets to thereby obtain dried plasma particles and humid air
Implementation Method 3
the capture filter captures the dried plasma particles and allows the humid air to pass
Data Source
AI summary
The present invention includes a spray drying disposable device for use in a spray drying system. The disposable has a spray drying head and a plasma drying chamber. The head has a spray dry nozzle assembly in fluid communication with the plasma source and the pressurized aerosol gas source. The pressurized gas flows in a vortex pattern that atomizes plasma droplets in the chamber. The head also includes a plenum has uniform air pressure of the drying gas. A baffle plate forms the floor of the plenum having drying gas jets that supply drying gas to the chamber. The atomized plasma droplets evaporate in the presence of the drying gas emitted from the jets to obtain dried plasma particles and humid air. A capture filter captures the dried plasma particles and allows the humid air to pass. The humid air passes through the gas outlet and the exhaust port.