Disposable Plasma Spray-Drying Chamber for Aseptic Processing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing spray drying systems are impractical for use by untrained operators and are not suitable for aseptic manufacturing of human plasma for transfusion, particularly in remote or emergency settings, and they fail to provide a dried plasma product that can be readily available and rehydrated quickly.
Innovation Solution
A spray drying disposable device with a spray drying head and chamber that includes a nozzle assembly, plenum, and baffle plate, designed for efficient atomization and evaporation of plasma into a dried powder, which can be easily handled and operated by minimally trained personnel, ensuring aseptic processing and rapid rehydration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional spray drying systems are used, then plasma can be dried, but the systems are complex and require highly skilled operators with extensive training
Solution Approach 1:
The spray drying system is divided into modular components including a disposable drying chamber, reusable spray drying head, and integrated heating system. This segmentation allows the complex system to be broken down into manageable, easily replaceable parts that reduce operational complexity while maintaining reliable plasma drying capability.
Solution Approach 2:
The disposable drying chamber is designed as a self-contained unit with pre-assembled components that require minimal setup or maintenance. The chamber includes built-in flow paths, heating elements, and collection systems that automatically function without requiring highly skilled operators to manage or adjust individual components.
2Reliability
If conventional spray drying systems are used, then plasma can be processed, but they are not suitable for aseptic manufacturing and require highly trained personnel
Solution Approach 1:
The drying chamber is designed as a disposable unit that is sterilized and sealed before use, eliminating the need for complex cleaning and sterilization procedures between uses. This disposable approach simplifies operation for minimally trained personnel while maintaining aseptic conditions throughout the plasma processing cycle.
Solution Approach 2:
The disposable drying chamber is pre-sterilized and pre-assembled with all necessary components in place before delivery to the user. This preliminary preparation eliminates the need for operators to perform complex setup, sterilization, or maintenance tasks, making the system easy to operate while ensuring aseptic processing capabilities.
3Quantity of substance
If plasma is stored frozen or as liquid, then plasma is available, but it requires long storage time or quick thawing which delays availability
Solution Approach 1:
The system transforms plasma from liquid or frozen state directly into a dried powder form through spray drying, creating a stable intermediate product that can be stored indefinitely without freezing or thawing requirements. This phase transition enables plasma to be stored at ambient temperatures while maintaining availability and biological activity.
Solution Approach 2:
Plasma is processed into dried powder form in advance during the spray drying cycle, creating a ready-to-use product that eliminates the need for subsequent thawing or preparation steps. This preliminary transformation of plasma into a stable dried form significantly reduces the time required for plasma availability in emergency situations.
4Manufacturing precision
If complex spray drying equipment is used, then plasma can be dried with high precision, but the equipment is difficult to operate and maintain
Solution Approach 1:
The complex spray drying components including heating elements, flow control mechanisms, and collection systems are extracted into a disposable drying chamber that is discarded after single use. This extraction of complexity into a consumable component allows the main equipment to remain simple while maintaining high plasma drying precision through the engineered disposable unit.
Solution Approach 2:
The disposable drying chamber is designed as a low-cost, single-use component that encapsulates all the complexity of plasma drying in a pre-engineered unit. This approach trades the high cost and complexity of maintaining expensive equipment for the simplicity of using inexpensive disposable chambers that require no maintenance while achieving consistent drying precision.
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 device enables the production of dried plasma that can be stored and rehydrated quickly, overcoming the limitations of existing systems by providing a safe, efficient, and accessible method for producing dried plasma units that can be used in emergency situations.
Implementation Method 1
the pressurized aerosol gas flows in a vortex pattern, wherein, when in use, the pressurized aerosol gas atomizes the plasma entering the drying chamber to obtain atomized plasma droplets
Implementation Method 2
atomized plasma droplets evaporate in the presence of the drying gas emitted from the one or more drying gas jet to thereby obtain dried plasma particles
Implementation Method 3
a baffle plate forming the floor of the plenum having one or more drying gas jets, wherein drying gas jet provides drying gas to the drying chamber
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.