Fermenter Pressure Gradient Insulator Contamination Control
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Solution Overview
Problem
The production of biologically active compounds through fermentation poses a risk of contamination and exposure to aerosols, as the relative low pressure in the working chamber allows particles and germs to infiltrate, potentially harming personnel and compromising the integrity of the biologically active material.
Innovation Solution
An apparatus with a pressure gradient is designed, featuring a fermenter within an insulator that is connected to a working chamber via a pressure sluice, where the insulator maintains a low pressure and the working chamber maintains a higher pressure relative to ambient, with HEPA filters in air ducts to minimize germ contamination, and separate insulators for fermentation and purification steps at controlled temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a low pressure is maintained in the working chamber to prevent contamination, then the risk of aerosol infiltration increases, but maintaining high pressure to prevent infiltration complicates the system design and energy consumption
Solution Approach 1:
The system is divided into multiple pressure zones: the first chamber (fermenter) operates at overpressure relative to the second chamber (working chamber), while the second chamber operates at overpressure relative to the ambient environment. This segmentation allows each zone to have optimized pressure control, preventing both contamination and aerosol infiltration without requiring a single complex pressure control system.
Solution Approach 2:
The second chamber acts as an intermediary zone between the first chamber (fermenter) and the ambient environment. It buffers pressure differences and provides an additional barrier against contamination and aerosol infiltration, simplifying the overall pressure control requirements by distributing pressure management across multiple zones.
2Ease of operation
If manual operations are performed in the working chamber, then operational flexibility is maintained, but exposure to aerosols and biological materials increases
Solution Approach 1:
The second chamber serves as a protective intermediary zone that allows manual operations to be performed with flexibility while preventing direct exposure to aerosols and biological materials from the first chamber. The pressure gradient and physical barrier provided by this intermediate chamber protect personnel while maintaining operational ease.
Solution Approach 2:
The pressure difference that could potentially cause aerosol infiltration is converted into a protective feature. The overpressure in the first chamber relative to the second chamber ensures that aerosols are prevented from moving into the working chamber, turning a potential hazard into a safety mechanism.
3Reliability
If overpressure is maintained in the first chamber to prevent contamination, then sterility is ensured, but energy consumption increases
Solution Approach 1:
The pressure maintenance requirement is segmented across two chambers with different pressure levels. The first chamber maintains overpressure relative to the second chamber for sterility, while the second chamber maintains overpressure relative to the ambient environment for personnel protection. This segmentation allows each chamber to use energy only for its specific pressure differential, reducing total energy consumption compared to maintaining one large pressure differential.
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 setup effectively prevents contamination of biologically active materials from the environment and reduces exposure of personnel to aerosols, ensuring operational safety while maintaining efficient production and purification processes.
Implementation Method 1
a pressure gradient in relation to ambient pressure prevails in both the insulator and in the working chamber
Implementation Method 2
HEPA filters in air ducts to minimize germ contamination
Implementation Method 3
separate insulators for fermentation and purification steps at controlled temperatures
Data Source
AI summary
The present invention relates to a process and an apparatus for the fermentational production of biologically active materials, wherein a fermenter is located in an insulator which, in turn, is located within a working chamber or is adjacent to it. A pressure gradient in relation to ambient pressure prevails in both the insulator and in the working chamber.