Single-Use Manifold Fluid Recovery for Biopharmaceutical Waste Reduction
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Solution Overview
Problem
Conventional fluid distribution systems in biopharmaceutical applications face challenges in efficiently aliquoting fluids to multiple containers while maintaining sterility, leading to costly fluid wastage and reduced drug production due to residual fluid in manifolds after filling sequences.
Innovation Solution
A fluid distribution system comprising a pump, a single-use filler manifold with independently occludable outlets, and a control unit programmed to manage fluid distribution, allowing for targeted filling and underfilling to recover and reuse residual fluid, thereby minimizing waste and optimizing drug formulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If manual manipulation of the manifold is performed to force fluid into odd containers, then fluid recovery is attempted, but this results in operator time consumption and potential sterility compromise
Solution Approach 1:
The system enables automatic fluid recovery through programmable control of valves and pumps, eliminating the need for manual operator intervention. The control unit automatically sequences the recovery process, allowing the system to service itself without human involvement while maintaining sterility through closed-system operation.
Solution Approach 2:
Manual mechanical manipulation of the manifold by operators is replaced with an automated control system that uses electronically controlled valves and pumps. The control unit programmatically manages the recovery process, substituting human mechanical actions with automated mechanical and electronic systems.
2Loss of substance
If residual fluid is discarded to ensure sterility and proper filling, then sterility is maintained, but costly drug product is wasted
Solution Approach 1:
Instead of discarding residual fluid in the manifold, the system recovers it through automated transfer to a recovery container. The control unit sequences valve operations to redirect fluid that would otherwise be wasted, capturing it for potential reuse or proper disposal while eliminating the need to discard filled containers.
Solution Approach 2:
A recovery container serves as an intermediary element between the manifold and the final product containers. This intermediate storage allows the system to capture and hold residual fluid, enabling its transfer and potential reuse without compromising the sterility of the main filling process or the integrity of filled containers.
3Manufacturing precision
If automated control is implemented to manage fluid distribution, then filling precision is improved, but system complexity increases
Solution Approach 1:
The control unit performs multiple functions including managing filling sequences, coordinating valve operations, controlling pump timing, and managing recovery operations. This multi-functional controller consolidates what could be multiple separate control systems, achieving precise automated control while limiting the increase in overall system complexity through functional integration.
Data Source
AI summary
A fluid distribution system includes single use distributor manifolds each having a distributor manifold inlet and a plurality of distributor manifold outlets in fluid communication with the distributor manifold inlet. A set of single use filler manifolds can be sequentially connected to a respective one of the outlets of a single use distributor manifold immediately upstream of the connection point of the set of single use filler manifolds. In embodiments, an upstream distributor manifold can be used to feed fluid to a set of intermediary distributor manifolds where the set of intermediary distributor manifolds corresponds to the number of outlets of the upstream distributor manifold.