Membrane Valve Cassette Reconfiguration for Flexible Bioprocessing
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Solution Overview
Problem
Current modular bioprocessing systems lack sufficient reconfigurability, requiring multiple units for different operations and skilled operators, which increases complexity and costs.
Innovation Solution
A reconfigurable bioprocessing system with a base unit and removably attachable membrane valve cassettes, featuring a common interface for valve actuators that can be easily reconfigured using a control system to perform various bioprocessing operations, including pressure monitoring, air trapping, and conductivity sensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate modular units are used for different bioprocessing operations, then each operation can be performed with dedicated equipment, but the overall system complexity and cost increase
Solution Approach 1:
The patent implements a universal base unit with standardized valve actuator interfaces that can accommodate multiple types of bioprocessing cassettes (chromatography, filtration, mixing, etc.). This multi-functional design allows a single base unit to perform various bioprocessing operations by simply changing the cassette, thereby reducing system complexity while maintaining operational reliability for each specific process
2Manufacturing precision
If skilled operators are used to manually configure and operate the system, then complex operations can be performed accurately, but labor costs and operational complexity increase
Solution Approach 1:
The system incorporates automated features including automatic cassette identification when inserted into the base unit, automated fluid path configuration based on the identified cassette type, and integrated sensors for real-time monitoring of pressure, flow, and other parameters. This self-service capability reduces dependence on skilled operators while maintaining operational precision
Solution Approach 2:
The system includes integrated sensors that provide real-time feedback on fluid flow, pressure, and other process parameters. This feedback mechanism allows the control system to automatically adjust operations and alert operators to any issues, thereby maintaining high operational precision with reduced skilled labor requirements
3Productivity
If traditional cleaning procedures are used for reusable components, then equipment can be reused to reduce costs, but cross-contamination risk and time-consuming cleaning processes occur
Solution Approach 1:
The patent employs disposable bioprocessing cassettes that are pre-sterilized and intended for single use. After completion of a bioprocessing operation, the cassette is discarded, eliminating the need for cleaning and validation processes. This approach significantly reduces cross-contamination risk and improves process efficiency by allowing immediate setup for the next operation without cleaning downtime
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 a single base unit to perform multiple bioprocessing operations with reduced skilled labor requirements, minimizing holdup volume and tubing length, thus enhancing efficiency and reducing operational complexity.
Implementation Method 1
membrane valves that are pneumatically actuated by application of pneumatic pressure from a pneumatic control system
Data Source
AI summary
The present disclosure relates to a reconfigurable bioprocessing system (80) operable to perform a predetermined set of bioprocessing operations within the bioprocessing system (80), the bioprocessing system (80) comprising: a base unit (60) comprising a plurality of valve actuators, wherein at least one of the plurality of valve actuators is configured to releasably engage with a membrane valve cassette (200, 300, 400) that is removably attachable to the base unit (60), and wherein the at least one of the plurality of valve actuators is actuatable to regulate fluid flow through the membrane valve cassette (200, 300, 400); and a control system (20) operable to selectively actuate respective ones of the plurality of valve actuators to provide a valve configuration within the membrane valve cassette (200, 300, 400) to enable the base unit (60) and the membrane valve cassette (200, 300, 400) together to perform one of the predetermined set of bioprocessing operations.