Nested Vertical Mixer for Nanocarrier Scale-Up
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Solution Overview
Problem
Existing methods for producing nanocarriers and nanoformulations face challenges in scaling up due to complex fluid dynamics in mixers, leading to instability of lipid nanoparticles and increased capital costs.
Innovation Solution
An apparatus with vertically oriented feeds and a nested configuration that ensures stable flow ratios, allowing for efficient mixing and production of nanocarriers and nanoformulations without the need for 'numbering up' during scale-up.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional mixers or micromixers are used for producing nanocarriers, then mixing can be achieved, but the apparatus is very sensitive to fouling and gas bubbles, requiring high-purity conditions and laborious removal of dissolved gases
Solution Approach 1:
The mixing process is segmented into distinct phases: a first mixing zone where initial mixing occurs, followed by a second mixing zone for further mixing. This segmentation allows each zone to handle specific aspects of mixing, reducing sensitivity to fouling and gas bubbles in any single zone while maintaining overall mixing effectiveness.
2Productivity
If T-shaped mixers are used for producing nanoformulations, then mixing of two fluids can be achieved, but the flow conditions change upon increasing production scale, making it non-trivial to transfer operating conditions from laboratory to industrial operation
Solution Approach 1:
The mixer incorporates adjustable flow rate ratios between the first and second fluids, allowing the system to adapt to different production scales while maintaining stable flow conditions. The dynamic adjustment capability enables seamless transfer from laboratory to industrial operation without changing fundamental flow patterns.
Solution Approach 2:
The mixer features a nested structure with a first mixing zone and a second mixing zone arranged concentrically, where the second zone is positioned within or around the first zone. This nested configuration maintains geometric similarity across different scales, ensuring stable flow conditions and consistent mixing performance from laboratory to industrial production.
3Productivity
If LNP nanoformulations are produced in conventional mixers, then the nanocarriers can be formed, but the nanocarriers are not stable for long in the mixture, requiring quick separation or additional stabilization steps
Solution Approach 1:
The mixing process is segmented into distinct zones with different residence times and flow conditions. The first mixing zone allows rapid nanocarrier formation, while the second mixing zone provides a controlled environment for stabilization, reducing the need for quick separation or additional stabilization steps.
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 apparatus achieves homogeneous mixing and stable flow conditions, resulting in nanocarriers and nanoformulations with a narrow particle size distribution and improved stability, enabling cost-effective and efficient large-scale production.
Implementation Method 1
a pump (6) which is incorporated in the discharge (8) in such a way that the mixture is conveyable by the pump (6) from the active element (3) via the discharge (8) into the collection vessel (1)
Implementation Method 2
an active element (3) for providing an at least biphasic mixture by mixing the first liquid phase with the second liquid phase
Implementation Method 3
the first feed (4) and the second feed (5) are vertically oriented at least on a vertical section
Data Source
Figure 1
Figure 2
Figure 2x
AI summary
The invention relates to an apparatus (0) and process for producing nanocarriers and/or nanoformulations and corresponding process products. The present invention has for its object to specify an alternative process for producing nanocarriers/nanoformulations and an accompanying apparatus for performing this process. The apparatus (0) according to the invention is characterized by a vertical orientation of the feed conduits (4,5) leading to an active element (3). The feed conduits (4), (5) are nested within one another and axially movable in terms of their orientation to one another. The process according to the invention provides for the mixing of at least two liquid phases with different acidities. The volume flow of the first phase is greater than that of the second phase.