Disposable Plasma Spray Drying for Aseptic Emergency Use
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Solution Overview
Problem
Existing spray drying systems are impractical for use by untrained operators and fail to provide aseptic manufacturing of dried plasma for human or animal medical use, particularly in settings like blood centers, leading to limited availability and accessibility of plasma in emergencies.
Innovation Solution
A disposable spray drying device with a spray drying head and chamber that allows for the aseptic drying of plasma into a dried powder, using a vortex pattern of pressurized aerosol gas and drying gas to atomize and evaporate plasma droplets, with a capture filter to produce a dried plasma unit that can be rehydrated quickly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional 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 separate plasma source. This segmentation allows each component to be optimized independently and simplifies operation by isolating complex functions in dedicated modules rather than requiring integrated expertise
Solution Approach 2:
The drying chamber is designed as a disposable component that is discarded after single use. This eliminates the need for operators to clean, maintain, or sterilize complex internal chambers, dramatically reducing the skill level required while maintaining aseptic conditions through the disposable nature of the component
2Reliability
If traditional spray drying systems are used, then plasma can be dried, but aseptic manufacturing for medical use is not achieved
Solution Approach 1:
The system separates the plasma processing function into a disposable drying chamber that is discarded after use, isolating the plasma from all potential contamination sources in the reusable components. This segmentation maintains aseptic conditions without requiring complex sterilization systems
Solution Approach 2:
The disposable drying chamber is designed as a sterile, single-use component that prevents recontamination of the plasma. The disposable nature eliminates the need for complex sterilization and maintenance systems while ensuring aseptic manufacturing standards are met
3Loss of time
If frozen plasma storage is used, then plasma is available for long periods, but rapid availability in emergencies is limited due to thawing time
Solution Approach 1:
The system transitions plasma from liquid or frozen state to dried powder state through spray drying. This phase transition enables long-term storage at ambient temperatures without the 30-45 minute thawing requirement, while the dried plasma can be rapidly reconstituted when needed, eliminating the time loss associated with thawing frozen plasma
4Adaptability or versatility
If complex spray drying machinery is used, then plasma can be processed, but the systems are difficult to operate in remote settings
Solution Approach 1:
The system is segmented into a portable disposable drying chamber that can be used in remote settings without requiring complex infrastructure. The modular design allows the drying chamber to be detached from the plasma source and processed independently, enabling operation in field conditions
Solution Approach 2:
The disposable drying chamber eliminates the need for complex, maintainable machinery in remote settings. Operators in field conditions can use the simple, single-use device without requiring technical expertise for maintenance or sterilization, greatly improving adaptability to diverse and remote environments
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 system enables easy, aseptic manufacture of dried plasma by minimally trained operators, providing rapid access to plasma in emergencies and improving storage and transport options compared to frozen plasma, while maintaining plasma integrity and protein functionality.
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
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.