Automated Sample Transfer Coupling Device for Bioprocessing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The seed train expansion process for recombinant protein production from mammalian cells is labor and infrastructure intensive, prone to contamination, and suffers from campaign-to-campaign variability due to lack of pH and oxygen control, requiring skilled operators and complex manual operations.
Innovation Solution
An automated system with a coupling device that forms a sample access assembly using first and second containers, incorporating a heating component to thaw samples and a separating component to maintain sterility, allowing for automated transfer of samples while minimizing operator intervention and ensuring a sterile environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual operations are used for seed train expansion, then flexibility and adaptability are maintained, but contamination risk increases and labor intensity increases
Solution Approach 1:
The system enables self-service automation where the automated sample transfer system performs thawing, sampling, and transfer operations without requiring skilled operators. The system includes automated heating components to thaw cryo-vials and robotic transfer mechanisms to move samples between containers, eliminating manual intervention and associated contamination risks.
Solution Approach 2:
Manual mechanical operations are replaced with automated mechanical systems. The coupling device uses automated mechanisms to separate and couple containers, heated blades to thaw samples, and robotic arms to transfer samples. This substitution of manual mechanical operations with automated systems reduces contamination risk while maintaining operational flexibility.
2Reliability
If automated sample transfer is implemented, then contamination risk is reduced and consistency is improved, but device complexity increases
Solution Approach 1:
The system is divided into modular functional units: a coupling device for container connection, a heating component for thawing, a separating component for sterile division, and a transfer mechanism for sample movement. Each module performs a specific function and can be independently maintained or replaced, reducing overall system complexity while maintaining high reliability.
Solution Approach 2:
The coupling device serves multiple functions: it couples and decouples containers, provides sterile access, enables sample transfer, and maintains sterility through integrated heating and separating components. This multi-functionality reduces the need for separate dedicated devices, thereby reducing overall system complexity while improving reliability.
3Productivity
If manual thawing and transfer operations are performed, then operational flexibility is maintained, but operator skill requirements increase and time consumption increases
Solution Approach 1:
The system performs thawing and transfer operations autonomously without requiring skilled operators. The heating component automatically thaws cryo-vials at controlled rates, and the transfer mechanism automatically moves samples between containers. This self-service capability eliminates operator skill requirements while significantly increasing transfer speed and productivity.
Solution Approach 2:
The system performs preliminary actions automatically before sample transfer: containers are pre-coupled, heating elements are pre-positioned, and transfer pathways are pre-established. This preliminary automation eliminates the need for operators to perform complex preparation tasks, reducing skill requirements while improving transfer speed.
4Manufacturing precision
If traditional culture vessels are used, then ease of operation is maintained, but campaign variability increases due to lack of control
Solution Approach 1:
The system incorporates feedback mechanisms that monitor and adjust process parameters in real-time. Temperature sensors feedback to control heating power, volume sensors feedback to control transfer amounts, and time feedback controls operation sequences. This feedback control ensures consistent campaign-to-campaign results while maintaining manageable system complexity through automated regulation.
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 automated system reduces contamination risks, minimizes operator intervention, and maintains sterility during sample transfer, thereby enhancing the efficiency and consistency of the seed train expansion process.
Implementation Method 1
The coupling device includes a heating component configured to heat at least a portion of the sample
Data Source
AI summary
A coupling device configured to form a sample access assembly is provided. The sample access assembly is configured to house a sample. The coupling device includes a heating component and a separating component. Further, the separating component is configured to separate portions of first and second containers that form first and second compartments of the sample access assembly. Moreover, the heating component is configured to heat at least a portion of the sample.