Separator Assembly Flow Control for Continuous Cell Culture

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Solution Overview

Problem

Current bioprocessing systems face challenges in maintaining desired cell concentrations and environmental stability during culture media removal and addition, leading to inefficiencies in batch processing that are time-intensive and costly.

Innovation Solution

A bioprocessing system with a separator assembly and controlled fluid flow lines allows for continuous or semi-continuous removal of cell products without significantly affecting cell concentration, enabling continuous bioprocessing by using reusable and washable components, and incorporating a controller for managing fluid flow to maintain optimal conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If culture media is removed and renewed in batch bioprocessing systems, then cell byproducts can be extracted and fresh nutrients can be added, but cell concentration becomes difficult to maintain and proliferation rates are disrupted

Engineering Contradiction:

Improvecell byproduct accumulationVSAvoidcell concentration

Core Design Contradiction:

Loss of substanceVSStability of the object's composition

Solution Approach 1:

The system implements continuous bioprocessing where culture media is continuously removed and replaced without batch interruptions. This continuous operation allows cell byproducts to be constantly extracted while fresh nutrients are continuously supplied, maintaining stable cell concentration and proliferation rates throughout the process rather than experiencing the disruptions inherent in batch processing cycles.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The bioprocessing system is divided into separate functional components: a containment environment for cell culture, a media removal system, and a media addition system. This segmentation allows independent optimization of each function, enabling continuous media exchange while maintaining stable cell concentration through controlled, separate operations rather than simultaneous batch processing.

Inventive Principle:

Principle #1Segmentation

2Productivity

If batch bioprocessing is used to target maximum cell proliferation, then cell harvesting can be optimized, but the process is time-intensive and requires repeated stopping and restarting

Engineering Contradiction:

Improvecell harvesting efficiencyVSAvoidbatch processing time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The system eliminates batch processing cycles by implementing continuous operation where cells are continuously harvested at optimal proliferation rates without stopping the bioprocessor. This continuous harvesting maintains cells in their optimal growth phase indefinitely, eliminating the time losses associated with repeated batch cycles of stopping, harvesting, and restarting the system.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The system pre-establishes continuous flow conditions and harvesting mechanisms before maximum cell proliferation is reached, allowing the system to operate continuously at optimal productivity levels rather than periodically interrupting to harvest batches. This preliminary setup enables sustained high-rate harvesting without the need to restart processes.

Inventive Principle:

Principle #10Preliminary action

3Loss of substance

If reusable and washable components are used in bioprocessing systems, then cost and waste can be reduced, but system complexity and cleaning requirements increase

Engineering Contradiction:

Improvemedia wasteVSAvoidsystem configuration

Core Design Contradiction:

Loss of substanceVSDevice complexity

Solution Approach 1:

The system implements continuous operation with reusable components that can be continuously processed through wash and sterilization cycles without interrupting bioprocessing. This continuous operation allows media and components to be reused indefinitely, dramatically reducing waste while the automated continuous cleaning systems manage the added complexity without requiring manual intervention or system shutdowns.

Inventive Principle:

Principle #20Continuity of useful action

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 maintains consistent cell proliferation rates and reduces downtime by allowing continuous operation, enhancing productivity and reducing waste through reusable components and efficient media management.

Implementation Method 1

a separator assembly having a separator inlet, a retentate outlet, and a permeate outlet

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Data Source

PatentUS20250382563A1Bioprocessing system and methods

Publication Date: 2025.12.18 DONALDSON CO INC

AI summary

A bioprocessing system including a contained bioprocessing environment, a separator assembly, a first retentate flow line, a second retentate flow line, and a retentate system outlet flow line. The separator assembly includes a separator inlet, a retentate outlet, and a permeate outlet. The separator assembly is configured to be fluidly coupled to the contained bioprocessing environment. The first retentate flow line is configured to extend from the retentate outlet to the separator inlet. The second retentate flow line is configured to extend from the retentate outlet to the contained bioprocessing environment. The retentate system outlet flow line is configured to extend from the retentate outlet to a system outlet.