Sterile Filter RFID Tag Integration for Solution Mixing
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Solution Overview
Problem
Current methods fail to reliably produce a sterile solution with a defined composition from two different mediums, lacking sufficient assurance of sterility and mixing ratio control.
Innovation Solution
A device with a static mixer, sensor device, and sterile filter connected via a process controller, utilizing RFID tags for data storage and control, ensures sterility and precise mixing ratio management, allowing for easy addition of a third medium and monitoring of container compatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sterile filter is installed downstream of the static mixer, then sterility of the solution is ensured, but device complexity increases due to additional components and RFID tag integration
Solution Approach 1:
The sterile filter with RFID tag is pre-installed and prepared before the mixing process, allowing verification of sterility and compatibility in advance. The RFID tag stores necessary information about the filter's sterility status and compatibility with buffer solutions, enabling preliminary checks before the solution passes through the filter.
Solution Approach 2:
The RFID tag acts as an intermediary between the sterile filter and the process controller, storing and transmitting process-relevant data such as filter identity, sterility status, and compatibility information. This intermediary enables automatic verification without direct physical interaction between the controller and filter.
2Reliability
If RFID tags are used to store process-relevant data, then process control and verification are improved, but manufacturing complexity increases
Solution Approach 1:
The RFID tag is integrated into a disposable sterile filter that is used once and then discarded. This eliminates the need for complex cleaning and validation processes, as the entire filter assembly with RFID tag can be replaced after use. The RFID tag enables verification of the filter's identity and sterility status without requiring complex manufacturing processes for the tag itself.
3Manufacturing precision
If the branching valve is controlled by the process controller based on sensor data, then mixing ratio precision is improved, but device complexity increases
Solution Approach 1:
The sensor device measures the mixing ratio of the solution and provides feedback to the process controller. Based on this feedback, the process controller automatically adjusts the branching valve to maintain the desired mixing ratio. This closed-loop feedback system ensures precise mixing ratio control while using simple proportional control logic.
Solution Approach 2:
The system uses the flow energy of the solution itself to drive the mixing process in the static mixer, eliminating the need for external motors or moving parts. The branching valve is positioned to allow the solution to naturally flow through the system, with the process controller making minor adjustments based on sensor feedback, rather than requiring complex active control mechanisms.
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 solution effectively produces a sterile solution with a defined composition by ensuring sterility and precise mixing ratio control, reducing contamination risks and avoiding complex cleaning and validation processes, while enabling flexible production setups.
Implementation Method 1
The sterile filter has an RFID tag and the RFID tag stores process-relevant data which can at least be read by the process controller
Implementation Method 2
Static mixers are normally conduits or channels with fixed installations, which, by using the flow energy, cause a mixing of fluid product flows
Implementation Method 3
Each container is connected to a supply line of a static mixer via a pump that can be regulated by a process controller
Implementation Method 4
A sterile filter is arranged downstream of the static mixer in the flow direction
Data Source
AI summary
A device (1) for producing a solution of at least one liquid first medium and at least one second medium has a first container (2) for the first medium and a second container (3) for the second medium. Each container (2, 3) is connected to a supply line of a static mixer (9) via a pump (4, 5) that can be regulated by a controller (6). A sensor (10) is connected to the controller (6) downstream of the static mixer (9) in the flow direction. A branching valve (17) is downstream of the static mixer (9) in the flow direction and is controlled by the controller (6). A sterile filter (11) is downstream of the static mixer (9) and has an RFID tag (15) that stores process-relevant data to at least be read by the controller (6). A method also is provided for producing a solution using the device.