Disposable Plasma Drying Head With Vortex Atomization for Asepsis
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Solution Overview
Problem
Existing spray drying systems are impractical for use by untrained operators and are not suitable for aseptic manufacturing of human plasma for transfusion, particularly in remote or emergency settings, and they fail to provide a dried plasma product that can be readily available and rehydrated quickly.
Innovation Solution
A spray drying disposable device with a spray drying head and chamber that efficiently dries plasma into a dried powder, allowing for aseptic manufacture by minimally trained personnel, and produces a dried plasma unit that can be rehydrated quickly for use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional spray drying systems are used, then plasma can be dried, but the systems are complex, difficult to operate, and require highly skilled operators with extensive training
Solution Approach 1:
The patent employs a disposable drying chamber that is discarded after a single use, eliminating the need for complex cleaning and sterilization procedures. This disposable approach simplifies operation significantly, as users only need to load the chamber and initiate the drying cycle without managing complex system maintenance or sanitation protocols.
Solution Approach 2:
The spray drying system is divided into separate functional modules: a reusable spray drying apparatus and a disposable drying chamber. This segmentation allows the complex drying mechanism to be separated from the simple disposable chamber, making the overall system easier to operate while maintaining reliable plasma drying capability.
2Reliability
If traditional spray drying systems are used, then plasma can be dried, but the systems are large and complex machinery not suitable for remote or emergency settings
Solution Approach 1:
The disposable drying chamber is designed as a self-contained, compact unit that can be easily transported to remote or emergency settings. Since the chamber is discarded after use, there is no need for large infrastructure or complex support systems, making the overall device much smaller and more suitable for field operations.
Solution Approach 2:
The drying chamber integrates multiple functions into a single unit: plasma reception, drying, and product collection. This merging of functions eliminates the need for separate equipment components, reducing overall system size and complexity while maintaining reliable plasma drying capability.
3Quantity of substance
If plasma is stored frozen or as liquid, then plasma is available, but it cannot be readily available in emergency situations due to long storage or thawing times
Solution Approach 1:
The system utilizes phase transition by drying plasma into a powder form, which can be stored indefinitely at room temperature. When needed, the powder is rapidly rehydrated by adding liquid, reducing preparation time from 30-45 minutes to just a few minutes. This phase change enables plasma to be both easily stored and quickly available in emergency situations.
Solution Approach 2:
Plasma is dried into powder form in advance and stored ready for use. This preliminary processing eliminates the need for time-consuming thawing procedures when emergency plasma is needed, as the dried powder can be quickly rehydrated and deployed immediately.
4Reliability
If spray drying is performed in traditional systems, then plasma can be processed, but the drying chamber and components are not aseptically designed for manufacturing end products for human or animal medical use
Solution Approach 1:
The disposable drying chamber is designed and manufactured to aseptic standards, ensuring that the plasma product remains sterile throughout the drying process. The single-use nature of the chamber eliminates contamination risks associated with cleaning and sterilization, making the system suitable for manufacturing end products for human or animal medical use.
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 device enables easy, aseptic production of dried plasma that can be stored and rehydrated rapidly, overcoming the limitations of previous systems by providing a compact, user-friendly solution for plasma drying and ensuring plasma integrity and safety.
Implementation Method 1
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.