Vortex Plasma Spray Drying for Rapid Rehydration
Find Innovative SolutionsGenerate Solutions
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 disposable spray drying device with a spray drying head and chamber that includes a nozzle assembly, plenum, and baffle plate, which atomizes plasma into droplets and evaporates them using drying gas, capturing the dried particles in a filter while maintaining system integrity, allowing for rapid drying and easy handling by minimally trained personnel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If complex spray drying machinery is used, then manufacturing capability is improved, but ease of operation deteriorates
Solution Approach 1:
The system is divided into a reusable spray drying apparatus and a disposable drying chamber assembly. The disposable chamber is pre-assembled with all necessary components (nozzle, filter, collection container) sealed together, eliminating the need for operators to assemble or maintain complex internal structures. This segmentation allows highly capable manufacturing through the disposable's pre-engineered aseptic design while simplifying operation to simple insertion and removal of the disposable unit.
Solution Approach 2:
The drying chamber assembly is designed as a single-use disposable component that is discarded after one use. This eliminates the need for operators to clean, maintain, or sanitize complex internal chambers, significantly reducing training requirements. The disposable nature ensures aseptic manufacturing is built-in rather than requiring operator skill to maintain.
2Reliability
If traditional plasma storage methods are used, then storage capability is improved, but availability time deteriorates
Solution Approach 1:
The system transitions plasma from liquid or frozen state to dried powder state through spray drying. The dried plasma powder can be stored at ambient temperatures without requiring freezing or thawing cycles. When needed, the powder is rapidly rehydrated by adding sterile water, reducing preparation time from 30-45 minutes (thawing) to just a few minutes (rehydration). This phase change enables both reliable long-term storage and rapid availability.
3Quantity of substance
If large plasma quantities are stored, then supply capability is improved, but accessibility deteriorates
Solution Approach 1:
The system changes the physical state of plasma from liquid/frozen to dried powder form. This parameter change enables compact storage of large plasma quantities in a space-efficient dried state that can be easily transported to remote locations. The dried powder maintains plasma integrity during storage and transport, then can be rapidly rehydrated at the point of use, providing both large quantity availability and ease of accessibility in remote or emergency settings.
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 aseptic manufacture of dried plasma that can be stored and rehydrated quickly, overcoming the limitations of previous systems by providing a compact, easy-to-use solution for producing small quantities of dried plasma suitable for emergency use.
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
Implementation Method 3
drying gas source, a plasma source and a pressurized aerosol gas source
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.