The present disclosure generally relates to a method and machine for providing filled bags of sterile solution and, more particularly, to a small scale solution manufacturing machine to implement the method of providing sterile solution product container or bags.
Conventional methods for manufacturing bags of sterile solution include filling bags in a clean environment with a solution, sealing the filled bag of solution, and then sterilizing the fluid and bags in a sterilizing autoclave. This can be referred to as terminal sterilization. Another conventional method is to sterile filter a solution and to fill and seal sterile bags in an extremely high-quality environment designed and controlled to prevent contamination of the solution during the filling process and to seal the filled bag. This can be referred to as an aseptic filling process.
Terminal sterilization generally requires autoclaves to produce the sterilizing heat and steam needed. These autoclaves generally are not economical unless they can produce large batches of terminally sterilized bags. Thus the capital expenditure needed and space requirements lead to centralized manufacturing facilities that produce the filled bags and then ship them some distance to their destination for use. Also, the application of terminal sterilization processes may degrade the solution formulation thereby leading to incompatible or unstable formulations. Moreover, terminal sterilization does not eliminate non-viable contamination.
The aseptic manufacturing process must occur in a sterile working environments, and require expensive equipment, stringent procedures and extensive monitoring to ensure that solution product bags meet certain environmental and manufacturing regulatory standards. Sterilizing a working environment, by itself, can be costly and time consuming. Additional precautions apply for technicians involved in the filling process to ensure the production of safe and sterile products. Even with these safeguards, unless it can be verified that the solution entering the bag is sterile, there is a risk that contaminants may have inadvertently been introduced into the solution during filling/sealing, and once introduced, unless the solution later passes through a viable sterilizing filter, the contaminants will remain in the solution. Again due to these requirements, sterile solution product bags are often produced in centralized locations and shipped some distance to their destination for use.
Considering the costs associated with manufacturing sterile solution product bags, most health centers and clinics outsource their supply of sterile bags to manufacturing companies. To maintain the sterility of the shipment of bags, the sterile product bags must be carefully packaged and shipped to ensure safe delivery. As such, buying sterile product bags from a remote location may be very expensive and may increase the risk of contamination.
A small scale solution manufacturing machine and method for filling product bags with sterile solution in accordance with the teachings described herein may address the cost limitations of terminal sterilization or aseptic filling, remove non-viable contaminants, eliminate post filtration contamination risks and provide quality assurance on a one-to-one basis. In other words, each product bag filled and sealed by the method described herein undergoes individual testing to ensure that the solution contained therein has undergone a terminal sterilization filtration thereby meeting regulatory and sterile standards. The construction, small footprint of the machine, and ability to produce small lots of bags in a continuous flow allows the machine to be located and production method employed at or within a close distance of the user.
In accordance with a first exemplary aspect, a method of providing a plurality of filled product bags of sterile fluid includes providing a plurality of products bags, wherein each product bag has a bladder, a stem fluidly connected to an opening of the bladder, and a filter of a desired construction disposed in-line with the stem. The method includes creating a plurality of filled product bags by performing the following on each product bag: at least partially filling the product bag with a sterile fluid to create a filled product bag and sealing the filled product bag. The method includes performing an integrity test on the filter and correlating an integrity of the contents of a filled product bag to an integrity of the filter based on an outcome of the integrity test.
In accordance with a second exemplary aspect, a method of providing filled product bags of sterile fluid using a machine includes loading a product bag onto a loaded cradle of a plurality of movable cradles carried by a carousel, the loaded cradle occupying a loading position, and the product bag includes a bladder, a stem fluidly connected to an opening of the bladder, and a filter disposed in-line with the stem. Next, the method includes moving the loaded cradle and the product bag to a filling station that includes a nozzle by rotating the carousel and moving the loaded cradle from the loading position to a filling position adjacent the nozzle. The method further includes connecting an inlet of the product bag to the nozzle by moving the loaded cradle and the product bag toward the nozzle and at least partially filling the product bag with a fluid dispensed through the nozzle to create a filled product bag. Then, the method includes moving the loaded cradle and the filled product bag to a sealing and cutting station that includes a sealing device and a cutting device by rotating the carousel from the filling position to a sealing and cutting position. In the sealing and cutting position, the method includes moving the sealing device to the stem of the filled bag, sealing the stem of the filled bag with the sealing device, and moving the sealing device away from the filled bag. The method includes moving the cutting device to the stem of the filter bag, cutting the stem at a location above the seal, and moving the cutting device away from the filled bag. After sealing and cutting the stem of the bag, the method includes moving the loaded cradle and the bag to a testing station that includes a testing device by rotating the carousel from the sealing and cutting position to a testing position and performing a filter integrity test on the filter at the testing position. At the testing station, the method further includes removing the filled product bag from the cradle and receiving the filled product bag in one of a rejected bin or an accepted bin based on the results of filter integrity test.
In accordance with a third exemplary aspect, an automated machine for creating a plurality of sterile fluid-filled product bags includes a nozzle assembly, a carrier having a movable cradle for receiving at least one product bag including a bladder, a stem fluidly connected to an opening of the bladder, and a filter disposed in-line with the stem. The machine further includes a filling station including the nozzle assembly having a nozzle configured to engage an inlet of the stem and fluidly connect with the bladder. A sealing and cutting station of the machine includes a sealing device configured to seal the stem of the product bag at a location above the opening of the bladder and below the filter, and a cutting device having a blade for cutting the stem at a location above the seal and below the filter. The machine includes a testing station having a filter integrity testing apparatus which includes a filter testing device and a pressure sensor. The filter testing device is configured to engage the inlet of the stem of each sterile fluid-filled product bag to perform a filter integrity test, and the filter passing the filter integrity test correlates to an accepted bag and the filter failing the filter integrity test correlates to a rejected bag.
In further accordance with any one or more of the foregoing first, second, or third aspects, a method and/or machine may further include any one or more of the following preferred forms. In a preferred form of the method, connecting the inlet of the stem to the nozzle includes moving the cradle.
In a preferred form, the method includes connecting an inlet of the stem to an outlet of a nozzle.
In a preferred form of the method, filling the product bag includes passing the fluid through the filter and into the bladder.
In a preferred form, the method includes securing an initially empty, sterile product bag to one of a plurality of movable cradles or conveyance systems.
In a preferred form, the method includes removing the filled product bag from the cradle, and depositing the filled product bag into a first bin for rejected bags if the filter fails the integrity test and a second bin for accepted bags if filter passes the integrity test.
In a preferred form of the method, at least partially filling the product bag includes drawing the fluid from a mixing bag through a fill tube, and dispensing the fluid from the fill tube through an outlet of the nozzle of the nozzle assembly.
In a preferred form of the method, connecting the inlet of the stem to the nozzle assembly includes engaging a luer fitting of the nozzle to the inlet of the stem.
In a preferred form, the method includes removing a sterile closure cap covering the inlet of the stem using a ramp by rotating the carousel from the loading position to the filling position and passing the cradle adjacent the ramp such that the ramp engages and removes the sterile closure cap of the stem as the carousel rotates.
In a preferred form of the method, creating a filled product bag includes measuring an amount of fluid in the bladder with a load cell, and discontinuing filling the product bag when the product bag contains a predetermined amount of fluid.
In a preferred form, the method includes discontinuing filling includes removing the inlet of the stem from the nozzle.
In a preferred form of the method, performing the integrity test includes performing at least one of a bubble test, a pressure degradation test, and alternate physical test on the filter and wherein performing the integrity test may include sensing a pressure applied to the filter with a pressure sensor.
In a preferred form, the method includes moving a diverter directed to one of the first bin or the second bin based on the results of the filter integrity test and wherein performing the filter integrity test includes assessing the filter for structural flaws.
In a preferred form of the method, filling the product bag includes passing the fluid through the filter.
In a preferred form of the method, passing the fluid through the filter includes passing the fluid through a sterilizing grade filter.
In a preferred form of the method, passing the fluid through the filter includes passing the fluid through a 0.2 micron filter.
In a preferred form, the method includes correlating the results of the filter integrity test to the quality of fluid in the filled product bag.
In a preferred form, the method includes assessing results from the filter integrity test and determining the filled bag as acceptable or unacceptable.
In a preferred form of the machine, the testing station further includes a diverter configured to move between a first position and a second position, and wherein the diverter occupies the first position in response to a pass result of the filter integrity test and the diverter occupies the second position in response to a fail result of the filter integrity test.
In a preferred form of the machine, the diverter is disposed below the filled bag and configured to direct the bag into one of a first bin or a second bin.
In a preferred form of the machine, the first bin receives a rejected filled product bag from the diverter in the first position, and wherein the second bin receives an accepted filled product bag from the diverter in the second position.
In a preferred form, the machine includes a station having a ramp located between the testing station and the filling station, wherein the ramp is configured to engage a sterile closure cap of the product bag and remove the sterile closure cap as the bag and the ramp move relative to the other.
In a preferred form of the machine, the ramp is forked and includes a slot for removing the sterile closure cap.
In a preferred form of the machine, the carrier comprises a carousel rotatable about a central axis, the carrier carrying a plurality of movable cradles.
In a preferred form of the machine, a plurality of stations are disposed about a perimeter of the carousel.
In a preferred form of the machine, the carrier carries a load cell to monitor the product bag.
In a preferred form of the machine, the cradle is movable relative to each of the plurality of stations.
In a preferred form of the machine, the sealing device includes an actuator to advance a sealer toward and away from the stem.
In a preferred form of the machine, the cutting device includes an actuator to advance the blade of the cutting device toward and away from the stem.
In a preferred form, the machine includes a mixing bag for containing a fluid, the mixing bag fluidly connected to the nozzle assembly.
The machine further includes at least one sterilizing filter disposed within a fill tube, the fill tube fluidly connecting the mixing bag to the nozzle assembly.
According to a first independent aspect, a method of providing a plurality of filled product bags of sterile fluid is provided. The method includes providing a plurality of product bags, wherein each product bag has a bladder, a stem fluidly connected to an opening of the bladder, and a filter disposed in-line with the stem. The method further includes creating a plurality of filled product bags by performing the following on each product bag. The method further includes at least partially filling the product bag with a fluid to create a filled product bag, wherein filling the product bag includes passing the fluid through the filter and into the bladder. The method further includes, after filling, sealing the filled product bag. The method further includes performing an integrity test on the filter and correlating an integrity of the contents of the filled product bag to an integrity of the filter based on an outcome of the integrity test.
In a second aspect according to the previous aspect, the method further includes connecting an inlet of the stem to an outlet of a nozzle.
In a third aspect according to the previous aspects, the method further includes securing a product bag to one of a plurality of movable cradles and rotating a carousel about a central axis, the carousel carrying the plurality of movable cradles evenly disposed on a perimeter of the carousel, wherein rotating the carousel moves each of the plurality of cradles between two positions of a plurality of positions.
In a fourth aspect according to the previous aspects, connecting the inlet of the stem to the nozzle includes moving the cradle.
In a fifth aspect according to the previous aspects, at least partially filling the product bag includes drawing the fluid from a mixing bag through a fill tube, and dispensing the fluid from the fill tube through the outlet of the nozzle.
In a sixth aspect according to the previous aspects, connecting the inlet of the stem to the nozzle includes engaging a luer fitting of the nozzle to the inlet of the stem.
In a seventh aspect according to the previous aspects, the method further includes removing a sterile closure cap covering the inlet of the stem before connecting the inlet to the nozzle.
In an eighth aspect according to the previous aspects, the method further includes measuring an amount of fluid in the bladder of the filled product bag with a load cell, and discontinuing filling the product bag when the product bag contains a predetermined amount of fluid.
In a ninth aspect according to the previous aspects, discontinuing filling includes removing the inlet of the stem from the nozzle.
In a tenth aspect according to the previous aspects, the method further includes disconnecting the inlet of the stem from the nozzle when the product bag is filled to the predetermined amount.
In an eleventh aspect according to the previous aspects, performing the integrity test includes performing at least one of a bubble test and a pressure degradation test.
In a twelfth aspect according to the previous aspects, performing the integrity test includes sensing a pressure applied to the filter with a pressure sensor.
In a thirteenth aspect according to the previous aspects, the method further includes depositing the filled product bag into a first bin for rejected bags if the filter fails the integrity test and a second bin for accepted bags if filter passes the integrity test.
In a fourteenth aspect according to the previous aspects, the method further includes moving a diverter directed to one of the first bin or the second bin based on the results of the filter integrity test.
In a fifteenth aspect according to the previous aspects, performing the filter integrity test includes assessing the filter for structural flaws.
In a sixteenth aspect according to the previous aspects, passing the fluid through the filter includes passing the fluid through a sterilizing grade filter.
In a seventeenth aspect according to the previous aspects, passing the fluid through the filter includes passing the fluid through a 0.2 micron filter.
In an eighteenth aspect according to the previous aspects, the method further includes removing the filled product bag from the cradle.
In a nineteenth independent aspect, a method of providing filled product bags of sterile fluid using a machine is provided. The method includes loading a product bag onto a loaded cradle of a plurality of movable cradles carried by a carousel, the loaded cradle occupying a loading position, the product bag including a bladder, a stem fluidly connected to an opening of the bladder, and a filter disposed in-line with the stem. The method also includes moving the loaded cradle and the product bag to a filling station that includes a nozzle by rotating the carousel and moving the loaded cradle from the loading position to a filling position adjacent the nozzle. The method also includes connecting an inlet of the product bag to the nozzle by moving the loaded cradle and the product bag toward the nozzle. The method also includes at least partially filling the product bag with a fluid dispensed through the nozzle to create a filled product bag. The method also includes moving the loaded cradle and the filled product bag to a sealing and cutting station that includes a sealing device and a cutting device by rotating the carousel from the filling position to a sealing and cutting position. The method also includes moving the sealing device to the stem of the filled product bag, and sealing the stem of the filled product bag with the sealing device. And, the method further includes moving the sealing device away from the filled product bag, moving the cutting device to the stem of the filled product bag, cutting the stem at a location above the seal with the cutting device, and moving the cutting device away from the filled product bag. And, the method further includes moving the loaded cradle and the filled product bag to a testing station that includes a testing device by rotating the carousel from the sealing and cutting position to a testing position, performing a filter integrity test on the filter at the testing position, removing the filled product bag from the cradle, and receiving the filled product bag in one of a rejected bin or an accepted bin based on the results of filter integrity test.
In a twentieth aspect according to the previous aspects, the method further includes removing a sterile closure cap covering the inlet of the stem using a ramp by rotating the carousel from the loading position to the filling position and passing the loaded cradle adjacent the ramp such that the ramp engages and removes the sterile closure cap of the stem as the carousel rotates.
In a twenty-first aspect according to the previous aspects, the method further includes correlating the results of the filter integrity test to a quality of fluid in the filled product bag.
In a twenty-second aspect according to the previous aspects, filling the product bag includes passing the fluid through the filter.
In a twenty-third aspect according to the previous aspects, the method further includes assessing results from the filter integrity test and determining the filled product bag as acceptable or unacceptable.
In a twenty-fourth aspect according to the previous aspects, the method further includes rotating the carousel about a central axis, the carousel carrying the plurality of movable cradles evenly disposed on a perimeter of the carousel, wherein rotating the carousel moves each of the plurality of movable cradles between two positions of a plurality of positions.
In a twenty-fifth aspect according to the previous aspects, atleast partially filling the product bag includes drawing the fluid from a mixing tank through a fill tube, and dispensing the fluid from the fill tube through the nozzle of the nozzle assembly.
In a twenty-sixth aspect according to the previous aspects, connecting the inlet of the stem to the nozzle assembly includes engaging a luer fitting of the nozzle to the inlet of the stem.
In a twenty-seventh aspect according to the previous aspects, creating a filled product bag includes measuring an amount of fluid in the bladder with a load cell, and discontinuing filling the product bag when the product bag contains a predetermined amount of fluid.
In a twenty-eighth aspect according to the previous aspects, discontinuing filling includes removing the inlet of the stem from the nozzle.
In a twenty-ninth aspect according to the previous aspects, the method further includes disconnecting the inlet of the stem from the nozzle when the product bag is filled to the predetermined amount.
In a thirtieth aspect according to the previous aspects, performing the integrity test includes performing at least one of a bubble test and a pressure degradation test.
In a thirty-first aspect according to the previous aspects, performing the integrity test includes sensing a pressure applied to the filter with a pressure sensor.
In a thirty-second aspect according to the previous aspects, the method further includes moving a diverter directed to one of the first bin or the second bin based on the results of the filter integrity test.
In a thirty-third aspect according to the previous aspects, performing the filter integrity test includes assessing the filter for structural flaws.
In a thirty-fourth aspect according to the previous aspects, filling the product bag includes passing the fluid through the filter and into the bladder.
In a thirty-fifth aspect according to the previous aspects, passing the fluid through the filter includes passing the fluid through a sterilizing grade filter.
In a thirty-sixth aspect according to the previous aspects, passing the fluid through the filter includes passing the fluid through a 0.2 micron filter.
In a thirty-seventh aspect preferably, but not necessarily, according to the previous aspects, an automated machine for creating sterile fluid-filled product bags is provided. The machine includes a nozzle assembly, a carrier, a filling station, a sealing and cutting station, and a testing station. The carrier can have a movable cradle for receiving at least one product bag, the product bag including a bladder, a stem fluidly connected to an opening of the bladder, and a filter disposed in-line with the stem. The filling station includes the nozzle assembly, the nozzle assembly having a nozzle configured to engage an inlet of the stem and fluidly connect with the bladder. The sealing and cutting station includes a sealing device configured to seal the stem of the product bag at a location above the opening of the bladder and below the filter, and a cutting device having a blade for cutting the stem at a location above the seal and below the filter. The testing station includes a filter integrity testing apparatus. The filter integrity testing apparatus including a filter testing device and a pressure sensor. The filter testing device is configured to engage the inlet of the stem of each sterile fluid-filled product bag to perform a filter integrity test, and wherein the filter passing the filter integrity test correlates to an accepted bag and wherein the filter failing the filter integrity test correlates to a rejected bag.
In a thirty-eighth aspect according to the previous aspects, the testing station further includes a diverter configured to move between a first position and a second position, and wherein the diverter occupies the first position in response to a pass result of the filter integrity test and the diverter occupies the second position in response to a fail result of the filter integrity test.
In a thirty-ninth aspect according to the previous aspects, the diverter is disposed below the filled product bag and configured to direct the filled product bag into one of a first bin or a second bin.
In a fortieth aspect according to the previous aspects, the first bin receives a rejected filled product bag from the diverter in the first position, and wherein the second bin receives an accepted filled product bag from the diverter in the second position.
In a forty-first aspect according to the previous aspects, the machine further includes a station having a ramp located between the testing station and the filling station, wherein the ramp is configured to engage a sterile closure cap of the product bag and remove the sterile closure cap as the product bag and the ramp move relative to the other.
In a forty-second aspect according to the previous aspects, the ramp is forked and includes a slot for removing the sterile closure cap.
In a forty-third aspect according to the previous aspects, the carrier comprises a carousel rotatable about a central axis, the carousel carrying a plurality of movable cradles.
In a forty-forth aspect according to the previous aspects, a plurality of stations are disposed about a perimeter of the carousel.
In a forty-fifth aspect according to the previous aspects, the carrier carries a load cell to monitor the product bag.
In a forty-sixth aspect according to the previous aspects, the cradle is movable relative to each of the plurality of stations.
In a forty-seventh aspect according to the previous aspects, the sealing device includes an actuator to advance a sealer toward and away from the stem.
In a forty-eighth aspect according to the previous aspects, the cutting device includes an actuator to advance the blade of the cutting device toward and away from the stem.
In a forty-ninth aspect according to the previous aspects, the machine further includes a mixing bag for containing a fluid, the mixing bag fluidly connected to the nozzle assembly.
In a fiftieth aspect according to the previous aspects, the machine further includes at least one sterilizing filter disposed within a fill tube, the fill tube fluidly connecting the mixing bag to the nozzle assembly.
A machine for providing sealed product bags filled with a sterile solution is illustrated in
In
The product bag assembly compartment 14 houses a processing system 22 (also shown in
The machine 10 may provide air filtration and purification devices and systems in the product bag assembly 14 and the solution and distribution compartments 12. A HEPA filter 64 adjacent to the processing system 22 maintains a clean working environment within the product bag assembly compartment 14. In some versions, the product bag assembly compartment 14 may also be located under a hood which provides a constant pressure gradient to eliminate contaminants from the environment. In yet another embodiment, the air of the product bag assembly compartment 14 may be filtered using ultraviolet light technology, such as ultra violet germicidal irradiation, that may either supplement or replace the HEPA filter 64 or other filtration methods and/or devices. Additional processes for assembling and installing the machine 10 may be automated to avoid contamination. For example, a nozzle, which connects a mixing bag in the solution and distribution compartment 12 with the filling station 36 in the product bag assembly compartment 14, may have a sterile closure cap that is removed in an automated fashion by a machine or a device after the nozzle is installed and the compartment 14 has been adequately filtered.
As best illustrated in
The on-board central processing unit (CPU) 64 of the machine 10 (illustrated in
As discussed above, the CPU 64 controls the automated rotation and at the aspects of the processing system 22 by communicating with the carousel assembly 24.
As used herein, the term “tooling” may be used to describe any device, mechanism, apparatus, or actuator, including tubes, diverters, load cells, sensors, proximity switches, etc., that are assigned to a particular stage and/or station 34, 36, 38, 40 of the processing system 22, and are positioned relative to the station 34, 36, 38, 40 to perform an assigned task of the process. The tooling may be externally located from the carousel assembly 24 or may be one of the internal components 65 mounted to the core 66. The tooling, whether externally or internally located relative to the carousel assembly 24, may directly or indirectly interact with the product bag 28 as the product bag 28 reaches each station. Such interactions as described herein, include but are not limited to measuring, cutting, sealing, engaging, removing, connecting, and/or gripping various parts or components of the product bag 28.
The stem 104 is a narrow tube that fluidly connects an inlet 124 of the stem 104 to the opening 114 of the bladder 102. The stem 104 includes a tapered head 126 defining the inlet 124, a collar 128 connecting a first stem part 130 to the tapered head 126, a second part 132, and a duct 134 defining a stem outlet 136. The sterile closure cap 108, in this version, has a hemispherical knob 138 attached to a neck 140 that sealably covers or is inserted into the inlet 124 of the stem 104 and maintains the sterility of the interior during storage and distribution. The filter 106, in this version, has a flat filter membrane 142 disposed in-line with the stem 104 between the first and second parts 130, 132 of the stem 104. The tapered head 126 may be a female fitting that sealingly engages a male, luer fitting of the machine 16 during filling, as described below and illustrated in
So configured, a solution may enter the inlet 124 of the stem 104 and pass through the head 126 and into the first part 130 toward an inlet 144 of the filter 106. The solution then passes through the flat filter membrane 142, out a filter outlet 146, and into the second part 132 of the stem 104. The duct 134 directs the filtered solution from the second part 132 and to the opening 114 of the bladder 102. The second part 132 of the stem 104 is defined by the area of the stem 104 between the outlet of the filter 146 and an inlet 148 of the duct 134 and may be referred to as a cut and seal area 132. The stem 104 provides an isolated fluid connection between the inlet 124 and the bladder 102, such that once the solution is filtered through the filter membrane 142, the filtered solution passes directly into the sterilized environment of the bladder 102.
The filter 106 illustrated in
An alternative product bag 150 illustrated in
The filter pore size for product bags 100, 150 effectively sterilizes the solution and removes non-viable contaminants as the solution passes through the inlet 124 of the stem 104 and into the bladder 102 at the bladder opening 114. While the product bag 100 of
The nest 206, which is attached to the back plate 204, includes first and second gripping fingers 215a, 215b that releasably grip the collar 128 of the stem 104 (
The hang pins 210a, 210b are retained within an angled bore of their respective support blocks 212a, 212b. A connecting pull bar 222 (
As illustrated in
In one version, the aforementioned bag with multiple bladders can take the form depicted in
The term actuator, as referred to herein, includes a motor that moves or controls a mechanism or system that may be powered by electric current, hydraulic fluid pressure, or pneumatic pressure. The carousel described herein may be controlled or operated by a rotary actuator, but other embodiments may include a linear actuator. For example, the carousel may be replaced with a linear assembly line, such as a conveyor belt, that moves in spaced intervals between positions and/or stations. In this example, the stations would be positioned relative to the linear conveyor belt or other method of linear conveyance to perform each process involved and required for filling bags of sterile solution.
Station I. Cap Removal Station
Referring now to
As depicted in
The cap removal tooling 400 engages the neck 140 of the sterile closure cap 108 to remove the sterile closure cap 108 from the inlet 124 of the stem 104 in a sterile manner as the loaded cradle 310 passes the cap removal tooling 400 when the carousel 72 rotates (
Station II. Filling Station
Turning now to
Returning back to the loaded cradle 310 of
The filling station tooling 500 described herein may be automated or manually controlled. In the preferred example illustrated in
Station III. Sealing and Cutting Station
Similarly, the cutting device includes a first actuator 622 that advances the cutter 608 toward and away from the stem 104. The cutter 608 of the cutting device 604 includes jaws 612 having a blade 624 and a stem guide 626 to cut the stem 104 when the jaws 612 are closed. The stem guide 626 provides a semi-circular aperture 628 to receive the stem 104 as the blade 624 cuts through the stem 104. The midpoint of the jaws 612 of the cutter 608 is aligned with the stem 104.
The sealer 606 and the cutter 608 are positioned so that the jaws of each device engage the sealing and cutting area 132 of the stem 104 (
In the preferred example of
Although
The integrity test may be run before the stem 104 is sealed and cut. In an embodiment of the system and machine, the third station 38 may only have a sealing or crimping device. In this case, the stem 104 may be hermetically crimped, rather than sealed, at the third station 38 before moving to the testing and unloading station 40. After the filter integrity test has been performed, the stem 104 may then be sealed and cut as described herein.
To avoid microbial growth, it may be advantageous to seal (or crimp) the stem 104 shortly after the product bag 100 has been filled with fluid. The filter media effectively filters out microbes and bacteria when the product bag 100 is filled at the filling station 36. Therefore, it is possible that the filtered microbes may grow through the pores and the bacteria may release endotoxins, therefore creating a sterility issue, if the stem 104 of the bag is not sealed or hermetically crimped in due time.
Station IV. Testing and Unloading Station
To perform the filter integrity test using a pressure degradation test procedure, the test head 712 engages the head 126 of the stem 104 and applies an air pressure of a predetermined value to the inlet 124 and filter membrane 142. In an embodiment the pre-determined value is the pressure where gas cannot permeate the membrane 142 of an acceptable filter. A pressure sensor, or other method of measuring the integrity of the filter, is located within the test head 712 and measures the pressure decay or diffusion rate through the filter membrane 142. The results from the integrity test are assessed to determine the quality of the filter 106, and therefore the quality of the solution of the filled product bag 100. If the pressure sensor measures a decay or a unexpected rate of decay, then the filter 106 fails the test.
Alternatively in a bubble point test, the test head 712 gradually increases the pressure applied to the filter 106, and the increase in pressure is measured in parallel with the diffusion rate of the gas through the media 142. Any disproportionate increase in diffusion rate in relation to the applied pressure may indicate a hole or other structural flaw in the filter membrane 142, and the filter would fail the integrity test
Based on the results of the filter integrity test, a determination that the solution of the filled product bag is either sterile or has the potential of being compromised may be made with a high degree of certainty. The filter integrity test performed at the testing station 40 is not limited to those methods described herein, and may include a different acceptable filter test designed to assess the quality and performance of the filter.
As illustrated in
After the diverter 708 either remains in the first position or moves the chute 714 to the second position, the pin-pull device 710 may then remove the filled product bag 100 from the cradle 310. In
Referring back to the
As depicted in
In the preferred example illustrated in
According to a preferred method of providing filled product bags of sterile fluid, the method may include securing a product bag 100 to one of a plurality of movable cradles 200. After securing the product bag 100 to a movable cradle 200, an inlet 124 of the stem 104 may be connected to an outlet 532 of a nozzle assembly 506, at least partially filling the product bag 100 with a fluid through a nozzle 508 of the nozzle assembly 506 to create a filled product bag 100, wherein filling the product bag 100 includes passing the fluid through the filter 106 and into the bladder 102. After filling, the method includes creating a seal on the stem 104 of the filled product bag 100 at a location 632 below the filter 106, cutting the stem 104 at a location 630 above the seal and below the filter 106. Once the stem 104 is cut and the bag 100 sealed, the method proceeds in performing an integrity test on the filter 106, removing the filled product bag 100 from the cradle 200, and depositing the filled product bag 100 into a first bin for rejected bags if the filter fails the integrity test and a second bin for accepted bags if filter passes the integrity test.
The method and machine disclosed herein provide considerable benefits over current methods of terminal sterilization. The machine is portable and self-containing, allowing remote health facilities and clinics to process a supply of sterile product bags without incurring the costs of outsourcing from a third party. Additionally, the process and method described herein provide sterile solution bags without using a sterilizing autoclave and/or expensive sterilization equipment required to sterilize the working environment and eliminates the risk of formulation degradation due to heat exposure. The self-contained and automated machine reduces the sterilization procedures necessary to be performed in terminal sterilization processes.
The method and machine disclosed herein reduces risk of contamination. The product bag having a filter disposed in-line with a stem avoids exposing the post-filtered sterile fluid to the working environment. Rather, the sterile filtered solution is never exposed to environment thereby producing a fluid that has been subject to terminal sterilization filtration. Moreover, in the case a filled product bag were determined to be compromised, the compromised bag would be contained and discarded without contaminating the processing equipment of the machine or other product bags being processed.
Further, the machine and processing system allow for a one-to-one processing and testing correlation such that the quality of the solution in the product bag is ensured without puncturing or destroying the filled bag.
This is the US national phase of International Patent Application No. PCT/US2017/014264, filed Jan. 20, 2017, which claims the priority benefit of U.S. Provisional Patent Application No. 62/281,825, filed Jan. 22, 2016, the entire contents of each of which are incorporated by reference herein.
Filing Document | Filing Date | Country | Kind |
---|---|---|---|
PCT/US2017/014264 | 1/20/2017 | WO | 00 |
Publishing Document | Publishing Date | Country | Kind |
---|---|---|---|
WO2017/127632 | 7/27/2017 | WO | A |
Number | Name | Date | Kind |
---|---|---|---|
3233384 | Barton et al. | Feb 1966 | A |
3902068 | Wood | Aug 1975 | A |
3938519 | McPhee | Feb 1976 | A |
4036698 | Bush et al. | Jul 1977 | A |
4116646 | Edwards | Sep 1978 | A |
4265760 | Abel et al. | May 1981 | A |
4353398 | Weiler et al. | Oct 1982 | A |
4360435 | Bellamy et al. | Nov 1982 | A |
4369898 | Andersson | Jan 1983 | A |
4502614 | Weiler et al. | Mar 1985 | A |
4507114 | Bohman et al. | Mar 1985 | A |
4515007 | Herman | May 1985 | A |
4521366 | Mason et al. | Jun 1985 | A |
4547289 | Okano et al. | Oct 1985 | A |
4610790 | Reti et al. | Sep 1986 | A |
4623516 | Weiler et al. | Nov 1986 | A |
4636307 | Inoue et al. | Jan 1987 | A |
4636313 | Vaillancourt | Jan 1987 | A |
4668401 | Okumura et al. | May 1987 | A |
4671762 | Weiler et al. | Jun 1987 | A |
4695382 | Cronin | Sep 1987 | A |
4712590 | Gianfilippo | Dec 1987 | A |
4730435 | Riddle et al. | Mar 1988 | A |
4738782 | Yamauchi et al. | Apr 1988 | A |
4779448 | Gogins | Oct 1988 | A |
4807676 | Cerny et al. | Feb 1989 | A |
4820297 | Kaufman | Apr 1989 | A |
4842028 | Kaufman et al. | Jun 1989 | A |
4872974 | Hirayama et al. | Oct 1989 | A |
4881176 | Kononov | Nov 1989 | A |
4915847 | Dillon | Apr 1990 | A |
4937194 | Pattillo | Jun 1990 | A |
4943287 | Carmen | Jul 1990 | A |
5064529 | Hirayama et al. | Nov 1991 | A |
RE33924 | Valeri | May 1992 | E |
5180504 | Johnson et al. | Jan 1993 | A |
5209044 | D'Addario | May 1993 | A |
5221474 | Yokono et al. | Jun 1993 | A |
5249409 | Jensen | Oct 1993 | A |
5275724 | Bucchianeri et al. | Jan 1994 | A |
5310094 | Martinez et al. | May 1994 | A |
5353630 | Soda et al. | Oct 1994 | A |
5368586 | Van Der Heiden et al. | Nov 1994 | A |
5417101 | Weich | May 1995 | A |
5476592 | Simard | Dec 1995 | A |
5480554 | Degen et al. | Jan 1996 | A |
5488811 | Wang et al. | Feb 1996 | A |
5490848 | Finley et al. | Feb 1996 | A |
5493845 | Adolf et al. | Feb 1996 | A |
5507959 | Glick | Apr 1996 | A |
5538638 | Hedman | Jul 1996 | A |
5563334 | Bracht et al. | Oct 1996 | A |
5584997 | Yagihashi et al. | Dec 1996 | A |
5594161 | Randhahn et al. | Jan 1997 | A |
5616828 | Kuczenski | Apr 1997 | A |
5674404 | Kenley et al. | Oct 1997 | A |
5733619 | Patel et al. | Mar 1998 | A |
5788862 | Degen et al. | Aug 1998 | A |
5808181 | Wamsiedler et al. | Sep 1998 | A |
5881535 | Gliniecki et al. | Mar 1999 | A |
5911886 | Delmas | Jun 1999 | A |
6059968 | Wolf, Jr. | May 2000 | A |
6149997 | Patel et al. | Nov 2000 | A |
6228271 | Cote | May 2001 | B1 |
6245228 | Kelada | Jun 2001 | B1 |
6324898 | Cote et al. | Dec 2001 | B1 |
6358420 | Blickhan et al. | Mar 2002 | B2 |
6451201 | Cadera et al. | Sep 2002 | B1 |
6465068 | Patel et al. | Oct 2002 | B1 |
6495039 | Lee et al. | Dec 2002 | B1 |
6504606 | Yagita | Jan 2003 | B2 |
6660171 | Zuk, Jr. | Dec 2003 | B2 |
6666970 | Jornitz et al. | Dec 2003 | B1 |
6904370 | Levinson et al. | Jun 2005 | B1 |
6983504 | Grummert et al. | Jan 2006 | B2 |
7048775 | Jornitz et al. | May 2006 | B2 |
7117901 | Martinell Gisper-Sauch et al. | Oct 2006 | B2 |
7166217 | Holmes et al. | Jan 2007 | B2 |
7281409 | Baumfalk et al. | Oct 2007 | B2 |
7354758 | Guenec et al. | Apr 2008 | B2 |
7396451 | Holmes et al. | Jul 2008 | B2 |
7413665 | Holmes et al. | Aug 2008 | B2 |
7444795 | Yasuhira | Nov 2008 | B2 |
7544300 | Brugger | Jun 2009 | B2 |
7592178 | Ding et al. | Sep 2009 | B2 |
7594425 | Lewnard et al. | Sep 2009 | B2 |
7727219 | Lampeter | Jun 2010 | B2 |
7749393 | Brugger et al. | Jul 2010 | B2 |
7770434 | Brussermann | Aug 2010 | B2 |
7972515 | Mangum et al. | Jul 2011 | B1 |
8003768 | Gordon | Aug 2011 | B1 |
8225824 | Eliuk | Jul 2012 | B2 |
8271139 | Bellafiore | Sep 2012 | B2 |
8272251 | Jons et al. | Sep 2012 | B2 |
8361320 | Zuk, Jr. | Jan 2013 | B2 |
8366855 | Murray | Feb 2013 | B2 |
8499919 | Giribona | Aug 2013 | B2 |
8865064 | Meier et al. | Oct 2014 | B2 |
9072996 | Jornitz et al. | Jul 2015 | B2 |
9095801 | Stering | Aug 2015 | B2 |
20020117232 | Gisper-Sauch et al. | Aug 2002 | A1 |
20020162778 | Peabody | Nov 2002 | A1 |
20030174306 | Grant | Sep 2003 | A1 |
20030230521 | Schick | Dec 2003 | A1 |
20030234211 | Seiler et al. | Dec 2003 | A1 |
20040007540 | Verpoort et al. | Jan 2004 | A1 |
20040022696 | Zigler et al. | Feb 2004 | A1 |
20040031744 | Nakashima | Feb 2004 | A1 |
20040147865 | Cianci et al. | Jul 2004 | A1 |
20040155066 | Schick | Aug 2004 | A1 |
20040226898 | Halstead et al. | Nov 2004 | A1 |
20040237654 | Savall et al. | Dec 2004 | A1 |
20050209547 | Burbank et al. | Sep 2005 | A1 |
20050279419 | Tribble | Dec 2005 | A1 |
20060048486 | Laing et al. | Mar 2006 | A1 |
20060054557 | Hori et al. | Mar 2006 | A1 |
20060124515 | Rajagopalan et al. | Jun 2006 | A1 |
20070079649 | Nauseda et al. | Apr 2007 | A1 |
20070119121 | Woods | May 2007 | A1 |
20070175816 | Verpoort et al. | Aug 2007 | A1 |
20070251299 | Brussermann et al. | Nov 2007 | A1 |
20080051937 | Khan et al. | Feb 2008 | A1 |
20080087613 | Hudock et al. | Apr 2008 | A1 |
20080105618 | Beckius et al. | May 2008 | A1 |
20090173685 | Imai et al. | Jul 2009 | A1 |
20090299651 | Sadar | Dec 2009 | A1 |
20100004588 | Yeh et al. | Jan 2010 | A1 |
20100004602 | Nord | Jan 2010 | A1 |
20100004619 | Rondeau | Jan 2010 | A1 |
20110049026 | Ryu et al. | Mar 2011 | A1 |
20110067485 | Grant et al. | Mar 2011 | A1 |
20110094310 | DiLeo et al. | Apr 2011 | A1 |
20110094619 | Steel et al. | Apr 2011 | A1 |
20120024156 | Yoshida et al. | Feb 2012 | A1 |
20120080375 | Scheu et al. | Apr 2012 | A1 |
20120222774 | Husnu et al. | Sep 2012 | A1 |
20120282143 | Marquis et al. | Nov 2012 | A1 |
20120297862 | Mayr et al. | Nov 2012 | A1 |
20130055794 | Armour | Mar 2013 | A1 |
20130130973 | Wahren et al. | May 2013 | A1 |
20130233810 | Zuk, Jr. | Sep 2013 | A1 |
20130240436 | Johnson et al. | Sep 2013 | A1 |
20140012185 | Ishizuka et al. | Jan 2014 | A1 |
20140033798 | Peeler et al. | Feb 2014 | A1 |
20140083170 | Pavlik | Mar 2014 | A1 |
20140238110 | Williams | Aug 2014 | A1 |
20150033828 | Li et al. | Feb 2015 | A1 |
20150265958 | Brown | Sep 2015 | A1 |
20150283479 | Perreault et al. | Oct 2015 | A1 |
20150284173 | Defemme et al. | Oct 2015 | A1 |
20150298995 | Johann et al. | Oct 2015 | A1 |
20150307606 | Basarkar et al. | Oct 2015 | A1 |
20160201019 | Stokes et al. | Jul 2016 | A1 |
Number | Date | Country |
---|---|---|
2498602 | Jul 2002 | CN |
101816846 | Sep 2010 | CN |
201643862 | Nov 2010 | CN |
201732014 | Feb 2011 | CN |
102109364 | Jun 2011 | CN |
201939752 | Aug 2011 | CN |
102313691 | Jan 2012 | CN |
102430340 | May 2012 | CN |
102435224 | May 2012 | CN |
102947186 | Feb 2013 | CN |
103393542 | Nov 2013 | CN |
103476381 | Dec 2013 | CN |
203337507 | Dec 2013 | CN |
203493987 | Mar 2014 | CN |
104048839 | Sep 2014 | CN |
204797991 | Nov 2015 | CN |
105209342 | Dec 2015 | CN |
204910247 | Dec 2015 | CN |
204988705 | Jan 2016 | CN |
205262990 | May 2016 | CN |
15004569 | Jul 2015 | CO |
3238649 | Apr 1984 | DE |
3333283 | Apr 1985 | DE |
4339589 | Dec 1994 | DE |
29618092 | Dec 1996 | DE |
20212749 | Oct 2002 | DE |
10151270 | May 2003 | DE |
202010017082 | May 2011 | DE |
10165044 | Jan 2013 | DE |
102011111050 | Feb 2013 | DE |
102012216772 | Mar 2014 | DE |
202015101765 | Apr 2015 | DE |
102014113638 | Mar 2016 | DE |
0116362 | Aug 1984 | EP |
0314822 | May 1989 | EP |
0476194 | Mar 1992 | EP |
0582822 | Feb 1994 | EP |
0667954 | Aug 1995 | EP |
0624359 | May 1997 | EP |
0790051 | Aug 1997 | EP |
0545000 | Oct 1997 | EP |
0820343 | Jan 1998 | EP |
1579838 | Sep 2005 | EP |
1775002 | Apr 2007 | EP |
1882486 | Jan 2008 | EP |
1935470 | Jun 2008 | EP |
2012906 | Jan 2009 | EP |
2059443 | May 2009 | EP |
2260918 | Dec 2010 | EP |
2331078 | Jun 2011 | EP |
2502610 | Sep 2012 | EP |
2658502 | Nov 2013 | EP |
2684551 | Jan 2014 | EP |
2767583 | Aug 2014 | EP |
2840379 | Feb 2015 | EP |
2909904 | Jun 2008 | FR |
2153247 | Aug 1985 | GB |
2362841 | Dec 2001 | GB |
2365511 | Feb 2002 | GB |
S5840202 | Mar 1983 | JP |
S6058530 | Apr 1985 | JP |
6091203 | Jun 1985 | JP |
S60197287 | Oct 1985 | JP |
S621410 | Jan 1987 | JP |
H01139108 | May 1989 | JP |
02290228 | Nov 1990 | JP |
H038420 | Jan 1991 | JP |
H03110445 | May 1991 | JP |
H04142445 | May 1992 | JP |
H04348252 | Dec 1992 | JP |
H0523551 | Feb 1993 | JP |
H0643089 | Feb 1994 | JP |
6-34636 | May 1994 | JP |
H10225628 | Aug 1998 | JP |
2009-519440 | May 2009 | JP |
5389885 | Jan 2014 | JP |
2014128780 | Jul 2014 | JP |
2014521405 | Aug 2014 | JP |
2015-74457 | Apr 2015 | JP |
2389513 | May 2010 | RU |
247843 | Jul 1969 | SU |
WO-8803829 | Jun 1988 | WO |
WO-9614913 | May 1996 | WO |
WO-2004009201 | Jan 2004 | WO |
WO-2004096319 | Nov 2004 | WO |
WO-2005077499 | Aug 2005 | WO |
WO-2008039278 | Apr 2008 | WO |
WO-2009006850 | Jan 2009 | WO |
WO-2010065810 | Jun 2010 | WO |
WO-2011154072 | Dec 2011 | WO |
WO-2012103124 | Aug 2012 | WO |
WO-2013009765 | Jan 2013 | WO |
WO-2014008400 | Jan 2014 | WO |
WO-2014105946 | Jul 2014 | WO |
WO-2014147159 | Sep 2014 | WO |
WO-2015023468 | Feb 2015 | WO |
WO-2015082855 | Jun 2015 | WO |
WO-2013186631 | Jul 2015 | WO |
WO-2016030013 | Mar 2016 | WO |
WO-2016109230 | Jul 2016 | WO |
Entry |
---|
International Search Report and Written Opinion for International Application No. PCT/US2017/014264, dated May 15, 2017. |
Chinese Patent Application No. 201780007336.2, Notification of First Office Action, dated Nov. 19, 2018. |
Japanese Patent Application No. 2018-535037, Notice of Reasons for Rejection, dated Dec. 10, 2018. |
Korean Patent Application No. 10-2018-7020665, Notice of Preliminary Rejection, dated Dec. 7, 2018. |
Russian Patent Application No. 2018130311, Decision to Grant and Search Report, dated Feb. 19, 2019. |
German Patent Application No. 112017000474.8, Office Action, dated May 14, 2019. |
European Patent Application No. 17705206.5, Communication Pursuant to Article 94(3) EPC, dated May 31, 2019. |
Malaysia Patent Application No. PI 2018001312, Exam and Search Report dated Jul. 8, 2019. |
Great Britain Patent Application No. GB1911992.4, Search Report, dated Dec. 24, 2019. |
Canadian Patent Application No. 3011514, Office Action, dated Nov. 20, 2019. |
Colombia Patent Application No. NC2018/0006820, Office Action, dated Sep. 6, 2019. |
Australian Patent Application No. 2019236592, Examination Report No. 1, dated Nov. 20, 2020. |
Canadian Patent Application No. 3011514, Office Action, dated Apr. 23, 2020. |
Colombian Patent Application No. NC2018/0006820, Second Office Action, dated May 27, 2020. |
European Patent Application No. 19213877.4, Extended European Search Report, dated Feb. 26, 2020. |
European Patent Application No. 19213877.4, Communication Pursuant to Article 94(3) EPC, dated Mar. 16, 2021. |
Number | Date | Country | |
---|---|---|---|
20190002136 A1 | Jan 2019 | US |
Number | Date | Country | |
---|---|---|---|
62281825 | Jan 2016 | US |