Patent Application
20220136757
This disclosure relates, in general, to systems and methods for homogeneous and reproducible freezing and thawing of aqueous solutions of biological materials, in particular those used in chemical, and pharmaceutical processes. This disclosure relates to a system and a method to improve the uniformity of the heat transfer coefficient of containers filled with biological materials during the freezing and thawing process, in particular a system that is easily transported and incremented to other conventional freeze-thaw methods and equipment.
Biological materials are produced industrially in large batches that are stored for extended periods of time and are typically frozen to minimize degradation during its relatively long shelf life. The process of freeze-thaw of biological solutions poses several challenges that need to be considered, such as freeze-thaw operation parameters, storage of substance, shipping in frozen state, and logistics. The choice of the storage container is one of the most important consideration of the freeze-thaw process since they can have an impact on stability and downstream operations of a formulation. Commonly used containers for frozen biological materials include bags and bottles/carboys. Although the disposable bags offer advantages over bottles/carboys, the potential risk of breakage of a bag or tubing assemblies leading to contamination risk and loss of product is a bigger concern as compared to bottles/carboys. Bottle/carboy systems are simple and more robust than bags, and if a biological formulation is robust and stable under a wide range of freeze-thaw conditions, this is the preferred mode of operation for many companies.
Currently, the freezing process involves placing the bottles and/or carboys comprising the biological solution in conventional upright or chest freezers and allowing the product to freeze. However, product losses are often observed when biological solution freezing is carried out using conventional freezers with set-point temperatures ranging from −20° C. to −80° C. This is attributed to the inadequacy of such freezers to provide the cooling rates necessary for a given load configuration. Conventional freezers lack uniform cooling throughout the entire freezer space since the containers are placed in the freezer side by side and sometimes stacked, resulting in different thermal gradients for different containers. Under these conditions, the freezing rate and product quality is thus dependent on freezer capacity, freezer load, space between containers, container size, container shape, and airflow properties inside the freezer. Another option of the freezing process involves the use of cold air and blast freezers to rapidly freeze the biological material below their glass transition temperature. In a typical air-blast freezer, the cooled air is circulated by fans over the containers confined in an insulated closed room or chamber. The extent of cooling achieved depends on several factors such as position of fans, chamber capacity, load configuration, temperature and velocity of airflow. Even when using this fast freezing method, freezing heterogeneity can occur from container to container; consequently, heterogeneity in the quality of a product batch may occur.
Another consequence of different freezing rates is the heterogeneity in solutes distribution (macro cryoconcentration or freeze-concentration) that occurs at a macro scale in frozen solutions of biological materials. Cryoconcentration has been associated with heterogeneous ice matrix, which could result in degradation of biological material and quality loss; further, slow freezing and thawing compromises the stability of biological substances. Furthermore, heat transfer at the top of the containers, both by convection and radiation, leads to the formation of an ice crust consisting an ice layer on top of the liquid, at the air-liquid interface. The ice crust contributes to increased internal pressure in the containers and consequently results in damage or rupture of the containers. Portuguese national provisional patent application No. 115152, filed on Nov. 12, 2018 disclosed an insulator device to prevent ice crust formation on the top of the liquid, at the air-liquid interface, in the head-space region of containers. This device allows improvement in the freezing process by avoiding ice-crust formation and the increase in pressure inside the containers thus preventing container damage or rupture.
Although bottles and carboys have been widely used in many biopharmaceutical companies, the existence of scale-down models that mimic large-scale systems is desired for developmental studies and optimization of the freezing-thawing process. Recently, document WO2018211437A1 discloses a scale-down system designed for bottles.
Although there are already systems and methods that help to improve the process of freezing and thawing using bottles and carboys, such as the ice crust insulator device and the scale-down system, these systems still cannot solve the problem of freezing heterogeneity in multiple containers within a single batch. Specifically, the problem of freezing heterogeneity when using currently available freezers, conventional or blast freezers, and freezers being located in different sites. Most of the time, freezing equipment are already installed and differs from site to site in the same biopharmaceutical company, therefore it is desirable to design a simple, portable system for homogeneous and reproducible freezing and thawing of biological materials which can be used in conjunction with existing equipment in different locations. Moreover, it may be convenient that the system and method can incorporate the already disclosed ice crust insulator device and the scale-down system, thus preventing the above described problems. This will allow container to container homogeneity of the freezing process even when using different freezer types.
The present disclosure provides a system and a method for homogeneous and reproducible freezing and thawing of biological materials, in particular, a system that is easily transported and used in conjunction with other conventional freeze-thaw methods and equipment.
This disclosure provides a system and a method to improve the uniformity of the heat transfer coefficient of containers filled with biological materials during the freezing and thawing process.
The system disclosed includes a portable air blast system configured to receive a container filled with biological materials and to be placed in a cooling or heating chamber. The system allows homogeneous and reproducible freezing and thawing of biological materials. This portable air blast system improves the uniformity of the heat transfer coefficient in the walls of the container, thus allows similar freezing/thawing rates to be achieved even when using different cooling or heating chambers.
The portable air blast system, herein disclosed, may comprise a stand designed to receive the container and for maintaining the container's position in the center of the vent enclosure. The portable air blast system may also comprise a vent enclosure designed to ensure uniform vertical airflow and may further comprise a fan to force the air within the chamber to pass through the vent in order to improve the uniformity of the heat transfer coefficient in the container walls during the freezing and thawing process.
Another aspect of this disclosure relates to a method to improve the uniformity of the heat transfer coefficient of containers filled with biological materials during the freezing and thawing process, using the presently disclosed system, comprising the steps of: (1) providing a cooling or heating chamber; (2) providing at least one portable air blast system; (3) placing the container in the center of the portable air blast system; (4) placing the portable air blast system inside the cooling or heating chamber; and (5) turning on the fan until the biological material completely freezes or thaws.
Another aspect of this disclosure relates to the use of a plurality of portable air blast systems combined in a single chamber and a trolley to quickly load the chamber with the portable air blast system, or a plurality of portable air blast systems.
Another aspect of this disclosure relates to a platform configured to receive the portable air blast system that can provide rotation, rocking, shaking, vibrations or other forms of mechanical motion to induce the convection of the liquid inside the container. The platform is to be used during the thawing process.
An aspect of the present disclosure relates to a system for freezing and thawing aqueous solutions of biological materials, in particular, a system to improve the uniformity of the heat transfer coefficient of containers filled with biological materials, comprising:
In an embodiment, the portable air blast system is configured to receive a container, is made of a rigid material, such as plastic, polymer or other material having high rigidity.
In an embodiment, the portable air blast system configured to receive a container comprises a stand, a vent enclosure and a fan enclosure.
In an embodiment, the portable air blast system comprises a stand to receive the container and sustain its position in the center of the vent enclosure.
In an embodiment, the stand may have a support designed accordingly to receive the container.
In an embodiment, the stand may have pins to connect the stand to the vent enclosure.
In an embodiment, the pins maintain a distance between the stand and the vent enclosure ranging from 1 cm to 10 cm, more preferably ranging from 2 cm to 5 cm.
In an embodiment, the portable air blast system comprises a vent enclosure to obtain a uniform vertical airflow in all side walls of the container.
In an embodiment, the distance between the walls of the vent enclosure and the side walls of the container is approximately constant and comprised between 1 cm and 10 cm, preferably between 1 cm and 3 cm.
In an embodiment, the air velocity inside the vent should preferably be higher than double of the outside air downward velocity.
In an embodiment, the air within the vent has a velocity in a range from approximately 0.5 m/s to approximately 20 m/s, preferably in a range from approximately 1 m/s to approximately 10 m/s, and more preferably from approximately 2 m/s to approximately 8 m/s.
In an embodiment, the portable air blast system comprises a fan enclosure with fan to force the air from the chamber or room to pass through the vent.
In an embodiment, the fan may have a support to be connected to the vent enclosure, preferentially an insulating support.
In an embodiment, the fan is located at the top of the vent enclosure, preferably above the container.
In an embodiment, a fan or a blower can be used, preferably a fan is used, more preferably an axial fan is used.
In an embodiment, the fan uses batteries.
In an embodiment, the fan may have a control system, preferentially to control velocity.
In an embodiment, the fan should be suitable for use in a cryogenic environment.
In an embodiment, more than one fan can be used, preferably the fans are juxtaposed horizontally or vertically.
In an embodiment, the portable air blast system could be made of modular segments that attach to each other.
In an embodiment, the container is a container of fixed shape.
In an embodiment, the container is made of a rigid and biocompatible material such as of glass, polyethylene terephthalates, polycarbonate, polytetrafluoroethylene, polyethylene, polyesters, polyamides, polypropylenes, ethylene-vinyl alcohol copolymer, polyvinylidene fluoride, polyvinylchlorides, and copolymers, mixtures or laminates that comprise the above.
In an embodiment, the container has a volumetric capacity in a range from approximately 1 mL to approximately 20 L, preferably in a range from approximately 100 mL to approximately 10 L.
In an embodiment, the container is a deformable container.
In an embodiment, the deformable container is made of a biocompatible polymeric material such as, ethylene-vinyl acetate copolymer, ethylene-vinyl alcohol copolymer, polytetrafluoroethylene, polyethylene, polyesters, polyamides, polypropylenes, polyvinylidenefluoride, polyurethanes, polyvinylchlorides, and copolymers, mixtures or laminates that comprise the above.
In an embodiment, the deformable container has a volumetric capacity in a range from approximately 10 mL to approximately 20 L, preferably in a range from approximately 10 mL to approximately 1 L.
In an embodiment, the deformable container is placed inside a rigid shell, preferentially made of a material with low heat resistance such as a metal (for instance, stainless steel, aluminium or copper).
In an embodiment, the container may comprise an ice-crust attenuator device.
In an embodiment, the container may comprise a scale-down device.
In an embodiment, the cooling or heating chamber may be static or be an air blast, or a controlled temperature room.
In an embodiment, a plurality of portable air blast systems could be combined in a single chamber.
In an embodiment, there is a typical the distance between the several portable air blast systems to assure that the air outside the vent has a velocity in a range from approximately 0.05 m/s to approximately 1 m/s, preferably in a range from approximately 0.1 m/s to approximately 0.5 m/s.
In an embodiment, a trolley is used to load the chamber with the portable air blast system, or a plurality of portable air blast systems.
In an embodiment, a platform configured to receive the portable air blast system can provide rotation, rocking, shaking, vibrations or other forms of mechanically inducing the convection of the liquid inside the container.
An aspect of the present disclosure relates to a method to improve the uniformity of the heat transfer coefficient of containers filled with biological materials characterized by:
In an embodiment, the biological materials comprises protein, amino acid and peptide formulations, DNA, RNA and nucleic acid solutions, cell suspensions, tissue suspensions, cell aggregates suspensions, cell growth media, serum, biologicals, blood products, preservation solutions, fermentation broths, and cell culture fluids with and without cells, mixtures of the above and their fragments.
An aspect of the present disclosure relates to a portable air blast system for freezing and thawing biological solution inside a container comprising a vent enclosure with walls;
In an embodiment, the portable air blast system further comprising a controller for controlling the vertical airflow velocity.
In an embodiment, the portable air blast system further comprising a fan enclosure.
In an embodiment, the portable air blast system comprises
In an embodiment, the stand of the portable air blast system further comprises a solid base and pins for connecting the stand to the vent enclosure.
In an embodiment, the stand of the portable air blast system is configured so that the position of the container is maintained in the center of the vent enclosure.
In an embodiment, the distance between the stand and the vent enclosure ranges from 2 cm to 5 cm.
In an embodiment, the distance between the walls of the vent enclosure and the side walls of the container ranges from 1 cm to 3 cm and is approximately constant to ensure a similar vertical airflow velocity around all side walls of the container.
In an embodiment, the vertical airflow velocity ranges from approximately 0.5 m/s to approximately 20 m/s, preferably approximately 1 m/s to approximately 10 m/s, and more preferably approximately 2 m/s to approximately 8 m/s.
In an embodiment, the portable air blast system is made of a rigid material, preferably plastic, more preferably polymer.
In an embodiment, the fan is positioned within the fan enclosure.
In an embodiment, the fan is an axial fan.
An aspect of the present disclosure relates to a method of freezing and thawing biological solution inside a container by using the portable air blast system as disclosed, comprising:
In an embodiment, the method of freezing and thawing biological solution inside a container further comprising placing more than one air blast system into a chamber.
In an embodiment, in the method of freezing and thawing biological solution inside a container, the position of the container is maintained in the center of the vent enclosure.
In an embodiment, in the method of freezing and thawing biological solution inside a container, each air blast system is placed at a distance from each other to ensure that the air outside the air blast system vent has a velocity ranging from 0.05 m/s to 1 m/s, preferably from 0.1 m/s to 0.5 m/s.
These and other objects, features and advantages of the disclosure will be evident from the following detailed description when read in conjunction with the accompanying drawings.
For an easier understanding of the disclosure the attached drawings are joined, which represent preferred embodiments of the disclosure that, however, are not meant to limit the object of the present application.
As described above, the process of freezing and-thawing of biological materials poses several challenges; the lack of homogeneity associated with the freezing and thawing phenomena is one of the main problems. Many variables contribute to freezing inconsistency, the major issue relates to the different freezing rates experienced by multiple containers within a single batch of product. Currently, the freezing process involves placing the bottles and/or carboys comprising the biological materials in a conventional upright or chest freezers, or blast freezers and then allowing the product to freeze. The freezing rate and product quality is dependent on the freezer capacity, freezer load configuration, space between containers, container size, container shape, and airflow properties inside the freezer. When using blast freezers, although the freezing time is faster than using a static freezer (
Another problem relates to the existence of different freezing and thawing equipment used in several sites of the same biopharmaceutical company. As such, it is desirable to have a portable system, simple for use in different locations, in order to achieve homogeneous and reproducible freezing and thawing of biological materials and can be used in conjunction with existing equipment. Moreover, having a portable system enables the shipping of the air blast system together with any product thus allowing accurate thawing in another location which may have lesser technical capabilities. This ensures the quality of the product and reproducibility of the process throughout the supply chain even when using different equipment.
The present disclosure describes a system and method that enables improvement in the uniformity of the heat transfer coefficient of the external surface of containers filled with biological materials during the freezing and thawing process, while preventing damage or rupture of the containers. The portable system disclosed allows any chamber to be used for freezing or thawing, and also significantly decreases the time required to freeze or thaw a biological material in a container.
In an embodiment, the system is configured to receive a container filled with biological materials for freezing and thawing. The system includes a portable air blast system 10 configured to receive a container 50 filled with biological materials. Said portable air blast system 10 is configured to be placed in a cooling or heating chamber, for homogeneous and reproducible freezing and thawing of biological materials, respectively. The main purpose of said portable air blast system is to improve the uniformity of the heat transfer coefficient in the walls of the container, achieving similar freezing/thawing rates even using different cooling or heating chambers. (See
In an embodiment, the portable air blast system 10 comprises a stand 20, a vent enclosure 30 and a fan enclosure 40. (See
In an embodiment, the stand 20 is designed to receive a container 50 and to maintain the container's position in the center of the vent enclosure 30, in order to achieve a uniform distribution of air on all the side walls of the container. The stand 20 may have several supports 202 to receive the container 50, designed accordingly to the container to be used with. Said stand 20 may have a solid base 201 and pins 203 to connect the stand 20 to the vent enclosure 30 and to maintain a distance between the stand 20 and the vent enclosure 30. The distance between the stand 20 and the vent enclosure 30 ranges from 1 cm to 10 cm, preferably ranging from 2 cm to 5 cm, this is to ensure that air is distributed into the vent 302. When the portable air blast system 10 is placed inside an air blast chamber with lateral ventilation, the stand 20 may have an opening below, to ensure that air is uniformly distributed in the vent 302. In another embodiment, the container 50 can be maintained in the center of the vent enclosure 30 by a support claw connected to the vent enclosure 30. (See
In an embodiment, the portable air blast system 10 comprises a vent enclosure 30 designed to create a vent 302, in order to obtain a vertical velocity field that is substantially identical around all side walls 503 of the container. To ensure similar vertical velocity field around all side walls 503 of the container, the distance between the walls of the vent enclosure 301 and the side walls 503 of the container is substantially constant and comprised between 1 cm and 10 cm, preferably between 1 cm and 3 cm. The vent enclosure 30 may decouple the vertical airflow that passes inside the vent 302 of the downward flow that passes outside. The air velocity inside the vent 302 should preferably be higher than the double of the outside air downward velocity. In a preferred embodiment, the air within the vent 302 has a velocity ranging from approximately 0.5 m/s to approximately 20 m/s, preferably ranging from approximately 1 m/s to approximately 10 m/s, and more preferably from approximately 2 m/s to approximately 8 m/s. (See
In an embodiment, the portable air blast system 10 comprises a fan enclosure 40 with a fan 402 to force air in the chamber or room to pass through the vent 302 in order to improve the uniformity of the heat transfer coefficient on the container's walls during the freezing and thawing process. In a preferred embodiment, the fan 402 is located at the top of the vent enclosure 30, above the container, by using an insulating support 401. In an embodiment, a fan or a blower is used, preferably a fan 402 is used, more preferably an axial fan is used. In another embodiment, batteries could be used to power on the fan, and can be packed inside the insulating support 401. In another embodiment, the velocity of the fan 402 may also be controlled to conveniently increase or decrease the heat transfer for different stages of the process, for sensitive biological materials or for scale-down purposes. In an embodiment, said fan 402 is suitable for use in a cryogenic environment. In another embodiment, more than one fan 402 can be used to force the air to pass through the vent 302, for example 2 or 4 fans juxtaposed horizontally or vertically, or one at the top and another at the bottom of the vent enclosure. (See
In an embodiment, a temperature probe is located at one or more points within the portable air blast system and inside the container. The temperature probe provides an indication of the temperature of the airflow at a particular location inside the portable air blast system and indicates the time-temperature profile of the freezing/thawing of the biological material inside the container. Temperature probe may comprise a thermocouple, a thermistor, or other conventional temperature sensing devices suitable for use in a cryogenic environment.
In another embodiment, an air velocity probe is located at one or more points of the portable air blast system, to provide information about the airflow velocity inside the portable air blast system at a particular location. Air velocity probe comprises an anemometer, pitot tube, or other conventional sensing devices suitable for use in a cryogenic environment.
In an embodiment, the container 50 configured to be filled with biological materials can be in several shapes and structural characteristics, such as bottles or carboys. Preferably, said container 50 should maintain its shape when empty and do not significantly deform when filled with product. Said container 50 can be made of a rigid and biocompatible material to promote compatibility with biological materials. The materials can be, for instance, glass, polyethylene terephthalates, polycarbonate, polytetrafluoroethylene, polyethylene, polyesters, polyamides, polypropylenes, ethylene-vinyl alcohol copolymer, polyvinylidenefluoride, polyvinylchlorides, copolymers, and mixtures or laminates that comprise the abovementioned. Said container 50 may vary in size and volumetric capacity. In a preferred embodiment, the container 50 has a volumetric capacity ranging from approximately 1 mL to approximately 20 L, preferably ranging from approximately 100 mL to approximately 10 L. Said container 50 configured to be filled with biological materials may comprise a head-space region, and one cap with at least one port with tubing for aseptic filling and venting purposes.
In an embodiment, the container 50 may also comprise an ice crust attenuator device 60 configured for attachment to the head-space of the container. The main purpose of the ice crust attenuator 60 device is to prevent the formation of the ice crust that leads to increased pressure inside the containers, and consequently resulting in their damage.
In another embodiment, the container may also comprise a scale-down device that mimic large-scale containers for development studies and optimization of the freezing-thawing process. In this embodiment using the scale-down device, the air velocity in the vent may be conveniently adjusted to control the average heat transfer coefficient, for example to match that of the large-scale container.
In another embodiment, deformable containers 70 may also be frozen or thawed with the portable air blast system 10, in this case by placing the deformable container 70 inside a rigid shell 701. The rigid shell is preferably made of a material with low heat resistance such as a metal (for instance, stainless steel, aluminum or copper). Said deformable container 70, such as bags, may deform when filled with product, and can be made of a biocompatible polymeric material to promote compatibility with biological materials. The biocompatible polymeric materials may be, for instance, ethylene-vinyl acetate copolymer, ethylene-vinyl alcohol copolymer, polytetrafluoroethylene, polyethylene, polyesters, polyamides, polypropylenes, polyvinylidenefluoride, polyurethanes, polyvinylchlorides, and copolymers, mixtures or laminates that comprise the above. The deformable container 70, may vary in size and volumetric capacity. In a preferred embodiment, the deformable container 70 has a volumetric capacity ranging from approximately 10 mL to approximately 20 L, preferably ranging from approximately 10 mL to approximately 1 L. (See
In the present disclosure, biological materials may comprise protein, amino acid and peptide formulations, DNA, RNA and nucleic acid solutions, cell suspensions, tissue suspensions, cell aggregates suspensions, cell growth media, serum, biologicals, blood products, preservation solutions, fermentation broths, and cell culture fluids with and without cells, mixtures of the above and their fragments.
The portable air blast system 10, depicted in
Further examples are discussed in detail below with regard to the use of the disclosed portable air blast system to freeze an aqueous solution in a container.
In an embodiment, for example, the portable air blast system 10 was used to freeze a volume of 1.8 L of a 5% (m/V) sucrose aqueous solution in a Polyethylene terephthalate (PET) bottle of 240 (h)×120 (w)×120 (d) mm of dimensions. The test was performed with an ice crust attenuator device 60 as described above. In one experiment, the bottle was placed directly inside an ultra-low freezing chamber with the temperature setpoint at −80° C. and the bottle was allowed to freeze. In another experiment, the bottle was frozen inside the portable air blast system and placed in an ultra-low freezing chamber with the temperature setpoint of −80° C.
In another embodiment, a plurality of portable air blast systems 10 could be combined in a single chamber 80. (See
In another embodiment, the portable air blast system 10 is be made of modular segments attachable to each other. The portable air blast system 10 comprises the possibility of interchangeable modules for different functions, to receive different containers and devices. The modular assembly of the portable air blast system 10 opens up the possibility of transforming and adapting the system to different scenarios. Different modules can be added or changed to increase the dimensions of the system, to conveniently adapt to different containers, to change the air flow profile and to receive different devices such as probes, batteries, electronics, etc. The modular assembly also allows for ease of transportation, manufacturing, parts replacement and in place assembly. (See
In another embodiment, the system also includes a trolley to allow quick loading of the chamber with a portable air blast system, or a plurality of portable air blast systems.
In another embodiment, the container is agitated during thawing to mix the biological solution. This can be achieved by using a platform configured to receive the portable air blast system, that can provide rotation, rocking, shaking, vibrations or other forms of mechanical motion to induce the convection of the liquid inside the container.
Another aspect of this disclosure relates to a method to improve the uniformity of the heat transfer coefficient of containers filled with biological materials during the freezing and thawing process, using the previously described system, comprising the steps of: (1) providing a cooling or heating chamber; (2) providing at least one portable air blast system; (3) placing the container in the center of the portable air blast system; (4) placing the portable air blast system inside the cooling or heating chamber; and (5) turning on the fan until the biological material completely freezes or thaws.
The term “comprising” whenever used in this document is intended to indicate the presence of stated features, integers, steps, components, but not to preclude the presence or addition of one or more other features, integers, steps, components or groups thereof.
It will be appreciated by those of ordinary skill in the art that unless otherwise indicated herein, the particular sequence of steps described is illustrative only and can be varied without departing from the disclosure. Thus, unless otherwise stated the steps described are so unordered meaning that, when possible, the steps can be performed in any convenient or desirable order.
The disclosure should not be seen in any way restricted to the embodiments described and a person with ordinary skill in the art will foresee many possibilities to modifications thereof.
The above described embodiments are combinable. The following claims further set out particular embodiments of the disclosure.
| Number | Date | Country | Kind |
|---|---|---|---|
| 115345 | Feb 2019 | PT | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/IB2020/051479 | 2/21/2020 | WO | 00 |
