Table of Contents
- Introduction
- Single-use technologies: cost- and planet-friendly biomanufacturing solutions
- Open-architecture single-use system use and design
- Conclusion
- References
Introduction
With increased climate instability and growing concerns, it might seem like there is nothing you, as a business, can do to change the course in which the planet is going. But luckily that is not the case! Implementing sustainability practices in the industry has been one of the top priorities as of late. Resource management has become an important topic amongst employees, investors and regulatory institutions. One area which is within your business control is the environmental impact of biomanufacturing. This is one of the first steps, where you can strive to reduce your footprint and implement more sustainable practices that will benefit you and the environment!
By shifting your process away from stainless steel and towards single-use solutions you will implement more flexibility in your process, by reducing variability, all while increasing both efficiency and quality!
In this guide, we will first take you over the benefits of introducing single-use solutions into your process in case you are not convinced yet. Following that, we compiled some examples of single-use solutions we offer at Pharsol. We are more than happy to adapt them for your process.
Single-use technologies: cost- and planet-friendly biomanufacturing solutions
Even though there is a common misbelief that single-use technologies are harmful to the environment due to the waste produced, that myth has been busted by several studies and exemplary results of implemented single-use technologies.
Keep reading for the main benefits of single-use setups:
- Minimum energy demand and limited use of water, since the consumption of resources, such as water and energy, is lower, by minimizing cleaning.
- Minimized risk of cross-contamination, as the whole production part is replaced with new parts.
- Reduced complexity of automation and manufacturing costs by eliminating the need for Cleaning-In-Place (CIP) and Sterilization-In-Place (SIP) systems.
- Saving time by reducing the time needed to set up new production lines and validation. Single-use systems are designed to be set up, used, packed and disposed of quickly, making it possible to produce different products in the same production plant.
- Ease of disposal after the end of process run. Throwing it out after you are done using it reduces the chance of cross-contamination and enables you to spend less money on cleaning the equipment afterwards.
- Reduced overall costs of running the process, as well as smaller investment costs. Practicality of quickly setting up a processing line and disposing of it afterwards reduces costs everywhere. The most obvious reduction can be noted in the cleaning and sterilization processes. Consequently, this enables a smaller initial investment into early R&D efforts, making the whole production process a lot cheaper.
The collected data highlights the lower environmental impact of single-use technologies, compared to traditional stainless steel setups. Once the single-use components reach their end-of-life the disposal has minimal environmental impact, compared to energy and water use needed for CIP/SIP. Additionally, it needs to be noted that geographical region of where the single-use equipment is used, the proximity of disposal processing facilities, and that the cleanliness of the electrical grid heavily impacts the overall environmental footprint. However, when analysing the freshwater consumption, single-use is always better than traditional biomanufacturing even when location, electrical grid, or transport logistics are taken into account.
Open-architecture single-use system use and design
Running the bioprocess requires not only bioreactors and control units, but also hoses, connectors, clamps and other accessories. Cost-effective single-use components that connect fluid management systems are the way to achieve the highest degree of flexibility. This is done by implementing the plug-and-play concept in your assemblies, meaning that connecting a component is as simple as disconnecting and disposing of it.
In our catalogue, you will find all of the products that you will need in the laboratory, either components or pre-assembled plug-and-play kits, easily integrated into your existing setup.
We are specialised in production of custom assemblies for bioprocesses. All our assemblies consist of connectors that can be found in our catalogue (sterile connectors, tube-to-tube connectors, check valves, luers, etc.).
Our assemblies can be used for the following processes:
- Buffer and media transfer (feeds, addition of base/ acid, antifoam, growth medium and other liquids),
- Collecting samples with zero risk of contamination,
- Media filtration,
- Inoculation,
- Removal of liquids from bioprocess,
- Carboy Assemblies,
- Peristaltic Pump Tube assemblies.
We understand that time is important to our clients. For this reason, we fully adapt to your requirements. The process of our work begins with the application you need to address, and it consists of four steps: Concept - Design - Prototype - Your product.
First your needs and ideas are evaluated, which allows us to together determine the product concept. By making a prototype it is determined if the product concept is feasible. This part of the process allows you to be creative and modify your design without financial challenges. By following all four steps of the product design process we make sure your needs and visions are met with the highest quality.
With our assemblies, you can now easily connect multiple containers, vessels and process lines in one controllable system. On the following pages, you will find some examples of our solutions. We are more than happy to adapt them for your process.
Sampling kit
Simple, safe and efficient – these are the main benefits of using a sampling kit. The sampling kit is designed to streamline the collection and transfer of samples, by reducing the number of steps. This set is made of:
- silicon hose (1/4”)
- clamp
- luer, male and female
The length and size of hoses and connectors can be changed.
Medium / Inoculum kit for bag
The system is made for any type of single-use bioreactor. It can be plugged into a Liquid Addition Manifold. This set is made of:
- silicon hose (1/4”)
- clamp
- RQC connector
- sterile connector (unisex)
The kit is connected to the single-use bag on one side, and to the medium/inoculum kit for bioreactor on the other. The length and size of hoses and connectors can be changed.
Medium / Inoculum kit for bioreactor
The system is made for any type of single-use bioreactor. It can be plugged into Liquid Addition Manifold. This set is made of:
- silicon hose (1/4”)
- clamp
- RQC connector
- sterile connector (unisex)
The kit is connected to the bioreactor on one side and to the medium/inoculum kit for the bag on the other.
The length and size of hoses and connectors can be changed.
Base / Acid addition kit
The system is made for any type of single-use bioreactor. This set is made of:
- silicon hose (1/4”)
- clamp
- luer
- sterile filter 0.45 μm + 0.2 μm
The kit is connected to the bioreactor on one side, and to the bottle of liquid on the other. The liquid is then added through a peristaltic pump into the bioreactor.
The length and size of hoses and connectors can be changed.
Liquid addition manifold
The system is made for any type of single-use bioreactor. This set is made of:
- silicon hose (1/4”)
- clamps
- Y connectors
- aseptic sterile connectors (unisex)
The manifold can be customized on demand.
Liquid addition kit 1
The system is made for any type of single-use bioreactor. This set is made of:
- silicon hose (1/4”)
- clamp
- luer
- RQC connector
The kit is meant to be connected to the bioreactor on one side, and to the syringe on the other.
The length and size of hoses and connectors can be changed.
Liquid addition kit 2
The system is made for any type of single-use bioreactor. It can be plugged to Liquid Addition Manifold. This set is made of:
- silicon hose (1/4”)
- clamp
- T connector
- luer
- RQC connector
- sterile connector (unisex)
The kit is meant to be connected to the Liquid addition manifold on one side and to the syringe and single-use bag on the other.
Conclusion
Single-use solutions offer an advantage in flexibility and productivity to bioprocess developers and manufacturers, by lowering the consumption of water and energy, boosting productivity, minimizing the risk of cross-contamination, saving time, reducing costs, and facilitating disposal.
Adapt an easy plug-and-play setup with standard disposable connectors for your bioprocess and jump on the fast lane to sustainability. Our fully customized systems and high-quality services offer the flexibility to maximize efficiencies, minimize costs and alleviate risks in the production of biopharmaceutical processes.
References
- Plastic not fantastic but single-use is still greener, says industry (https://www.biopharma-reporter.com/Article/2013/10/04/Plastic-not-fantastic-but-single-use-is-still-greener-says-industry)
- https://www.cytivalifesciences.com/en/us/solutions/bioprocessing/knowledge-center/single-use-and-sustainability
- SINGLE-USE MARKET – Rise of Single-Use Technologies & Systems in Biopharmaceuticals (https://drug-dev.com/single-use-market-rise-of-single-use-technologies-systems-in-biopharmaceuticals/)
- Life Cycle Assessment: Biopharma SUTs - BioProcess InternationalBioProcess International (bioprocessintl.com)
- New Plastics Economy: Rethink Biopharma SUS - BioProcess InternationalBioProcess International (bioprocessintl.com)
