Containment System for Mixing Dry Powders with Solvents During Drug Production or Processing
20220250013 ยท 2022-08-11
Assignee
Inventors
- John H. Roosa (Hillsborough, NJ, US)
- Alan S. D'Alessandro (Forked River, NJ, US)
- Robert O'Connor (Aberdeen, NJ, US)
- Luke Schenck (Yardley, PA)
- Timothy Stanoch (Lansdale, PA, US)
Cpc classification
B08B15/026
PERFORMING OPERATIONS; TRANSPORTING
B01F35/7547
PERFORMING OPERATIONS; TRANSPORTING
B01F35/71805
PERFORMING OPERATIONS; TRANSPORTING
B08B15/023
PERFORMING OPERATIONS; TRANSPORTING
B01F35/184
PERFORMING OPERATIONS; TRANSPORTING
International classification
Abstract
A solids charging containment apparatus and method for mixing a solvent with a dry powder, comprising a dual compartment isolator for safely removing the dry powder from a dry powder container, a mixing vessel, and a negative cascading pressure controller. The dual compartment isolator comprises a staging compartment, a charging compartment and a raw material entry port, which is connected to the staging compartment and configured to isolate the dry powder container from the surrounding atmosphere. The mixing vessel includes a mixing chamber and a solids charging port fluidly connecting the mixing chamber to a containment valve in the charging compartment of the dual compartment isolator. The negative cascading pressure controller generates negative pressure in both the staging compartment and the charging compartment. The containment apparatus and method may be used to produce a slurry or solution mixture of solvent and dry powder during drug processing.
Claims
1. A containment system for mixing a solvent with a dry powder without exposing the dry powder to a surrounding atmosphere, wherein the dry powder is supplied to the containment system in a dry powder container having a sealed connection, the containment system comprising: (a) a dual compartment isolator for safely removing the dry powder from the dry powder container, the dual compartment isolator including a staging compartment, a charging compartment, a raw material entry port, connected to the staging compartment, the raw material entry port being configured to isolate the dry powder container from the surrounding atmosphere while transferring the dry powder container into the staging compartment, a partition separating the staging compartment from the charging compartment, a resealable opening in the partition that permits the dry powder container to be transferred out of the staging compartment and into the charging compartment without exposing the dry powder to the surrounding atmosphere, a containment valve, located inside the charging compartment, the containment valve having a fitting suitably configured to mate with the sealed connection on the dry powder container, and a negative cascading pressure controller for generating negative pressure in both the staging compartment and the charging compartment; and (b) a mixing vessel for mixing the dry powder with the solvent, the mixing vessel including a mixing chamber, a solids charging port fluidly connecting the mixing chamber to the containment valve in the charging compartment of the dual compartment isolator to permit the dry powder to pass out of the dry powder container through the containment valve and into the mixing chamber without exposing the dry powder to the surrounding atmosphere, a solvent inlet for admitting the solvent into the mixing chamber; and an agitator for mixing the solvent and the dry powder together in the mixing chamber to produce a solvent and dry powder mixture, and an outlet valve for discharging the solvent and dry powder mixture from the mixing chamber.
2. The containment system of claim 1, further comprising a discharge device for facilitating discharge of the dry powder mixture from the mixing chamber via the outlet valve.
3. The containment system of claim 2, wherein the discharge device comprises a pump, a positive pressure source, or a negative pressure source.
4. The containment system of claim 1, wherein the containment valve in the charging compartment comprises a split butterfly valve.
5-6. (canceled)
7. The containment system of claim 1, further comprising a second solvent inlet on the mixing vessel configured to admit a second solvent into the mixing chamber.
8. The containment system of claim 7, wherein the second solvent is an anti-solvent.
9-12. (canceled)
13. A containment system for mixing a solvent with a dry powder without exposing the dry powder to surrounding atmosphere, wherein the dry powder is supplied to the containment system in a dry powder container having a sealed connection, the containment system comprising: a) a dual compartment flexible isolator for safely removing the dry powder from the dry powder container, the dual compartment flexible isolator including a top portion and a bottom portion, the top portion and the bottom portion being linked together by one or more side walls, forming an interior portion, the interior portion comprising an internal wall that is sealingly connected to the side walls and that separates the interior portion into a first compartment and a second compartment; at least one glove formed in at least one of the side walls, said at least one glove extending into the interior portion of the dual compartment flexible isolator; and a first sealable opening formed in one of the side walls for permitting a dry powder material container to be placed inside the first compartment; a second sealable opening formed in the internal wall for permitting the dry powder container to be moved from the first compartment into the second compartment without exposing the dry powder to surrounding atmosphere; a containment valve, located inside the second compartment, the containment valve having a fitting suitably configured to mate with the sealed connection on the dry powder container, and a negative cascading pressure controller for generating negative pressure within the first compartment and second compartment; and b) a mixing vessel for mixing the dry powder with the solvent, the mixing vessel including a mixing chamber; a solids charging port, fluidly connecting the mixing chamber to the containment valve in the second compartment of the dual compartment flexible isolator to permit the dry powder to pass out of the dry powder container through the containment valve and into the mixing chamber without exposing the dry powder to surrounding atmosphere, a solvent inlet for admitting the solvent into the mixing chamber; an agitator for mixing the solvent and the dry powder together in the mixing chamber to produce a solvent and dry powder mixture; and an outlet valve for discharging the solvent and dry powder mixture from the mixing chamber.
14. The containment system according to claim 13, wherein the containment valve in the second compartment comprises a split butterfly valve.
15. The containment system according to claim 13, wherein the dual compartment flexible isolator comprises four side walls.
16. (canceled)
17. The containment system according to claim 13, wherein the negative cascading pressure controller provides a first negative pressure differential between the outside of the dual compartment flexible isolator and the first compartment of about 0.01 to about 0.5 inches of water (first negative pressure differential as referenced from the outside of the dual compartment flexible isolator), and a second negative pressure differential between the first compartment and the second compartment of about 0.01 to about 0.5 inches of water (second negative pressure differential referenced from the inside of the first compartment of the dual compartment flexible isolator).
18-19. (canceled)
20. The containment system according to claim 13, further comprising an additional port for connecting the dual compartment flexible isolator to another device.
21. The containment system according to claim 20, wherein said additional port may be selectively connected to (i) a vacuum source, and (ii) a source of inert gas, whereby air within said dual compartment flexible isolator may be replaced by inert gas.
22-25. (canceled)
26. A dual compartment flexible isolator comprising: a top portion and a bottom portion, the top portion and the bottom portion being linked together by one or more side walls, forming an interior portion, the interior portion, comprising an internal wall that is sealingly connected to the side walls and that separates the interior portion into a first compartment and a second compartment; at least one glove formed in at least one of the side walls, said at least one glove extending into the interior portion of the dual compartment flexible isolator; and a first sealable opening formed in one of the side walls for permitting a dry powder material container to be placed inside the first compartment; a second sealable opening formed in the internal wall for permitting the dry powder material container to be moved from the first compartment into the second compartment without exposing dry powder material in said dry powder material container to surrounding atmosphere; a containment valve, located inside the second compartment, the containment valve having a fitting suitably configured to mate with a sealed connection on the dry powder material container; and a negative cascading pressure controller for generating negative pressure within the first compartment and second compartment.
27. The dual compartment flexible isolator according to claim 26, wherein the containment valve in the second compartment comprises a split butterfly valve.
28. The dual compartment flexible isolator according to claim 26, further comprising a port for connecting the dual compartment flexible isolator to another device.
29-30. (canceled)
31. A containment system for mixing a solvent with a dry powder without exposing the dry powder to a surrounding atmosphere, comprising: a) a primary containment subsystem comprising a containment valve with a fitting configured to accept a sealed connection on a dry powder container, and a connection to solids charging port of a mixing vessel; and b) a secondary containment subsystem comprising the mixing vessel, a dual compartment flexible isolator, and a negative cascading pressure controller.
32. The containment system of claim 31, further comprising a tertiary containment subsystem comprising a negatively-pressurized room, or a down-flow booth, or a gas exhaust, or a solvent exhaust, or protective flooring, or a single-use protective curtain, or a combination of one or more thereof.
33. The containment system according to claim 31, wherein the dual compartment flexible isolator comprises: a staging compartment, a charging compartment, a raw material entry port, connected to the staging compartment, the raw material entry port being configured to isolate the dry powder container from the surrounding atmosphere while transferring the dry powder container into the staging compartment, a partition separating the staging compartment from the charging compartment, and a resealable opening in the partition that permits the dry powder container to be transferred out of the staging compartment and into the charging compartment without exposing the dry powder to the surrounding atmosphere.
34-35. (canceled)
36. A method of producing a slurry or solution from a dry powder and a solvent, comprising: providing a dual compartment isolator, the dual compartment isolator comprising a staging compartment, a raw material entry port connected to the staging compartment, a charging compartment, a containment valve located in the charging compartment, and a partition between the staging compartment and the charging compartment, connecting a negative cascading pressure controller to the dual compartment isolator; providing a mixing vessel comprising a solvent inlet, a mixing chamber and a solids charging port fluidly connected to the mixing chamber; receiving a dry powder container containing the dry powder, the dry powder container having a sealed connection; activating the negative cascading pressure controller to produce negative pressure in both the staging compartment and the charging compartment of the dual compartment isolator; admitting the dry powder container into the staging compartment via the raw material entry port; transferring the dry powder container from the staging compartment to the charging compartment by passing the dry powder container through a resealable opening in the partition; closing the resealable opening in the partition; connecting the sealed connection on the dry powder container to a fitting on one end of the containment valve in the charging compartment of the dual compartment isolator; connecting the solids charging port on the mixing vessel to an opposite end of the containment valve; opening the sealed connection on the dry powder container and the fitting on the containment valve to permit the dry powder to pass out of the dry powder container in the charging compartment of the dual compartment isolator, through the sealed connection and the fitting and the solids charging port, and into the mixing chamber of the mixing vessel; introducing the solvent into the mixing chamber of the mixing vessel via the solvent inlet; and agitating the dry powder and the solvent in the mixing chamber to produce the slurry or solution.
37-38. (canceled)
39. The method according to claim 36, wherein: the mixing vessel further comprises a second solvent inlet; and the method further comprises (i) introducing an anti-solvent into the mixing chamber of the mixing vessel via the second solvent inlet, and (ii) agitating the dry powder and the anti-solvent in the mixing chamber to produce the slurry.
40-42. (canceled)
43. The method according to claim 36, further comprising: (i) attaching a transfer device to the mixing vessel; and (ii) activating the transfer device to facilitate discharging the slurry or solution out of the mixing vessel.
44. The method of claim 43, wherein the transfer device comprises a pump, a positive pressure source, or a negative pressure source.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0059] By way of overview, exemplary embodiments of the present invention provide a system, apparatus and method that permits good manufacturing practice (GMP) levels of containment of raw material, such as a pharmaceutical substance or product, while the raw material is mixed with a solvent to produce a slurry or solution. Advantageously, embodiments of the present invention are usable in small, compact spaces (relative to the space required for conventional clean rooms used in sterile pharmaceutical manufacturing), flexible, easy to use and readily disposable after use.
[0060]
[0061] The containment system 100 also includes a containment valve 135, located inside the charging compartment 115. The containment valve 135 has a fitting (not shown in
[0062] The containment system 100 also includes a mixing vessel 140 for mixing the dry powder with a solvent 150 from a solvent vessel 155. The mixing vessel 140 includes a mixing chamber 145, a solids charging port 160 fluidly connecting the mixing chamber 145 to the containment valve 135 in the charging compartment 115 of the dual compartment isolator 105 to permit the dry powder 124 to pass out of the dry powder container 125 through the containment valve 135 and into the mixing chamber 145 without exposing the dry powder 124 to the surrounding atmosphere 190.
[0063] The mixing vessel 140 also includes a solvent inlet 165 for admitting the solvent 150 into the mixing chamber 145. Preferably, an agitator (not shown in
[0064] The lid of the mixing vessel 140 preferably has the following ports: a solvent inlet 165 comprising a dip tube, a nitrogen supply, a sample port via dip tube, an outlet dip tube, a butterfly valve for solids charging and a vent. Preferably, the sample port and associated dip tube is routed to the charging compartment 115 of the dual compartment isolator 105, and facilitates contained sampling in a Grade C environment. The butterfly valve may be any suitable size. But the valve is preferably from 2-6 inches in diameter.
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[0068] At Step 415, a dry powder container 125 containing the dry powder 124 is received. The dry powder container has a sealed connection. Then, at Step 420, a negative cascading pressure controller 185 is activated to produce negative pressure in both the staging compartment 110 and the charging compartment 115 of the dual compartment isolator 105. At Step 425, the dry powder container is admitted to into the staging compartment via the raw material entry port 130. A user may pass raw material (for e.g., a drug substance or a drug product) and processing equipment of choice (for example funnels, scoops, etc.) into the staging compartment 110 through the raw material entry port 130. The raw material entry port 130 may be a poly sleeve. The raw material entry port 130 is then tied off, thereby providing a seal to the compartment from the outside environment.
[0069] Step 430 transfers the dry powder container 125 from the staging compartment 110 to the charging compartment 115 by passing the dry powder container 125 through a resealable opening in the partition 122. The resealable opening 122 in the partition 120 is then closed at step 435. At Step 440, the sealed connection on the dry powder container 125 is connected to a fitting on one end of the containment valve 135 in the charging compartment 115 of the dual compartment isolator 105. Then, at Step 445, the solids charging port 160 on the mixing vessel 140 is connected to an opposite end of the containment valve 135.
[0070] Step 450 includes opening a) the sealed connection on the dry powder container 125, b) the fitting on the containment valve 135 and the solids charging port 160 on the mixing vessel 140 so that the dry powder 124 will pass out of the dry powder container 125 in the charging compartment 115 of the dual compartment isolator 105, through the sealed connection, the fitting and the solids charging port 160, and into the mixing chamber 145 of the mixing vessel 140. The mixing vessel 140, for example a 30 L mixing vessel, may be jacketed and heated or cooled using, for example, an associated Huber unit to control the jacket temperature.
[0071] At Step 455, the solvent 150 is then introduced into the mixing chamber 145 of the mixing vessel 140, via the solvent inlet 165. Solvent 150 is charged from a nitrogen inerted vessel or tank 155, preferably made of stainless steel, through an in-line filter into the mixing vessel 140, for example, the 30 L vessel. Finally, at Step 460, the dry powder 124 and the solvent 150 are agitated in the mixing chamber 145 to produce the slurry or solution 175.
[0072] Optionally, the mixture of solvent and desired material is further processed by subjecting the mixture to wet milling to reduce drug particle size and improve drug solubility. Any type of milling and milling device that is suitable for producing nanoparticles may be employed in conjunction with the present invention. Exemplary types of milling operations may include, without limitation, wet milling, media milling, cryogenic milling and high-pressure homogenization.
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[0079] The precipitation vessel 1120 includes a first inlet valve 1130 for receiving the milled mixture, slurry or solution from the wet milling device 1110 and a second inlet valve 1170 for receiving an antisolvent from an antisolvent vessel 1160, thereby facilitating mixing of the antisolvent and the milled mixture, slurry or solution. The precipitation vessel 1120 also includes a recirculation line valve 1140 for discharging the nanoparticle precipitate mixture, slurry or solution into the wet milling device 1110, with the assistance of a peristaltic pump 1150 that is used to control the flow rate. The precipitation vessel 1120 also includes an outlet valve for discharging the nanoparticle precipitate mixture, slurry or solution into another device. A second peristaltic pump 1190 is used to prime the wet milling device 1110 through the precipitation vessel outlet valve 1180 and to maintain the flow rate.
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[0083] While the invention has been described in detail with reference to specific examples, it will be apparent to one skilled in the art that various modifications can be made within the scope of this invention. Thus, the scope of the invention should not be limited by the examples described herein, but by the claims presented below.