RETENTION SYSTEM

Abstract

A Disposable Bioprocess System having a Single-Use-Bioreactor, a Single-Use-Pump and a single-use micro-organism retention filter. Combined most suitable for cultivation of suspended micro-organisms in a liquid media at high micro-organism concentration in a perfusion mode continuous process for expression of biological material. The inlet port of the liquid Single-Use-Pump connects via a valve to the broth reservoir of the Single-Use-Bioreactor through a liquid conveying port. The outlet port of the liquid pumping Single-Use-Pump connects via a valve to a micro-organism retention filter. And a method for operating the sterile Disposable Bioprocess System in perfusion mode for continuously processing.

Claims

1. A bioprocess Liquid System conveying a liquid comprising a biological material wherein the bioprocess Liquid System is adapted for connection and liquid communication with a liquid tight container, said bioprocess Liquid System comprising: a) at least one first housing adapted for conveying the liquid, wherein said at least one first housing has at least one rigid wall surrounding at least one chamber comprising a pumping element adapted for conveying said liquid, wherein the functionality of said pumping element is controlled by a Programable-Logic-Control (PLC) adapted for real time control of the pumping element for conveying the liquid, b) at least one second housing comprising at least one permeable membrane filter said second housing having a non-filtered inlet side and a filtered exit side, wherein the at least one first housing is in liquid communication with the at least one second housing, the at least one second housing having at least one first housing port being a non-filtered liquid entrance port, the at least one second housing having at least one second housing port being a concentrated non-filtered liquid retentate exit port, the at least one second housing having at least one third housing port being a liquid permeate exit port.

2. The bioprocess Liquid System of claim 1, comprising the liquid tight container having a wall surrounding an interior, wherein the interior is adapted to contain a liquid comprising a biological material, said liquid tight container comprises: at least one first port, located in the surrounding rigid wall said port adapted for exchange of the liquid with said at least one first housing, at least one second port, located in the surrounding wall said port adapted for exchange of the liquid with said at least one second housing comprising at least one permeable membrane filter.

3. The bioprocess Liquid System of claim 1, comprising the liquid tight container having a wall surrounding an interior, wherein the interior is adapted to contain a liquid comprising a biological material, said liquid tight container comprises: at least one first port, located in the surrounding rigid wall said port adapted for exchange of the liquid with said at least one second housing membrane filter first port, wherein at least one second port in said at least one second housing membrane filter is adapted for communicating with one first housing adapted for conveying the liquid.

4. The bioprocess Liquid System of claim 1, wherein said at least one first housing is a diaphragm pump comprising: the liquid chamber for conveying said liquid, comprising a dome part with a connection flange surrounding the liquid chamber, wherein the wall of the dome part comprises the at least one liquid port, the drive fluid chamber for exchange of a drive fluid, comprising a housing part with a connection flange surrounding the drive fluid chamber, wherein the wall of the housing part comprises the at least one drive fluid port, and the elastic non-permeable membrane as the pumping element located between the connection flanges of the liquid chamber and the drive fluid chamber separating a first interior volume of the liquid chamber from a second interior volume of the drive fluid chamber, wherein the elastic non-permeable membrane is fixed fluid tight at its circumference between the connection flanges of the liquid chamber and the drive fluid chamber, wherein any position of said elastic non-permeable membrane is measured by a pressure sensor and said elastic non-permeable membrane position is controlled by the PLC in loop with said pressure sensor and a drive fluid valve located in said loop.

5. The bioprocess Liquid System of claim 1, wherein said at least one first housing is a diaphragm pump comprising: the liquid chamber for conveying said liquid, comprising a dome part with a connection flange surrounding the liquid chamber, wherein the wall of the dome part comprises the at least one liquid port, the drive fluid chamber for exchange of a drive fluid, comprising a housing part with a connection flange surrounding the drive fluid chamber, wherein the wall of the housing part comprises the at least one drive fluid port, and the elastic non-permeable membrane as the pumping element located between the connection flanges of the liquid chamber and the drive fluid chamber separating a first interior volume of the liquid chamber from a second interior volume of the drive fluid chamber, wherein the elastic non-permeable membrane is fixed fluid tight at its circumference between the connection flanges of the liquid chamber and the drive fluid chamber, wherein any position of said elastic non-permeable membrane is measured in real time by a position sensor and said elastic non-permeable membrane position is controlled by the PLC in loop with said position sensor and a drive fluid proportional valve located in said loop.

6. The bioprocess Liquid System of claim 1, wherein said at least one first housing is a double reciprocating pump system comprising: a first reciprocating pump comprising a first static housing, wherein the pumping element is a first reciprocating piston located inside the first static housing, wherein the position of the first reciprocating piston is controlled proportionally by the PLC, and a second reciprocating pump comprising a second static housing, wherein the pumping element is a second reciprocating piston located inside the second static housing, wherein the position of the second reciprocating piston is controlled proportionally by the PLC, and a valve body adapted for controlling the liquid communication with the first and second housing and the permeable membrane filter, wherein the valve body function is controlled by the PLC, wherein the first and second reciprocating pumps operates in opposite directions.

7. The bioprocess Liquid System of claim 1, wherein said at least one first housing is a reciprocating piston pump comprising: a reciprocating piston housed inside a static housing, said piston connected to a linkage penetrating at least one static housing end wall fluid tight and said linkage connected to an externally arrange reciprocating driving force and a position sensing device, said reciprocating piston position measured by a position sensing device and said piston position proportionally adjusted by a PLC in a loop with said position sensor and a drive fluid valve for dynamic movements according to a program stored in said PLC memory, said reciprocating piston separates said housing in a first and a second chamber of dynamic variable volume and pressure corresponding said piston position in so that one chamber create pressure above and the neighboring chamber pressure below atmospheric pressure and vice versa according to piston position and speed, wherein each first and second chamber of said static housing comprises a first set of exit/entrance ports for drive fluid pressure and volume interactions, wherein each exit/entrance port is each coupled to a third and fourth pump housing adapted for conveying the liquid in communication with the permeable membrane filter.

8. The bioprocess Liquid System of claim 1, wherein said at least one first housing is a reciprocating piston pump comprising: a reciprocating piston housed inside a static housing, said piston connected to a linkage penetrating at least one static housing end wall fluid tight and said linkage connected to an externally arrange reciprocating driving force and a position sensing device, said reciprocating piston position measured by a position sensing device and said piston position proportionally adjusted by a PLC in a loop with the position sensor and a drive fluid valve for dynamic piston movements according to a program stored in said PLC memory, said reciprocating piston separates said housing in a first and a second chamber of dynamic variable volume and pressure corresponding said piston position in so that one chamber create pressure above and the neighboring chamber pressure below atmospheric pressure and vice versa according to piston position and speed, wherein each first and second chamber comprises a first set of exit/entrance ports for a drive fluid pressure and volume interactions and each exit/entrance port coupled to an externally arranged third and fourth passive pump chamber comprising a second set of exit/entrance ports said third and fourth passive pump chamber comprising fluid communication via said second set of exit/entrance ports with a permeable membrane filter device.

9. The bioprocess Liquid System of claim 1, wherein said at least one first housing is a centrifugal pump, wherein the pumping element is a rotating impeller inside said first housing wherein the position and/or rotation speed of said rotating impeller is controlled by the PLC.

10. The bioprocess Liquid System of claim 1, wherein said at least one first housing is a peristaltic pump, wherein the pumping element is a stationary elastic tube, said stationary elastic tube is on its outside in contact with at least two moving bodies and on the opposite side is in contact with a rigid and stationary wall wherein any position of the at least two moving bodies is controlled by the PLC.

11. The bioprocess Liquid System according to claim 2, wherein at least one port of the liquid tight container wall is equipped with connecting means adapted for liquid exchange with the at least one first and/or second housing.

12. The bioprocess Liquid System of claim 1 comprising a fluid regulating valve arranged in the liquid communication and controlled by the PLC.

13. The bioprocess Liquid System of claim 1, said bioprocess Liquid System comprising one or more rigid polymer material fluid tight containers and / or fluid tight flexible polymer foil container bags and one or more membrane filters assembled with said bioprocess Liquid System of claim 1.

14. The bioprocess Liquid System of claim 1, wherein said bioprocess Liquid System comprises: means of process liquid communication configured to extend from the interior of a liquid tight container to said at least one electronically controlled liquid pumping device, means of non-filtered liquid communication configured to extend from said at least one electronically controlled conveying liquid pumping device providing a non-filtered liquid communication to a first inlet port of at least one membrane filter device, further means for retentate liquid is configured to extend from said second outlet port of said membrane filter and conveyed back to the interior of said liquid tight container, said second outlet port providing a liquid exit port of said filter device through which retentate is to be returned to the process liquid of the interior of said liquid tight container, and said third permeate outlet port communicates between said filter device and said exterior facility area for conveying filtered process liquid that has passed through said permeable membrane of said filter device to said exterior facility area as harvested liquid product.

15. The bioprocess Liquid System of claim 1, wherein said Bioprocess Liquid System comprises: means of liquid communication configured to extend from the interior of said one liquid tight container to at least one membrane filter device second port, means of liquid communication configured to extend from the interior of said membrane filter device through said first port to at least one electronically controlled liquid pumping device liquid port, further means of liquid communication configured to extend from said at least one PLC controlled liquid pumping device providing a liquid communication to a first inlet port of at least one membrane filter device, a further means for retentate liquid is configured to extend from said second retentate port of said membrane filter device and conveyed to the interior of said liquid tight container, said second retentate port providing a liquid communication of said filter device through which retentate is returned to the process liquid of the interior of said liquid tight container, and said third permeate outlet port communicates between said filter device and said exterior facility area for conveying filtered process liquid that has passed through said permeable membrane of said filter device to said exterior facility area as harvested liquid product.

16. The bioprocess Liquid System of claim 1, wherein said bioprocess Liquid System comprises: means of process liquid communication configured to extend from the interior of a liquid tight container to said at least one electronically controlled liquid pumping device, means of non-filtered liquid communication configured to extend from said at least one pneumatically controlled conveying liquid pumping device providing a non-filtered liquid communication to a first inlet port of at least one membrane filter device, said third permeate outlet port communicates between said filter device and said exterior facility area for conveying filtered process liquid that has passed through said permeable membrane of said filter device to said exterior facility area as harvested liquid product.

17. The bioprocess Liquid System of claim 2, wherein one or more liquid ports and/or liquid connections is adapted for communication with one or more sensors able to measure parameter variables selected from the group consisting of: pH, dissolved oxygen, bio mass viability and/or cell density, bio mass capacitance, turbidity, optical density, liquid conductivity, dissolved carbon dioxide, carbon dioxide gas, lactate, glucose, glutamine, glutamate, ammonia, fluid pressures, distance to and position determination of a surface, liquid level, fluid mass-flow, liquid velocity, liquid temperature, and gas temperature.

18. The bioprocess Liquid System according to claim 2, enclosed and sealed in one or more polymer film and or foil bags comprising a protected environment for sterilization and or transportation purposes and as to such supplied in a controlled pre-sterilized environment to end-user ready for use.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0073] FIG. 1 shows the complete PTF operating SUB with a SUP and a CFF integrated

[0074] FIG. 2 shows a tube penetrating the container vertical side wall

[0075] FIG. 3 shows a tube penetrating the container vertical side wall

[0076] FIG. 4 shows a tube connected to a one-way valve and a pump

[0077] FIG. 5 shows the invention mounted in a parallel operating Bioblock

[0078] FIG. 6 shows a PTF setup with a diaphragm SUP between a SUB and a CFF

[0079] FIG. 7A illustrates a PTF pump with valves and a Cross-Flow-Filter mounted

[0080] FIG. 7B illustrates a PTF pump with valves and a Cross-Flow-Filter mounted

[0081] FIG. 8 illustrates a possible flow and process diagram

DETAILED DESCRIPTION

[0082] It is an object of the present invention to provide a Disposable Bioprocess System supporting biological activity comprising: a fluid tight container comprising a process liquid broth volume surrounded by walls separating an interior process liquid volume from an exterior facility area wherein said process liquid volume communicates with a first liquid valve and a conveying liquid pumping device for pumping the process liquid in one direction away from the interior process liquid volume, and a second liquid valve and a filter device separating the interior process liquid volume from the exterior facility area wherein means of liquid communication from the interior process liquid volume (12d) of said fluid tight container (12a) to said liquid pumping device (15) a further means of non-filtered liquid communication extends from said pumping device (15) to a non-filtered first liquid communication port of said filter device (16), and further means for non-filtered retentate liquid re-circulated via a second liquid communication port (16a) of said filter device back to the interior process liquid volume of said container, said filter device comprises at least one third permeate outlet port (16d, 16e) for conveying filtered process liquid to said exterior facility area as harvested product; wherein the first liquid valve controls the communication between the interior process liquid volume and the pumping device, wherein the second liquid valve controls the communication between the pumping device and the filter device, and wherein a filter device outlet port communicate between the filter device and the exterior facility area.

[0083] The presented invention is a Disposable Bioprocess System for Continuous Processing of micro-organisms in the pharmaceutical industry integrating a Single-Use-Bioreactor (SUB), a Single-Use-Pump (SUP) and a single-use CFF based micro-organism retention device. Operating after the term Pulsating-Tangential-Flow, PTF of the Disposable Bioprocess System offer end-user benefits, freedom and features such as: [0084] Eliminate traditional time consuming steam sterilization as the PTF invention is pre-assembled, pre-sterilized with all necessary components ready for use right out of the box for lower cost of use and higher throughput in laboratories; [0085] Eliminate cross contamination as to the pre-assembled and pre-sterilized concept beneficial to both Research & Development as well full scale production; [0086] Minimizes instalment time as the PTF cell retention system integrate the SUP and CFF either inside the SUB or outside of the SUB container, which also allow instalment in parallel block’s or robotic devices for desired perfusion mode processes; [0087] Un-parallel control of broth velocities and volume through the CFF for different harvest and cleaning cycles by a sensor measuring on-line liquid level (potentially separated by a diaphragm or piston) inside the SUP; [0088] The Disposable Bioprocess System enables rapid evaluation of multiple micro-organism cultures, increasing productivity in cell line development with significant savings on materials and labour.

[0089] The pharmaceutical industry desires a SUB platform supporting increased volumetric efficiency, more on-line analyst measures all in a single-use design with capability intended for micro-organism retention in perfusion mode operation. Potentially in parallel processing with semi-automated robots such as the DASGIP parallel operating Bioblock or the fully automated TAP Biosystem (from now Sartorius Stedim Biotech) or individually performing the continuous processing. For reasons unknown such Disposable Bioprocess System product as presented here does not exist today.

[0090] The present invention relates to a Disposable Bioprocess System comprising a SUB for cultivation or a SUF for fermenting of biomass and selected components comprising advantages (below briefly described) such as; [0091] A container comprising a range of ports, mechanical connected with or an integrated part of a hollow plastic container with an interior reservoir optionally with one or more side wall ports. The container have selectable diameter or cross section (such as round, cylindrical or non-cylindrical such as square design) and heights offering a desired interior reservoir and respective volume; [0092] Optionally a draft tube stator arranged vertical inside said container operating with none or one or more baffles arranged perpendicular and radially to said draft tube stator exterior space said draft tube stator having an interior space housing fluid motion, agitation means. The interior reservoir fluid agitation device(s) create a radial swirl of media which the tube stator convert into axial fluid movement and more efficient mixing axial vortexes; [0093] Optionally a baffle arranged vertical inside said container operating as a SUB extending inwards from the container side wall; [0094] A fluid motion, agitating device arranged on a rotating shaft attached to component comprising magnets and a bearing in contact with the container bottom for magnetic power transfer through the bottom wall driven by external magnetic means; [0095] A fluid motion, agitation device arranged on a rotating shaft penetrating the container top via a bearing / sealing arrangements for kinetic power input; [0096] A tube arranged vertical inside said container with the purpose of supplying a mixed gas addition to insure for the cells safe aeration; [0097] Liquid communication between the broth of the container and a Single-Use-Pump device, said SUP devise a liquid conveying or/and liquid direction control device in order to facilitate the pumping operation. Said SUP device may be arranged inside the container or external to the container; [0098] Liquid communication between the container a single-use Cross-Flow-Filter devices, said CFF devise and one or more liquid conveying or/and pumping devices and liquid direction control devices in order to facilitate the advantageous micro-organism retention under perfusion mode operation. Said CFF device(s) may be arranged inside the container and/or external to the container; [0099] Manufactured from materials considered to be disposable and supplied sterilized to the end-user for cost efficient single-use applications.

[0100] Dimension of the SUB container are not limited by, but may correspond the preferred dimension of the Bioblock or robot assembly to which the STR may be installed in. The container provides an interior space with exterior walls and two in principle flat end covers being top cover and bottom cover. Dimension of the container, housing assembly range 10 to 500 mm in diameter such as 20 to 200 mm and height from 10 to 1.000 mm such as 50 to 500 mm. Or measured in container cross section from 1 to 2.000 cm2. Or measured in CV ranging few millilitre up to 2.000 liter.

[0101] The invented Disposable Bioprocess System further comprise a variety of additional arranged devices and features in order to expand the simple batch operation to the more advantageous perfusion mode operation. Such as one or more; hollow bodies appearing as reservoirs, Cross-Flow-Filter devices, aeration devices, instrumentation, sensors, liquid conveying devices, valves, actuators, fluid accumulators and the like for regulating process means.

[0102] In addition the invented Disposable Bioprocess System comprises a Single-Use-Bioreactor a liquid conveying or pumping device and a Cross-Flow-Filter device for micro-organism retention perfusion mode operation. Such CFF may be manufactured from rigid porous ceramic support integrating a thin micro-porous membrane into a honeycomb module or manufactured from flexible semi-permeable flat or round membranes or hollow fibers bundled into a cartridge. The CFF are arranged in liquid contact with the process liquid broth either inside of the SUB or outside of or next to the SUB either above or next to the SUB with drainage from the SUB either above or below the container broth level. The CFF are sequentially exposed to liquid feed drawn by a liquid conveying device from the SUB process liquid reservoir through valve means into and occupying the entire interior, retentate compartment of the CFF retentate channels. After partly or fully closing of both liquid conveying inlet and CFF outlet valves the liquid conveying creates TMP across the CFF membrane. Which allows at least a part of the expressed and desired protein product from the processes suspended in the media to pass over the membrane and hereby be converted to permeate, harvest. The remaining micro-organism rich liquids and suspended debris inside the CFF are simultaneously converted to retentate and returned by flushing through CFF exit to the reservoir by suitable velocity for the liquid conveying operation.

[0103] The permeate side of the CFF may preferably be exposed to a pressure below the retentate liquid pressure in order to overcome the TMP losses. In fact - its preferred that a force on the permeate side helps overcome the TMP of the semi-permeable membrane as limited liquids pass the membrane mostly caused by a membrane fouling, deposits typically created from the broth on the retentate side of the CFF.

[0104] The present invented Disposable Bioprocess System supports numerous requirements and facilitate a variety of rigid or semi-rigid or flexible products used for fabrication of basic parts. Materials such as polymers to form one or more parts of the invention are, but not limited to materials such as; polycarbonates, polyesters, nylons, polyamide, PTFE resins and other fluoropolymers, acrylic and methacrylic resins and copolymers, polysulphones, polyethersulphones, polyarylsulphones, polystyrenes, polyetherimides, polyethylene terephthalates, polyvinyl chlorides, chlorinated polyvinyl chlorides, ABS and its alloys and blends, polyolefins, preferably polyethylenes such as linear low density polyethylene, low density polyethylene, high density polyethylene, and ultrahigh molecular weight polyethylene and copolymers thereof, polypropylene and copolymers thereof and metallocene generated polyolefins. Or partly, semi rigid materials such as silicone, rubber and otherwise elastic materials.

[0105] The basic individual parts of the container manufactured by or assembled from: [0106] injection moulding or blow moulding or vacuum-thermo shaping of basic parts; [0107] welding basic parts together; [0108] moulding basic part pieces together via injection moulding process; [0109] sealing of basic parts between assembling surfaces by elastomeric element(s) such as an O-ring or flat washers or diaphragms may be nitrile rubber, silicone rubber, Viton rubber, latex rubber, EPDM or other elastic material; [0110] sealing basic parts between assembling surfaces by adhesive materials such as UV curing adhesives or epoxy’s and the like, or combinations hereof.

[0111] In a first embodiment the invented Disposable Bioprocess System provides a container according to the invention manufactured from disposable materials suitable for micro-organism retention perfusion mode comprising in a liquid loop: [0112] various ports arranged on said first container exterior wall for implementing sensors measuring process parameters; [0113] further various tubes, hoses, ports pass though the outer wall of which some extending to and or from the first container interior volume for various fluid communication with external devices, such as a liquid suction tube for connecting to the second container operating as a SUP; [0114] furthermore attending the first container a second tubular container operating as a SUP with a suitable interior volume comprising a first inlet port and a second outlet port and said container closed with a bottom cover, a top cover and comprising a liquid level sensor; [0115] furthermore attending the first container and second container arranged in liquid series a CFF device comprising a housing a micro porous internal separation wall a first inlet a second exit and a third harvest port; [0116] furthermore attending the first and second container and CFF device arranged a first valve guiding broth in one direction from first container to second container and a second valve conveying broth in one direction from second container to CFF device and a liquid connection from CFF device in return to said first container closing the liquid loop.

[0117] In a second embodiment the invented Disposable Bioprocess System provides a first container suitable for micro-organism perfusion mode operation comprising: [0118] various PG 13,5 ports arranged on the first container exterior wall for implementing sensors measuring various process parameters; [0119] further various tubes, hoses pass though said first container exterior wall of which some extending to and or from the interior volume of said first container for various fluid communication with exterior devices; [0120] a port arranged on the first container exterior wall furthermore for implementing a broth suction tube for conveying broth to a second container operating as a SUP. Said broth inlet from said first container comprising a suction tube inside first container is independent of penetrating said first container upper exterior wall the invented and presented Disposable Bioprocess System also becomes independent of the first container physical dimension - a valuable feature of the invention; [0121] furthermore attending the first container a second tubular container operating as a SUP with a suitable interior volume comprising a first inlet port and a second outlet port and said container closed with a bottom cover, a top cover and comprising a liquid level sensor; [0122] furthermore attending the first container and second container arranged in liquid series a CFF device comprising a housing a micro porous internal separation wall a first inlet a second exit and a third harvest port; [0123] CFF second exit port return processed liquid via a tube to first container completing the PTF concept; [0124] CFF third outlet is considered harvest port; [0125] SUP and CFF containers arranged independent of each other; [0126] a liquid agitating impeller or turbine arranged on a shaft inside the reservoir of the first container said shaft driven in rotation by external means;

[0127] The first liquid conveying variation of the invented Disposable Bioprocess System takes advantage of a second container operating as the liquid broth conveying pump and arranged in series in liquid connection to said first container. The interior space of said second container represent a first liquid broth and a second drive gas compartment. The process broth arrives from the container and contain micro-organism and various debris. The second container being the SUP comprises: [0128] a first inlet valve convey liquid from the first container liquid, broth reservoir; [0129] a second outlet valve which convey liquid broth to the CFF device first inlet port; [0130] a drive gas connection corresponding with external drive gas control means adjusting continuously the broth level height, the broth volume and velocity of the broth being conveyed by the pumping device in reciprocating action in a sequential though continues, one way, single direction liquid movement (opposite of alternating liquid movement which is dual-way liquid movement); [0131] a SUP activity sensor .sup._ such as a liquid surface height measuring sensor, or a liquid volume measuring sensor, such a internal or external arranged Single-Use-Sensors or Re-Usable-Sensors.

[0132] Said CFF device second exit side corresponds with an optional third valve said third valve outlet which correspond with the first container process broth reservoir finalizing the closed liquid loop. The SUP container as well as the valves and the CFF device may be arranged outside or inside the SUB container. And more than one of each of the SUP and of the CFF may be integrated with or within the SUB. In any suitable combination and numbers promoting the process.

[0133] If desirable there may be a separating device between the drive gas compartment and the liquid broth compartment inside the second container. Such as a diaphragm, a piston, a discs, wet on one side and dry, semi-dry on the opposite side.

[0134] For the cultivation start a desired amount of media covering at least sensors and agitation devices in the SUB is inoculated according to the desired recipe. When desired biomass and WV has reached its potential the process is converted from batch to retention perfusion mode operation.

[0135] Perfusion process of this invention is the combination of several different operations modes, principles: 1. Cultivation mode (typically continues for weeks in the SUB), 2. Harvest - the “membrane conveying mode” at low velocity in CFF. 3. Deposit removal - the “membrane cleaning mode” at high velocity in CFF.

[0136] Different and independent operational modes following each other at desired intervals as described here: [0137] process liquid of said SUB corresponds with one first valve insuring a one way, single direction fluid path from SUB to SUP; [0138] said first valve corresponds with one associated liquid conveying SUP; [0139] said liquid conveying SUP of variable capacity of / and pressure applied to the process broth conveyed from said SUB through said first valve; [0140] said liquid conveying SUP convey process broth in one direction (not alternating) through a second valve and to the first inlet of said CFF device(s) and further through the CFF inlet channels, across the membrane; [0141] to the retentate side of said CFF device(s) with volume and velocity though reduced pressure passing along the CFF device retentate membrane side to said CFF device opposite second outlet / end; [0142] and said processed fluid returned to said SUB - when in membrane cleaning mode sequentially high velocity flushing removes the membrane fouling, deposits, which is returned to the SUB; [0143] involving an optional third valve after the retentate / CFF exit when at least partly closed allow the liquid conveying SUP to apply higher pressure to the retentate side of said membrane(s) of said CFF device convey harvest through its pores by separating, avoiding micro-organisms and other particles from passing though said membrane said liquid when passed the membrane is considered to be the harvest or harvested product .sup._ when in membrane conveying mode; [0144] said harvested product is separated from the permeate side of said CFF device and collected externally and forwarded to down-stream processing; [0145] a volume from the cultivation broth (cell bleed) in said scalable Single-Use-Bioreactor is removed sequentially as waste in order to reduce the exponential growth and keep total desired bio mass at desired level; [0146] a corresponding volume fresh media is added, replenished to the first container, SUB accordingly; [0147] completing a cycle.

[0148] It is desirable to extent from the short SUB batch cultivation time (one week) and low micro-organism numbers high / bio mass (5-10 x 10E6 cells / millilitre. Practical PTF operational cell density range 20 - 100 x 10E6 cells / millilitre preferably measured with an on-line bio mass sensor. High cell density in general means higher productivity for the SUB. Longer cultivation time means more throughput, less time spend in starting the cultivation per run. A conventional batch process last one week plus one week for cleaning and process restart. It takes 7-10 days of batch cultivation before the PTF process can start. Continuous processing time of 5-6 weeks is relevant with 5-10 times the cell density to batch. With the present invention only one day is requited to start the next process. Compared batch against PTF then PTF is 30 times the amount of cells producing and product harvested.

[0149] The benefits of the second container representing the air column driven liquid conveying SUP (FIG. 1) are: low shear stress for the suspended cells, able to handle micro-carriers, neither micro-carries or cells damaged now not passing a peristaltic pump, no problems with clocking of the CFF as the setup is not a dead-end filtration, no alternating liquid flow, simplified operation, good control of liquid velocity and most important simplicity and of low cost allowing the SUP device to be designed from plastics and integrated fully and sterilized in the Disposable Bioprocess System.

[0150] General conditions for the first container, the SUB is that single micro-organisms may be kept in suspension or multiple micro-organisms aggregated in colonies kept in suspension or multiple micro-organisms adhered to micro-carriers kept in suspension.

[0151] A third embodiment comprises one or more containers if desired with different diameter and height and interior space volume. Either external to each other or the first container is arranged outside the second container which is here surrounding by the first container. The first container interior space contains process liquid broth including micro-organism and the second container being the SUP convey the broth and a third or optionally fourth containers being CFF devices. The second container interior space represent the air driven SUP pumping reservoir. The second container comprises a drive gas inlet, a first process broth inlet and a second process broth outlet. Said SUP first process liquid inlet correspond with the first SUB container reservoir via the first valve and the conveyed process liquid passing the second valve correspond via the second process liquid outlet corresponding with the first inlet of the broth side of a first CFF device. Said CFF device convey the broth to the retentate second exit retuned to the SUB. Said CF device from its permeate third exit convey the micro-organism free liquid via appropriate connections with external means for harvest being withdrawn from the all sterile setup.

[0152] Supply of controlled sterile drive gas volume and pressure to the second SUP container head space allow pressure control of the head space volume above the process liquid broth. Controlling head space drive gas pressure controls the process liquid surface level height. As the process liquid level in the first container is lower than second container liquid level and process fluid must pass the first valve to be conveyed into the second container interior space volume this is all controlled by the second container head space gas pressure. Variation in head space gas pressure regulate the liquid level and combined with a optional third valve supply process liquid under TMP control for harvest. Or process fluid at high velocity for removal of deposit on the membrane surfaces on the retentate side. The CFF benefit from on its retentate outlet an optional controlled third valve with liquid outlet connected to the first container process liquid reservoir. When the third valve is opened the membrane cleaning pulse of high velocity liquid is returned, conveyed back to first container process fluid reservoir.

[0153] Bringing the perfusion process into operation require the first container hold the process liquid and the suspended micro-organisms for the cultivation as a broth. A least one CFF operate sequentially separating the micro-organism (or micro-carriers) from the process liquid and hereby keep the micro-organisms predominantly inside the first container interior space at any time. One or more SUP and one or more CFF may operate in parallel if desired and even with different specification and different control parameters.

[0154] It’s end-user experience that the traditional and only commercial available stainless steel housing encapsulated CFF limits the process time as to extended membrane deposit issues When the one and only CFF device module loose transport capability it is impossible to exchange the CFF and re-insert a new fresh CFF under sterile conditions.

[0155] The presented invention promote extended cultivation time by facilitating more than one preinstalled CFF internal as well as external to the first container. This feature allow users to extent the first container process operation time in perfusion mode by the number of connected installed CFF modules.

[0156] The presented invention allow one liquid conveying second SUP container to be connected with one or more CFF devices. Performance of each CFF may be monitored continuously, such as by pressure drop (TMP) and mass flow sensors. The CFF may be of different size and different specifications. When the life time of the first CFF has reached a relevant upper limit of transmembrane pressure said CFF is blocked of by the third valve and the next and fresh CFF is brought into use – without risking / jeopardizing the sterile setup. The first and second valve preferably are low cost valves to be integrated in the invention. The third, fourth and more valves may be controlled hose / pinch valve allowing the complete process loop as presented in FIG. 8 to be pre-assembled and pre-sterilized hereby creating one sterile component fully eliminating further need for local sterilization.

[0157] In a fourth preferred embodiment (see FIG. 6) a free floating and non-controlled diaphragm based SUP is provided which convey broth from the SUB to and through the CFF. The SUP comprises two housing parts each with an interior chamber and groves for O-ring sealing on the circumference separated by and also sealed with when assembled by an elastic element Said elastic element is a moulded thin flexible sheet integrated with a sealing O-ring on the circumference. Material preferably with compatibility with the requirement of the biological process. Upper single-use curved dome part comprises two ports; a first inlet port for SUB connection via a first one-way valve and a second exit port for CFF connection via a one-way valve. The lower potential re-usable housing part comprises a port for drive gas connection. Such as controlled drive gas pressure between vacuum and shop compressed air. The diaphragm have two positions being maximum expanded to each of the two end positions as determined by the two pump housing parts interior dimension.

[0158] The SUB is a container with magnetic agitation transfer through the bottom plate of the container. Various agitation devices may be added to the SUB such as the shown rotating shaft mounted with an impeller and driven by an external rotational force. A suction tube penetrate through the SUB wall into the SUB interior broth volume for suction of broth. The suction tube convey via a hose to a first one-way inlet valve located outside on the SUP dome to the SUP upper interior liquid chamber between the elastic diaphragm and the upper dome housing. The elastic diaphragm separate the sterile, wetted environment on the upper side and below the non-wetted non sterile drive gas compartment. The SUB suction tube ends into a hose which continues to the first valve inlet barb. The first valve allow one direction broth flow from the SUB into the SUP chamber. The second valve allow one direction broth flow from the SUP pumping chamber to the CFF inlet port. The CFF facilities the broth to pass along its channels to the CFF exit from which a hose insure the now retentate is guided back into the SUB and mixed with the broth finishing the liquid cycle.

[0159] Further in a fifth preferred embodiment (see FIG. 7) the SUP for combined SUB and CFF operation in a perfusion process setup is a diaphragm pump. An SUP example is described in WO2010/069321 being a free-floating and both in motion and position controlled elastic diaphragm is provided which convey broth from the SUB to and through the CFF. The SUP comprises two housing parts each with an interior chamber and groves for O-ring sealing on the circumference separated by and also sealed with when assembled by an elastic element. Said elastic element is a moulded thin flexible diaphragm integrated with a sealing O-ring on the circumference. Material preferably with compatibility with the requirement of the biological process. Upper single-use curved dome part comprises two ports; a first inlet port for SUB connection via a first one-way valve and a second exit port for CFF connection via a one-way valve. The lower housing part comprises a port for drive gas connection. Such as controlled drive gas pressure between vacuum and shop compressed air. The re-usable lower pump housing is equipped with a sensor for determining the position of the elastic diaphragm in real-time and possible 0,1 mm accuracy. Data from a position sensor will allow velocity and volume control of the SUP by modern electronics able to calculate input against PID algorithms and output for real-time regulating a proportional valve opening for variable drive gas pressure on the non-wetted side of the diaphragm. Said diaphragm will change position accordingly and respectively move a desired portion of liquid according to selected diaphragm position. The diaphragm based pump operate in series with valves and arranged between the SUB and CFF and with one first valve on the inlet side of the SUP and one second valve on the pump outlet side facing the CFF retentate inlet side. Optionally one third valve on the CFF outlet side for TMP control. The diaphragm pump collaborate and operated in series with the first and second valves. Which allow control of and insure one-direction flow being the invented PTF concept. The SUP control liquid volume and velocity of the broth through the CFF and volume of harvest and re-circulation volume on the retentate side of the CFF. Pressure is supplied by the SUP in order to overcome the gradually increasing TMP in the harvest situation. Broth velocity in order to sequentially flush out collected membrane deposit restoring CFF transmembrane pressure to its original stage.

[0160] Overcoming increasing TMP is established when the SUP is filled with process broth and the CFF is filled with process broth and first valve closed, second valve open and third optionally valve partly closed. Expanding controlled the diaphragm of said pump will increase system pressure and overcome TMP and the membrane will convey liquid and hereby converts retentate to permeate as the desired type of harvest.

[0161] One practical way of procedure is when the SUP diaphragm is in the relaxed stage and pump chamber and the CFF is filled with process broth and only the first valve is closed. The optional third valve arranged in the opposite end of the CFF, with relevance to the pump, is now open and allow high velocity liquid (like from 1 to 20 m/s) to be pumped with one or more pulses through the CFF. Said liquid broth pass the open third valve and return back into the SUB reservoir dragging along the collected cell material, deposit, etc from the CFF retentate membrane surfaces. The liquid loop is that all components is both supplied such as and operate in a closed loop. No alternating flow of liquids is required for membrane deposit removal. Only one liquid direction in the invented PTF setup hereby improve in general system and in specific the CFF performance as “fresh” process liquid broth is used for sequential membrane cleaning.

[0162] The SUP in the embodiment of a diaphragm pump is based on a flexible and/or elastic element being the diaphragm able to expand to a desired shape and / or return to a desired shape when exposed to as drive gas pressure ranging from vacuum to atmospheric overpressure. Movement of the flexible and / or elastic element with drive gas on one side and process liquid on the other side separates the non-sterile, non-wetted side with the wetted and sterile environment. Furthermore the diaphragm may take different shapes and be arranged anywhere outside as well as inside the container or part the rigid container wall or partially outside and inside on the container wall. The diaphragm may take shaped as a sheet of elastic material, shape as a sphere, shape partially as a sphere, shape as a tube, shape as a cylinder, shape partially as a cylinder closed in one end.

[0163] For the invented PTF the first and second valve may be a passive one-way valve know in the industry as umbrella valves or ball valves or buck bill valves. Or valves controlled by external means such as pinch valves or hose valves or sheet valves or poppet valves or combinations hereof.

[0164] The person experienced in working with membrane filtration know that deposits, debris, clogging is a significant problem. Deposits on elastic membranes may during the process be removed with controlled rapid changes in broth velocity. Pumps as used in cell retention CFF systems on the market from Spectrum Laboratories Inc, CA, USA and from Refined Technology (now Repligen Corp, MA, USA) do not allow rapid changes in broth velocities. Spectrum Laboratories use centrifugal pumps and Refined Technology a limited flexibility in movement diaphragm pump.

[0165] The present invention benefit from huge span in rapid broth velocity changes (measured in meter/second) passing along the CFF membrane surface. For harvest mode low velocities like from 0,01 to 1 m/s is sufficient. For cleaning cycles higher velocities will promote removal of deposits at 1 to 20 m/s or more. The SUP of the system are able to controlled alter velocity between the individual pumping cycles from lowest to highest velocity from one to the next pumping cycle. Hereby the expression “harvest cycle” and “cleaning cycle” is created. Utilising better CFF performance and longer process life time before the otherwise accumulating CFF deposits limit process performance and the cultivation is terminated.

[0166] Exchange of thermal energy of the media reservoir such as heating for cultivation and cooling for fermentation may be performed by encapsulating the SUB with heating blankets or water jacketed systems.

[0167] Thermal control can also be used to control the total biomass, cell density in the broth. As an example mammalian cell lines such as CHO cells operate at maximum cell growth rate at 37° C. They more or less divide once per 24 hours and hereby grow exponentially and will as to such eventually block the SUB. Reducing temperature with 3 to10° C. will allow a stable cell density, cell population in the SUB such as 20 to 100 x 10E6 cells / millilitre for weeks.

[0168] Further desktop arranged parallel blocks, sockets, workstation, robots for insertion of the invented Disposable Bioprocess System will further give benefits such as easier sampling, simplified connection of the sensors to cabling and the associated PCS. The parallel operating setup may take any shape facilitating the installed SUB bodies. SUBs may be arranged in one or more rows arranged in both directions creating assemblies with from 1 to 48 SUBs or more in one setup.

Alternating-Tangential-Flow Details

[0169] The market dominating Alternating-Tangential-Flow concept “ATF” from Refined Technology is a dual flow direction, bi-directional flow concept in pulses. ATF offer reduced liquid exchange inside the Cross-Flow-Filter device as the CFF internal volume is not exchanged fully with fresh liquid at each stroke. Un-controlled dilution takes place inside the CFF.

[0170] The diaphragm pump of the ATF further offer only two positions for the elastic diaphragm. Two end positions and no positions in between allow no functionality as metering pump benefits except the total volume. The ATF diaphragm pump can only pump one specific volume being the particular pump size volume. As to this fact a range of pump sizes is required for different CFF sizes and different STRs. No valves are described in reference or used in practise for flow control or flow direction. The ATF concept pump do not allow programming for precise and selected pumped volumes for optimum perfusion performance and not combined with high velocities for controlled deposit removal prolonging the CFF lifetime.

[0171] ATF perfusion systems with cell retention CFF devices operate conventional glass/steel STR from 3 litre lab scale to 500 litre all steel production scale volume covered by 5 different pump sizes. The entire ATF selection of 5 pump sizes named ATF-2, 4, 5, 8, 10 cover a scalable factor of app. 1:55 over the entire range. The ATF pumps can only offer one full stroke in pumping capacity and not fractions of a stroke. Pump ATF-2 exchange 0.1 litre, ATF-4 exchange 0,4 litre .sup._ ATF 6 exchange 1,3 litre, ATF-8 exchange 2,5 litre, ATF-10 exchange 5,5 litre per stroke. Each of the 5 different pumps offer individual scalability of app 1:5 to STR volume. Each ATF pump must be connected to one specific size CFF with max ± 10 % surface area (app 0,1 or 0,75 or 2,5 or 4,2 or 10 m2) as to pump limitations. None of the ATF systems (pump housing, CFF housing, connections) is available in pre-assembled and pre-sterilised and disposable design. ATF is only available in stainless steel for manual mounting, insert of the CFF module, steam sterilization and rather complicated connection with the STR or large scale steel vessels.

Pulsating-Tangential-Flow Details

[0172] In comparison the present PTF invention utilise one liquid flow direction, mono-directional, single flow direction in pulses. The present invention utilize the entire CFF broth volume exchange each time a pulse appear from the SUP. Fresh broth, liquid is always added to the SUP controlled by a valve. The present invention allow full control of velocity from 0,01 to 20 m/sec and volume performed by the SUP, when integrating a sensor.

[0173] The invented Disposable Bioprocess System operating in PTF mode take advantage of a variety of pump principles.

[0174] In the present invention the second container SUP (FIGS. 1-5) is also a metering pump, when integrating a sensor, able to flow a desired and pre-controlled volume independent of time. The SUP can exchange a volume, such as the exact broth volume of the inside volume of the CFF at each pulse. With a stroke resolution of 0,1 mm and a 150 mm max stroke of the in FIG. 1 shown embodiment gives incredible 1:1.500 in volume variation in just one SUP size. Further one pump size will be able to satisfy the requirements of a very wide range of CFF modules with a factor 1:50 surface area and 1:50 range of SUBs which all reduce end-user investment. Perfusion system (PTF) of the present inventions will allow SUB sizes down to 0,25 litre SUB laboratory scale VV and up-scalable with impressive factor 500 with just one SUP size.

[0175] The present invention integrate a SUB with a SUP, a range of SUS, a single-use CFF, all hoses and all connections all fully pre-assembled, pre-sterilised and fully disposable for very simple and ease of use and much higher throughput at end-user site.

[0176] In the present invention the diaphragm pump (FIGS. 6 and 7) when integrating a sensor, utilise an extraordinary performance width in pumped velocity and measured volume. Able to flow a desired and pre-controlled volume independent of time, ranging from few ml/hour to litres per stroke. Each diaphragm SUP with diameter / volume, such as 100 mm / 0,5 litre, 150 mm / 1,7 litre, 220 mm / 5,5 litre is capable of 1:5.000 in dynamic range. In principle requiring only one 220 mm SUP covering the entire CFF range from 0,1 m2 to 10 m2 surface.

Operation Methods

[0177] In general the 3 most used cultivation, fermentation and operation modes for a bioreactors or fermenters harbouring suspended micro-organisms as bio mass are; [0178] batch with constant Working Volume (WV) and one time harvest with typical 5 and if successful 10 mio cells/ml; [0179] fed-batch starting up with minimal WV and process media sequentially or continuous being added for exponential increasing bio mass in increasing Working Volume and one time harvest; [0180] perfusion with extraordinary high levels of typically suspended bio mass, connected CFF devices for high levels of micro-organism retention, sequentially Working Volume and sequentially or continues media exchange and continues harvest.

[0181] Perfusion cultivation - additionally, the experienced user will preferably use the invented Disposable Bioprocess System platform as a PTF perfusion mode operating SUB in which a desirable average amount of micro-organisms, bio mass are kept in cultivation. The expressed product is removed sequentially though under continuous harvest for further down-stream processing. The micro-organisms within the SUB continue to grow exponentially and continue to express their desired product. As to this on a regular basis an amount of broth including the cells must be removed from the SUB and fresh media added. This sequentially part of the process loose biomass and product, but is the accepted method. As to this the micro-organism retention perfusion process is not a continuous process performing at steady state conditions. One or more CFF devises are typically used for separation of the desired expressed product from the media WV containing concentrated micro-organisms, nutrients, waste, product, etc. The retentate concentrate is returned to the SUB after retention in the CFF. The CFF is sequentially exposed to the liquid feed stock, process fluid from within the SUB, which sequentially separate the suspended micro-organisms / the retentate from the harvest / permeate now free from suspended micro-organisms. The CFF devise (one or more than one) may preferably be of single-use character and integrated within the SUB and all components assembled together and supplied sterilized in dual film bags. Conveyance of micro-organisms containing media from the SUB WV through and along the one or more channels in the CFF devise may be performed by one or more fluid conveying SUP devices. Pressure difference along and across the CFF will insure liquids from the SUB WV are sequentially conveyed to and occupying the entire interior compartment of the CFF channels for purification. The permeate side of the CFF may be either permanently or sequentially exposed for pressure lower than the (often atmospheric) pressure in the container. Removal of possible deposit / filter cake on the membrane surface is performed by rapid and or pulsating flow of liquid of such high velocity along the membrane surface that the particles adhering to the membrane is washed of, flushed back into the SUB container WV. Typical bio mass concentration for cultivation of mammalian cells with the cell retention systems here described range between 20 to 100 x 10E6 cells / millilitre or more.

[0182] The SUP is preferably also a disposable component and utilise a sensor able to give on-line information to a control device or a PCS, which can be used for velocity, volume and pressure control of said SUP. Preferable either a low cost SUS disposed with the invention or alternatively a high precision Re-Usable-Sensor. Good results have been obtained with a high precision tri-angular laser distance sensor able to measure between 30 and 200 mm length with resolution of 0,1 mm of the: [0183] dynamic liquid level height in the SUP tubular cylinder with better than 0,1 second response time; [0184] dynamic diaphragm position in the SUP body from beneath of the elastic diaphragm.

[0185] The SUP in a first embodiment and size as presented in FIG. 1 supplied with a suitable drive pressure of 1 to 8 Bar is able to perform from 1 stroke per hour to one stroke per second reaching 20 m/s velocity in this CFF examples being a hollow fibre module with 12 fibre tubes each 0,5 to 1 mm inside diameter and 400 mm long. Volumes ranging from few ml/hour to 150 ml/sec per stroke for the air column driven SUP as show in the FIG. 1 setup with 34 mm inner diameter tube. Hollow fibre tube specifications may be altered according to SUB volume and CFF surface.

[0186] The SUP in a second embodiment and size as presented in FIGS. 6 and 7 represents a precision pump able to convey a programmable volume at a programmable velocity. Supplied with a suitable drive pressure of 1 to 8 Bar the SUP is able to perform from 1 stroke per hour to one stroke per second reaching 0,01 to 20 m/s or more velocity in a connected CFF device. Volume depending on the diaphragm diameter and expansion rate and range from ml to litres per stroke.

[0187] Knowing the real-time position of a piston surface, liquid surface, diaphragm surface then simple mathematical calculation performed by a computer give accurate info about motion, velocity, volume ousted, etc.

[0188] Motion of said piston surface, liquid surface, diaphragm surface activated by drive gas pressure ranging from absolute to over atmosphere pressure. Pressure control by a pressure regulating valve, preferably a proportional valve. Said valve controlled by said computer or PCS.

[0189] The above described embodiments of the invented Disposable Bioprocess System are preferably connected to a PCS controlling the process variables and integrating the process information such as described in the process recipe: [0190] the PCS connected to multiple sensors integrated in said SUB and SUP and CFF from which the PCS continuously collects data of process variables; [0191] the Disposable Bioprocess System operational parameters are constantly altered by said PCS in communication with various actuators, devices integrated internally in said SUB, CFF and/or SUP or external to said Disposable Bioprocess System for process parameter control.

[0192] The PCS comprising controls for various In & Out channels such as: [0193] various electronic analogue as well as digital input channels for measuring, collecting data from a range of sensors; [0194] various pneumatic, gas, electronic analogue as well as digital output to a variety of actuators.

DETAILED DISCUSSION OF THE FIGURES

[0195] FIG. 1 illustrates in an x-ray view the invented sterile Disposable Bioprocess System 11 as supplied to the end-user fully assembled (here shown without a film protection bag). The SUB 12 container 12a include a sensor 13a, a sensor 13b and a biomass sensor 13c, twin impellers 17c, 17d mounted on shaft 17a, and one aeration tube 13e mounted through top cover 12b. The SUB 12 comprises a container 12a with vertical side wall 12c and inside the container a reservoir 12d and horizontal bottom wall 12e. The optional SUP suction tube 12f is connected via a 90 degree angled elbow arranged inside reservoir 12d and penetrating through the container 12a vertical side wall 12c via a port 12g to a first one-way SUP 15 inlet valve 14a before the SUP 15. The SUP 15 include an electronic liquid level / volume sensor 15a inside the SUP 15 housing 15b and a sterile filter 15c in series with the external and not shown drive gas control device. The CFF device 16 is arrange in series with and after a SUP 15 second one-way outlet valve 14d. CFF 16 receives the broth via SUP 15 second outlet valve. CFF 16 liquid retentate pass exit port 16b and is guided back to the SUB 12 via hose 16c and through SUB 12 vertical exterior side wall 12c inlet 16c and dumped in the SUB 12 broth reservoir 12d. The CFF 16 permeate outlet 16h and 16g, convey the product harvested through tube 16e and tune tube 16f. From the container 12a top cover 12b four externally arranged hoses 18a, 18b, 18c, 18d allow end-user to connect to external pumps and various media containers (not shown). The SUB 12 comprises a shaft 17a extending via a bearing 17e through the top cover 12b into the container 12a, wherein said shaft 17a is equipped with means extending radially from said shaft 17a providing the agitation, such as one or more impellers 17c, 17d.

[0196] FIG. 2 illustrate with a cross sectional view of the lower part as a container 22 with a vertical container wall 22a and a supporting bearing 27b arranged in the container 22 bottom wall 22e into which a rotating shaft 27a is supported. Said shaft 27a is mounted with two impellers 27c, 27d. A PG 13,5 size sensor 23b tip is shown. A first valve body 24a is arranged on the exterior side of the container 22 vertical wall 22a between the top cover (not shown) and the bottom wall 22e. The valve body 24a is arranged between a first support foot 24b at container 22 interior side of wall 22a and a second support foot 24c at exterior side of container wall 22a. The assembly of inlet foot 24b and the inlet one-way valve 24 and the outlet foot 24c convey liquid media in one direction from reservoir 22d to SUP 15. The SUP 15 inlet 22f vertical arranged suction tube 22f is fixed at its top in an elbow 22g inside reservoir 22d and fixed onto the container interior side wall 22c in a suitable height from bottom wall 22e. The suction tube 22f extent freely hanging in a suitable distance 22h over the container interior side of bottom wall 22e.

[0197] FIG. 3 illustrate with a cross sectional view a lower part of SUB 32 comprising a cylindrical container 32a. The vertical arranged suction tube 32f is fixed at the upper end in an angled elbow body 32g inside the container 32a onto the interior side of said container wall 32c. The suction tube 32f correspond through port 32d in the container wall 32c with a first inlet valve 34a arranged inside support food 34b said support foot arranged on the exterior side of the container wall 32c. Support foot 34b further support the SUP vertical cylinder 35 on the upper exterior side.

[0198] FIG. 4 illustrate one embodiment of the present invention in a cross-sectional view of a PTF perfusion system with view of a SUB 41 with container wall 42a and a supporting bearing 47b at the bottom wall into which a rotation shaft 47a is supported. The shaft 47a is equipped with two impellers 47c, 47d and a Head-Plate-Drive bearing support 47e mounted in cover wall 42h facilitating an externally top mounted servo motor (not shown). A PG 13,5 based sensor 43b and a similar size biomass sensor 43c is shown extending into the broth reservoir 42b through the top cover wall 42h. A first inlet valve 44a body is shown arranged outside the container 42a exterior side wall between the SUP 45 and the SUB 41 insuring one way direction liquid flow drawn from the media reservoir 42b. The vertical arranged suction tube 42f is fixed in a 90 degree angled liquid conveying body 42g inside and onto the container 42a side wall. The SUP cylinder 45 in arranged external to the SUB 42 after the first inlet valve 44a and receive process broth passing the first inlet valve 44a from the media reservoir 42b inside SUB 41.

[0199] FIG. 5 illustrate one embodiment of the present invention with one or more Disposable Bioprocess System’s 51 installed in a block 59a designed for thermal control and mechanical support. If desired also for agitation purposes of one or more (59a, 59b, 59c, 59d) individual Disposable Bioprocess System’s 51 being operated in parallel by a PCS (not shown). SUP 55 and CFF 56 shown installed on SUB 59a including only the CFF 56 return connecting hose 56a. All other hoses and accessories and sensors not show for simplicity.

[0200] FIG. 6 show an embodiment and the re-circulating liquid flow path in a PTF setup. A SUP 62 conveying broth between the SUB 60 and the CFF 64 and return the liquid to the SUB 60. The SUB 60 container agitate continuously the liquid broth with an impeller 61a mounted on a shaft 61b driven by external means (not shown) said shaft attached to rotating magnetic device 61c. A suction tube 62b penetrate through the SUB 60 cover wall 60a into the SUB 60 interior liquid broth reservoir 60b. SUP 62 sucks liquid broth through a first valve 62a via tube 62d from SUB 60 liquid reservoir 60a and convey via hose 62c broth to said first valve 62a located on the SUP 62 dome wall 62d. Said first one-way valve 62a receive broth from SUB 60 and pass the broth volume further on to the internal pumping chamber of the SUP 62 when SUP 62 are in suction, filling mode. A second one-way valve 62e receive broth from SUP 62 outlet and opens and convey broth from SUP 62 internal pumping chamber when SUP 62 are in pumping mode. Port 62g allow drive gas to enter SUP 60 for operation purposes. Said broth pass on to CFF 64 broth inlet port 64a and said CFF 64 convey the broth along its internal porous membrane (not visible) inside the CFF 64 tubular container 64b in which the CFF 64 convert broth to both retentate and permeate. Said retentate of CFF 64 exit port 64c and is returned to SUB 60 via hose 64d closing the process liquid loop. Said CFF 64 allow an amount of the liquid broth to pass the CFF porous membrane through one of or both of the permeate outlet ports 64e, 64f.

[0201] For simplicity only one sensor 60c is shown entering the container reservoir 60b through the cover wall 60a, other necessary hoses and sensors are not shown, no sensors inside SUP 64 is shown.

[0202] FIG. 7 show in 7a the SUP 72 assembled with CFF 74 connected and in 7b show the individual parts before assembling.

[0203] The SUP 72 comprises the expanded, curved elastic diaphragm 72a separating and suspended between the upper housing dome part 72b and lower housing part 72c. The dome 72b is secured mechanically with a coupling (not shown) to the re-usable SUP lower housing part 72c, which gives balance and support to the vertically arranged CFF 74. The SUP 72 facilitate a port 72d (62g) for the drive gas supply from external source (not show). The dome 72b exterior wall is equipped with the first inlet valve 72e housing and a second outlet valve 72f connected directly to the CFF 74 broth inlet port 74a. The curved single-use dome 72b is on the interior side of the flat circumference wall 72g attached fluid tight with a thin elastic curved diaphragm 72a separating the sterile, wetted environment 72h on the interior diaphragm side from the non-wetted non-sterile drive gas compartment 72i exterior side of the diaphragm. The SUB 60 suction tube 62b continuous into a hose 62c which continues to the SUP 62/72 inlet valve 62a/72e via first inlet port 72l. The first inlet valve 72e allow one direction broth flow from the SUB 60 into the SUP 62/72. The SUP 72 second outlet valve 72f allow broth in one direction to be conveyed from the SUP 72 pumping chamber 72h via second outlet port 72m to the CFF 74 first inlet port 74a. The CFF 74 facilities the broth to pass along its internal porous membrane surface (not shown) to the CFF 74 second exit port 74b from which a hose 64d insure the now retentate is guided, conveyed back into the SUB 60 reservoir and mixed with the broth finishing the PTF liquid cycle. A CFF 74 third and fourth permeate outlet ports 74c, 74d convey filtered process liquid to said exterior facility area as harvested product.

[0204] SUP 72 re-usable lower housing part 72c comprise a drive gas connection port 72d for controlled SUP 72 activity and a housing flange 72j suitable for gas tight connection with the diaphragm 72a circumference seal 72k.

[0205] Broth entering the SUP 72 pumping chamber 72h is enclosed, trapped between the elastic freely floating diaphragm 72a and the single-use rigid dome upper housing part 72b.

[0206] FIG. 8 block diagram illustrate and describe a relevant and practical flow diagram for a continuous cultivation and harvest process with a first container SUB 80, a liquid conveying second container SUP 82 and a third container CFF 84 in a closed process liquid loop.

[0207] The first container 80 house the biological activity process and convey cultivation broth to the second container SUP 82. The SUP pump broth to third container CFF 84 for separation into harvest and process liquid in return loop back to the SUB 80.

[0208] The first container SUB 80 comprises a broth outlet port 80a, a fresh media pump 80b and inlet port 80c, an agitation device 80d driven by servo motor 80e, a Glycose sensor 86a, a Lactate sensor 86b, dual biomass sensor 86c, a pH sensor 86d, a dissolved oxygen sensor 86e, a 86f temperature sensor and SUB temperature controlled via heating element 86g. Fresh media is added via pump 80b and used media (including cells), waste removed via pump 80f. Aeration gas added to the SUB via control valve 80g and sparged into the process broth 80h liquid volume and exhausted out through vent filter 80i.

[0209] The second container SUP 82 houses the pumping process and comprises a broth volume 82a and a drive gas volume 82b. Drive gas inlet 82c, a first inlet port 82d associated with first inlet valve 82e, a second outlet port 82f associated with a second outlet valve 82g, a liquid sensor 82h, a pressure sensor 82i, a drive gas port 82j connected to external mounted dual proportional valves 82k, 821 (one valve for vacuum and one for pressure drive gas). The liquid sensor 82h give in real-time information to the PCS (not shown) about the liquid level height, which the PCS use to adjust SUP 82 drive gas pressure (from absolute pressure to over atmospheric pressure) via external dual valve arrangement 82k, 821.

[0210] The third container CFF 84 houses the separation process and comprises a separating porous membrane 84a inside a CFF housing 84b with a broth side 84c and a permeate side 84d. CFF container 84 comprises a broth inlet port 84e and dual permeate outlet ports 84f, 84g and one retentate exit port 84h. Between permeate outlet port 84g and retentate exit port 84h a TMP sensor 84i is mounted. CFF 84 retentate exit port 84h guide retentate in process liquid loop to the SUB 80 and optionally use a control valve 84j in the retentate return line 84k for various process adjustments. Said CFF device 84 facilitate on its permeate side 84d one or more outlets 84f, 84g for product removal via optional controlled pumps (or optional valves) 84n, 84o.

[0211] In general the mechanically design is unlimited and illustrated without any PCS or control package or external liquid reservoirs associated with the Disposable Bioprocess System embodiment.

[0212] While the present invention has been described in connection with particular embodiments thereof, it will be understood by those skilled in the art that many changes and modifications may be made without departing from the scope of the invention as defined by the appending claims.