process line for the production of freeze-dried particles under closed conditions from end to end an

专利摘要:
PROCESS LINE FOR THE PRODUCTION OF FREEZE DRY PARTICLES. The present invention relates to a process line for the production of freeze-dried particles under closed conditions, the process line comprises a freeze dryer for the bulk production of freeze-dried particles under closed conditions, the freeze dryer it comprises a rotating drum for receiving the frozen particles and a stationary vacuum chamber that houses the rotating drum, in which for the production of the particles under closed conditions the vacuum chamber is adapted for closed operation during the processing of the particles; the drum is in open communication with the vacuum chamber; and at least one transfer section is provided for a product transfer between a separate device from the process line and the freeze dryer, the freeze dryer and the transfer section are separately adapted for closed operation, where the transfer section The transfer comprises an internal wall surface of controllable temperature.
公开号:BR112014008000B1
申请号:R112014008000-3
申请日:2012-10-04
公开日:2021-01-19
发明作者:Bernhard Luy；Manfred Struschka；Matthias Plitzko；Thomas Gebhard
申请人:Sanofi Pasteur Sa；
IPC主号:

专利说明:

Technique Field
[001] The invention relates to the general freeze-drying field of, for example, pharmaceutical products and other high-value goods. More specifically, the invention relates to a process line and a process for the production of freeze-dried particles and methods for the bulk production of freeze-dried particles under closed conditions in which the freeze dryer comprises a rotating drum. Background of the Invention
[002] Freeze drying, also known as lyophilization, is a process for drying high quality products such as, for example, pharmaceutical products, biological materials such as proteins, enzymes, microorganisms and, in general, any thermosensitive materials and / or sensitive to hydrolysis. Freeze drying provides the drying of the target product by sublimating ice crystals to water vapor, that is, through the direct transition of at least a portion of the water content of the product from the solid to the gas phase. Freeze drying is normally carried out under vacuum conditions (i.e., low pressure), but generally also works under different pressure conditions, for example, atmospheric pressure conditions.
[003] Freeze drying processes in the pharmaceutical area can be used, for example, for the drying of Active Pharmaceutical Ingredients ("APIs"), drugs, drug formulations, hormones, peptide-based hormones, carbohydrates, monoclonal antibodies , blood plasma products or derivatives thereof, immunological compositions that include vaccines, therapeutics, other injectables and, in general, substances that would not otherwise be stable for a desired period of time. In order for the freeze-dried product to be stored and transported, water (or another solvent) must be removed before sealing the product in vials or containers to preserve sterility and / or containment. In the case of pharmaceuticals and biologicals, the freeze-dried (lyophilized) product can be reconstituted later by dissolving the product in a suitable reconstitution medium (for example, pharmaceutical grade diluent) prior to administration, for example, injection.
[004] A freeze dryer is generally understood as a process device used in a process line for the production of freeze-dried particles such as granules or pellets with sizes in the range typically from a few micrometers to a few millimeters. The process line can be under closed conditions, that is, under the sterility protection requirement of the product or under the containment requirement, or both. Production under sterile conditions prevents contaminants from entering the product. Containment production means that neither the product, nor elements of it, nor any auxiliary or supplementary materials enter the environment.
[005] The implantation of a process line to operate under closed conditions is a complex task. Therefore, there is a general need for design concepts that reduce the complexity of process lines and process devices such as freeze dryers. Reducing the complexity of process lines and process devices allows for a more cost-effective production of pharmaceuticals and / or biopharmaceuticals and other high-quality products.
[006] Several design approaches for building freeze dryers are known. In one example, DE 10 2005 020 561 A1 describes the production of freeze-dried round particles in a drying chamber that includes a fluidized bed. In that device, a process gas with the appropriate temperature flows under the bed through a lower sieve through the drying chamber. The process gas is dehumidified, so that the process gas absorbs moisture in such a way that it consequently removes moisture from the product through sublimation. Although the design allows for the careful drying of round particles with amorphous structure, the need for a dehumidified process gas leads to relatively high costs seen in using this approach.
[007] WO 2006/008006 A1 describes a process for sterile drying, freeze drying, storage and testing of a pelleted product. The process comprises creating frozen pellets in a freezing tunnel, which are then directed to a drying chamber, in which the pellets are freeze-dried on a plurality of pellet-bearing surfaces; the pellets are, in this way, dried in bulk, that is, before filling the same bottles. From the feeding tunnel, the pellets are distributed through feeder channels over the pellet carriers. The heating plates are arranged below each of the carriers. A vibrator is provided to vibrate the drying chamber during the drying process. Pelletizing and freeze drying are carried out in a sterile volume supplied inside an insulator. After freeze drying, the pellets are discharged into a storage container. Although drying the pellets in bulk provides a higher drying efficiency than drying the pellets only after dispensing them in the jars, the other elements of the process lines of supplying a drying chamber with multiple pellet carriers, which have complex arrangements of feeder channels and channels for unloading the freeze dryer, heating plates and vibrating means lead to a complex arrangement that can be difficult to clean / sterilize, as well as other potential disadvantages. In addition, maintaining the entire process line of droplet generator, freezing tunnel and freeze dryer inside an insulator further adds complexity and costs associated with this design approach.
[008] WO 2009/109550 A1 describes a process for stabilizing an adjuvant containing a vaccine composition in dry form. The process comprises granulating and freezing a formulation, freeze-drying in bulk and then dry dispensing the product into final containers. The freeze dryer comprises pre-cooled trays that collect the frozen particles which are then loaded onto pre-frozen shelves in the freeze dryer. Once the freeze dryer is loaded, a vacuum is pulled into the freeze drying chamber to initiate the sublimation of water vapor from the pellets. In addition to tray-based freeze drying, numerous techniques, such as atmospheric freeze drying, fluidized bed drying, vacuum rotary drum drying, agitated freeze drying, vibrated freeze drying and microwave freeze drying are used. indicated as being applicable options for freeze drying.
[009] DE 196 54 134 C2 describes a device for freeze drying products in a rotatable drum. The drum is heated and the sublimation vapor released from the product is extracted from the drum. The drum is filled with the bulk product and is slowly rotated in order to achieve a stationary heat transfer between the product and the inner wall of the drum. The inner wall of the drum can be heated by a heating medium provided in an annular space between the drum and a chamber that houses the drum. Cooling can be achieved by a cryogenic medium inserted in the annular space. It is proposed that the device be used for pharmaceutical materials or biological materials. However, it is not specifically described how, for example, the sterility of the product is protected or achieved. After approaching WO 2006/008006 A1, an insulator would need to be provided to receive the DE 196 54 134 C2 freeze drying device for production under sterile conditions. This leads to a complex arrangement. Summary of the Invention
[0010] An object of the present invention is to provide a process line for the production of freeze-dried particles under closed conditions, wherein the process line comprises a freeze dryer for the bulk production of freeze-dried particles under closed conditions. closed, where the freeze dryer provides an efficient drying process, correspondingly shorter drying times and more cost-effective production than is currently obtainable using conventional process methods and devices.
[0011] According to one aspect of the invention, a process line for the production of freeze-dried particles under closed conditions with a freeze dryer for the bulk production of freeze-dried particles under closed conditions is provided to achieve one or more of the objectives mentioned above. In preferred embodiments, the freeze dryer comprises a stationary vacuum chamber, which houses one or more rotating drums, adapted to receive the frozen particles. For the production or processing of particles under closed conditions, the vacuum chamber is adapted for closed operation during processing and the drum is in open communication with the vacuum chamber.
[0012] As used in the present invention, the term "production" includes, but is not limited to, the production or processing of freeze-dried particles for commercial purposes, but also includes production for development purposes, test purposes, processing purposes research and the like. In particular embodiments, the processing of particles in the drum comprises at least the steps of loading the particles to be dried in the drum, freeze-drying the particles in the drum and unloading the dried particles from the drum. The particles can comprise granules or pellets, where the term "pellets" can preferably refer to particles with a tendency to be round, while the term "granules" can preferably refer to irregularly formed particles. In one example, the particles may comprise micropellets, that is, pellets with sizes in the micrometer range. According to a specific example, the freeze dryer can be adapted for the production of essentially round freeze-dried micropellets with an average value for their diameters selected from a range of about 200 to 800 micrometers (μm), for example, with a narrow particle size distribution of about ± 50 μm around the selected value.
[0013] The term "in bulk" can be widely understood as referring to a system or plurality of particles that come into contact with each other, that is, the system comprises multiple particles, microparticles, pellets and / or micropellets. For example, the term "in bulk" may refer to a loose amount of pellets that constitute at least part of a product stream, such as a batch of a product to be processed in a process device such as a blow dryer. freezing or a process line that includes the freeze dryer, in which the bulk is released in the sense that it is not filled in vials, containers or other containers to carry or conduct particles / pellets within the process device or line. process. A similar meaning is true for the term "bulk".
[0014] The bulk described in the present invention will normally refer to an amount of particles (pellets, etc.) that exceeds a package (secondary or final) or target dose for a single patient. Instead, the quantity of the bulk may refer to a primary package, for example, a production cycle may comprise the production of sufficient bulk to fill one or more intermediate bulk containers ("IBCs").
[0015] The terms "sterility" ("sterile conditions") and "containment" ("contained conditions") should be understood as required by the regulatory requirement applicable to a specific case. For example, "sterility" and / or "restraint" can be understood as defined in accordance with the requirements of GMP ("Product Manufacturing Practice").
[0016] The freeze dryer provides a process volume, within which process conditions such as pressure, temperature, humidity (ie vapor content, often water vapor, more generally vapor from any sublimation solvent) , etc., are controlled to achieve the desired process values for a prescribed period of time, for example, a production cycle. Specifically, the term "process conditions" means temperature, pressure, humidity, etc. in the process volume, where a process control can comprise controlling or driving such process conditions, within the process volume, according to a desired process regime, for example, according to a time sequence of a profile of desired temperature and / or pressure profile). Although "closed conditions" (sterile conditions and / or containment conditions) are also subject to process control, these conditions are discussed in the present invention in many cases explicitly and separately from the other process conditions indicated above.
[0017] The desired process conditions can be achieved by controlling process parameters by installing heating and / or cooling equipment, vacuum pumps, condensers and the like. The freeze dryer may comprise, together with the vacuum chamber, a vacuum pump and a condenser. The freeze-drying process in the process volume can be further supported by rotating the drum to increase the "effective" product surface, that is, the exposed product surface and thus available for heat and mass transfer, etc.
[0018] Specifically, the term "effective product surface" is understood in the present invention to refer to the product surface that is actually exposed and therefore available for the transfer of heat and mass during the drying process, where the mass transfer may, in particular, include evaporation of sublimation vapor. Although the present invention is not limited to any particular mechanism of action or methodology, it is contemplated that the rotation of the product during the drying process exposes more surface area of the product (that is, increases the effective product surface) than the methodologies conventional bottle-based and / or tray-based drying systems (which includes, for example, vibrating tray drying). Thus, the use of one or more drying devices based on a rotating drum can lead to shorter drying cycle times than conventional bottle-based and / or tray-based drying methodologies.
[0019] According to various modalities, the vacuum chamber supplies the process volume. In such an embodiment, the vacuum chamber is adapted to operate under closed conditions, that is, sterility and / or containment and, consequently, the vacuum chamber comprises a containment wall. The confinement wall is adapted to separate or hermetically isolate the process volume from an environment, thus defining the process volume. The vacuum chamber can be additionally adapted for closed operation, for example: 1) while loading the drum with the particles; 2) freeze drying of the particles; 3) freeze dryer cleaning, and / or 4) freeze dryer sterilization. The drum can be partially or totally confined within the process volume, that is, the rotating drum can be arranged entirely or partially within the process volume.
[0020] According to various modalities, the containment wall of the vacuum chamber contributes to establish and / or maintain the desired process conditions within the process volume during, for example, a production cycle and / or other operational phases such such as cleaning and / or sterilization.
[0021] In some embodiments, both the vacuum chamber and the drum contribute to provide the desired process conditions in the process volume. The drum can be adapted to assist in establishing and / or maintaining the desired process conditions. For example, one or more means of cooling and / or heating can be provided in and / or in association with the drum for heating and / or cooling the process volume.
[0022] The freeze dryer modalities designed for the production of particles under closed conditions include one or more means to feed the frozen particles in the freeze dryer under sterile conditions and / or containment conditions and / or include one or more means for discharge the freeze-dried particles under sterile conditions and / or freeze dryer containment conditions. Such unloading / loading means may comprise gates, doors, transfer sections and the like.
[0023] In accordance with various embodiments of the invention, the vacuum chamber comprises the internal wall surface of controllable temperature. In this regard, the vacuum chamber comprises a housing which is at least partly provided with a double wall. In variants of these modalities, the vacuum chamber is adapted for cooling the inner wall surface while loading the drum with the particles. Additionally or alternatively, the vacuum chamber is adapted for heating the inner wall surface in each, or both, between a freeze drying process and a sterilization process.
[0024] According to various embodiments of the invention, the drum comprises an internal wall surface of controllable temperature. In that regard, the drum comprises a housing which is at least partly provided with a double wall. In certain variations of these modalities, the drum is adapted for heating an internal wall surface during the freeze drying process. Additionally or alternatively, the drum can be adapted for additional cooling of a wall, for example, an inner wall surface, to assist in cooling the process volume through the inner wall of the vacuum chamber while loading the drum with the particles .
[0025] The modalities of the invention contemplate the use of additional or alternative means to supply heat to the particles during a lyophilization process. According to the particular modalities, microwave heating can be used. One or more magnetrons can be provided to generate microwaves which are preferably coupled to the drum by means of waveguides such as, for example, one or more metallic tubes. According to a particular embodiment, a magnetron is supplied in association with the vacuum chamber. A stationary metal tube with a diameter in the range, for example, about 10 cm to 15 cm, guides the microwaves from the magnetron through the vacuum chamber into the drum. Preferably, the waveguide enters the drum through an opening in the front plate (or back plate) of the same, for example, through a loading / filling opening.
[0026] According to other modalities, multiple magnetrons and / or waveguides can be used. It is contemplated that, if alternative heating mechanisms such as microwave heating are employed, heating mechanisms for heating one or both of an inner wall of the drum and an inner wall of the vacuum chamber are optional; however, the particular modes of a freeze dryer according to the invention offer several / alternative heating mechanisms such as, for example, heatable inner walls of the drum and / or the vacuum chamber and microwave heating for flexible use of according to different desired process regimes.
[0027] When using microwave heating, the waveguide and / or the magnetron can be hermetically separated from the process volume, for example, by a sealed microwave barrier.
[0028] In some embodiments of the invention, at least one of the components of the vacuum chamber and / or the rotating drum are arranged to be self-draining in relation to one or more of the cleaning and / or sterilization processes. One embodiment of the invention comprises a drum arranged to be tilted or tilted for one or more of the liquid drain (s) cleaning steps in the cleaning process, liquid drain (s) and / or condensate (s) in a process. sterilization process and / or product discharge after a freeze drying process. In addition or alternatively, the vacuum chamber can be arranged to be tilted or tilted for one or more of the liquid drain cleaning steps (s) in the cleaning and / or liquid drainage and / or condensate sterilization process (s) in a sterilization process. In some variants of these modalities, the vacuum chamber is adapted for draining liquids / condensates in a connection tube that connects the vacuum chamber to a condenser. In some embodiments, the drum and chamber are arranged at mutually opposite slopes.
[0029] According to various modalities, the freeze dryer is adapted to directly discharge the product into the vacuum chamber in a final container under closed conditions. The freeze dryer can be adapted for anchoring / undocking a container such as a filling container and / or the freeze dryer can be adapted to receive the container; for example, the vacuum chamber can be adapted to receive one or more containers for filling, i.e., discharging dry particles from the drum.
[0030] According to various modalities of the invention, at least one of the vacuum chamber and the drum is adapted for Cleaning in Place ("CiP") and / or Sterilization in Place ("SiP"). In particular, one or both of the vacuum chamber and the drum can be adapted for steam-based SiP. In some embodiments of the invention, one or more access points are provided on an outer drum wall surface to direct cleaning and / or sterilizing means over the inner wall surface of the vacuum chamber. In addition or alternatively, access points may be provided on the inner wall surface of the vacuum chamber to direct a means of cleaning and / or sterilizing over the outer wall surface of the drum and / or into the drum.
[0031] According to a further aspect of the invention, a process line for the production of freeze-dried particles under closed conditions is provided, wherein the process line comprises a freeze dryer as outlined in the present invention. According to various embodiments of this aspect of the invention, at least one transfer section is provided for a product transfer between a separate device and the freeze dryer, wherein each of the freeze dryer and the transfer section is separately adapted for closed operation. This implies that the freeze dryer and / or the transfer section can be individually adapted or optimized for closed operation. For example, the freeze dryer (its vacuum chamber) can be individually adapted for sterile operation and, independently of it, the transfer section can be individually adapted to protect a sterile product flow. In specific embodiments, the transfer section is adapted to protect sterility and / or maintain containment along a flow of product that extends through the transfer section to the rotating drum or out of the rotating drum / vacuum chamber of the freeze dryer.
[0032] In certain embodiments, the transfer section can be permanently mechanically mounted in the vacuum chamber (according to other modalities, a transfer section is mechanically mounted separably in the vacuum chamber). For example, the transfer section may comprise a structure provided with a double wall, in which the outer wall is a confinement wall that hermetically isolates the internal "process volume" from the transfer section of an environment, and the outer wall is mounted in the vacuum chamber to ensure airtight connection to the freeze dryer. An inner wall of the transfer section can form, for example, a guide means such as a tube to guide a flow of product into or out of the freeze dryer, for example, a rotating drum of the freeze dryer. The internal wall of the transfer section does not need to be engaged with the vacuum chamber and / or the freezing dryer rotating drum. For example, as the drum is in open communication with the vacuum chamber, the drum can be provided with an opening for a guide means of the transfer section that extends into the drum.
[0033] In a specific embodiment, a first transfer section is provided for a product transfer from a separate process device line for the production of frozen particles to the freeze dryer. The first transfer section may comprise a loading funnel that projects into the open drum without engaging it. Additionally or alternatively, a second transfer section can be provided for transferring product from the freeze dryer to a device separate from the process line to discharge the freeze-dried particles.
[0034] In variants of the invention, the freeze dryer comprises at least one discharge guide means for guiding the freeze-dried particles to be discharged from the open drum through the vacuum chamber to the second transfer section indicated above. Such a guide means can be arranged inside the drum and / or outside the drum inside the vacuum chamber. When disposed within the drum, a part or all of the guide means can be adapted to mix the bulk product when the drum is rotated in a rotational direction and to serve a discharge when the drum is rotated in another rotational direction.
[0035] One or more transfer sections of the device can be adapted for gravity transfer of the product (and / or other driving mechanisms, such as wart-based, pressure-based, pneumatic mechanisms). Generally, a transfer section for product transfer between devices separate from the process line under closed conditions incorporates more functionality than a simple guide means such as a tube or funnel. In a first aspect, the specific process conditions can be maintained along the flow path, for example, in relation to a desired temperature and, in a second aspect, the product transfer is conducted under closed conditions, for example, at transfer section can be adapted to protect sterility. Similarly, a transfer section for product transfer between devices separated from the process line under closed conditions incorporates more functions / functionality than an insulator comprising one or more simple guide means such as a tube or funnel, since a conventional insulator is not typically adapted to maintain specific process conditions. Specifically, in typical configurations seen in the field, the walls of an insulator provide airtight closure of a enclosed volume, but are not adapted to maintain desired process conditions within the volume.
[0036] The modalities of a transfer section according to the invention may comprise an internal wall surface of controllable temperature. For example, in cases where the transfer section comprises a double wall, as exemplified above, an inner surface of an outer wall or an inner surface of an inner wall that forms a guide medium such as a tube or funnel for a flow of product can be designed or modified to have controllable temperature. In certain embodiments of a process line comprising multiple transfer sections, one or more of the transfer sections are adapted for active temperature control, while one or more other transfer sections are not. For example, a transfer section provided for discharging freeze-dried particles from the freeze dryer may not be specifically adapted for active temperature control, since the particles after drying do not normally need specific cooling, whereas the transfer section that guides the frozen particles to freeze dryer drying can be adapted for active temperature control, in particular cooling, in order to provide ideal process conditions and thereby prevent or delay the development of undesired product characteristics , for example, agglomeration of frozen particles.
[0037] A transfer section according to the invention may comprise a valve or similar sealing / separating means for sealingly separating the freeze dryer from the other devices of the process line. The freeze dryer can be adapted for separate closed operating conditions which include, but are not limited to, freeze drying of particle and cleaning and / or sterilizing the freeze dryer. For example, in the case of a separate freeze drying operation performed under separation from other process devices, the freeze dryer may require dedicated equipment to control process conditions such as pressure. In these embodiments, dedicated equipment may include, but is not limited to, one or more vacuum pumps, which are not separated by sealing one or more transfer sections that guide the product flow in and / or out freeze dryer.
[0038] In accordance with still other embodiments of the invention, a process is provided for the bulk production of freeze-dried particles under closed conditions, in which the process is carried out using a freeze dryer as outlined and understood in the present invention. The process can comprise at least the following steps: 1) loading the frozen particles into a freeze dryer drum; 2) freeze drying the particles in the rotating drum that is in open communication with a freeze dryer vacuum chamber; and 3) freeze particles from the dryer. The vacuum chamber of the freeze dryer can be operated under closed conditions during the processing of the particles.
[0039] The process may additionally comprise one or more steps of controlling the temperature of an inner wall surface of at least one of a vacuum chamber and the drum. In some embodiments, the drum is rotated not only in the drying step, but also in the loading step. According to variants of these modalities, the drum is rotated in the loading step with an altered rotational speed, for example, slower, compared to the drying step. Advantages of the Invention
[0040] The invention provides among other design and modification concepts for devices for the production of freeze-dried bulk particles under closed conditions. Regarding the handling of the sterile product, the present freeze dryer can be operated in a non-sterile environment without the need for an additional insulator. The added complexity and costs related to the use of an insulator can therefore be avoided while product sterility is still provided in accordance with, for example, the requirements of Product Manufacturing Practice ("GMP"). According to certain embodiments, a limit is provided by the vacuum chamber of the dryer by inventive freezing, such as a confining wall that confines or defines the process volume. The limit can be adapted to function as a conventional insulator and / or to contribute to the establishment or maintenance of desired process conditions in the process volume, such as establishing and maintaining a desired temperature regime, pressure regime, etc.
[0041] In preferred embodiments, an insulator is not required to provide operation under closed conditions with the freeze dryer according to the invention. Consequently, in these embodiments, conventional insulators as typically employed in the field are not suitable for implanting a freeze dryer and / or process line in accordance with the design principles of the present invention. In contrast to conventional designs, for example, a means of insulating an insulator (for example, an insulating wall thereof) would have to be adapted not only to provide insulation or airtight separation between an interior and an exterior, but it would also have at least to be adapted to contribute to the control of desired process conditions in the interior.
[0042] More specifically, in conventional freeze-drying process lines after the initial establishment of sterile conditions inside the insulator (for example, according to GMP requirements), the operator needs to confirm every hour or every few hours that the sterility is actually being maintained inside the insulator. This situation requires the use of expensive sensor equipment and monitoring procedures. As described in the present invention, the present invention avoids these expensive equipment requirements and monitoring procedures. Consequently, in particularly preferred embodiments, production costs are considerably reduced compared to conventional freeze dryer / freeze drying process lines that employ insulators. Similar cost reductions can be made in relation to containment requirements in freeze drying processes.
[0043] According to another example, the confinement wall or similar process volume that defines the means of the vacuum chamber is designed in order to avoid, as much as possible, the critical areas particularly prone to contamination or pollution. In preferred embodiments, the vacuum chamber and / or drum are specifically adapted for efficient cleaning and / or sterilization. In a conventional freeze-drying scenario, it is not plausible that the insulator and an external surface of the processing equipment disposed within the insulator is specifically designed in this regard.
[0044] The housing / vacuum chamber can be seen as being particularly dedicated to providing a process volume and an isolation or separation medium for the process volume of the environment, while the drum can be seen as being particularly dedicated to providing a efficient sublimation of water vapor from the particles. Such separation of tasks allows separate optimization of tasks and reduces potential interference. Since the functions of supplying process conditions and sterility / containment can be separated in part or entirely from the drum, the rotation capacity of the drum can be ignored when optimizing these functions. This simplifies the design of the drum design and, in this way, eventually allows the wide application of drum-based freeze dryers. For example, considering a case in which the rotating drum for receiving the particles is in open communication with a housing chamber (vacuum chamber). Process conditions, within the process volume, can be set / maintained by the stationary chamber instead of the rotating drum. This simplifies the design in relation to process control media such as heating / cooling equipment, heating / cooling media and / or equipment to provide pressure (vacuum) conditions for the process volume. In one example, the need to couple a stationary vacuum pump to the rotating drum by a complex sealing means is avoided, since the pump only needs to be coupled to the stationary chamber.
[0045] As an additional example, the supply of the drum in open connection with the chamber simplifies the loading of the rotating drum with the particles. A complex sealing means for stationary equipment, for example, loading hoppers, which extends to the rotatable drum is not required.
[0046] Although the present invention is not intended to be limited to any mechanism, the use of a rotary drum for particle drying increases the effective product surface which, in turn, accelerates the mass and heat transfer compared to drying of particles at rest (considering, for example, bottle-based drying or conventional bulk drying in stationary trays). More specifically, in cases of freeze drying in a bottle, the increased availability of the product surface provided by the rotational movement of the drum allows for more efficient mass and heat transfer compared to what is seen in product bottle drying. For example, due to the increased product surface, the transfer of mass and heat does not need to occur through the frozen product, due to fewer layers of material that slow down a diffusion of water vapor compared to drying in flasks. In addition, no stop is present to hinder the release and removal of water vapor. With bulk drying, the need to load and unload bottles disappears, which in turn leads to a simplified design and / or increased flexibility options for the freeze dryer. As the filling step can be performed after freeze drying, vials, stops, containers, specific IBCs ("Intermediate Box Containers"), etc. are generally not required. Bulk drum-based drying can lead to more homogeneous drying conditions for the entire batch.
[0047] One or both of the vacuum chamber and the drum may comprise a temperature-controllable wall. This feature allows for efficient temperature control for operation under closed conditions and can prevent or reduce the use of other cooling / heating means, such as equipment to provide a dry, cold, and typically sterile gas flow through the process volume. and / or heating equipment such as radiators, heating plates, etc., within the process volume. This feature is designed to reduce the complexity and costs of the freeze dryer and / or the process line in which the freeze dryer can be used.
[0048] Various embodiments of the invention can be flexibly provided with one or more heating mechanisms. For example, for heating particles during lyophilization, in addition to or as an alternative to the heated drum and / or vacuum chamber walls, microwave heating (and / or other heating mechanisms) could be provided. It should be noted that microwave heating approaches often face the problem of microwave field inhomogeneities that can occur on wavelength scales, for example, on scales from about 10 cm to 15 cm. These scales are larger than the particle sizes (at or below centimeter scales) and therefore can result in some particles receiving excessive energy transfer and overheating, melting and even burning while the particles receive very little of a heat transfer with the result of having the sublimation delayed.
[0049] A measure to overcome the problem of inhomogeneity can be to supply multiple magnetrons and / or multiple waveguides that reach the interior of the freeze-drying cavity, for example the drum (or the vacuum chamber). However, according to specific embodiments of the invention, a single magnetron and a single waveguide to guide the microwaves to the drum through, for example, a front opening of the drum (for example, the loading opening) is sufficient . Without intending to stick to any theory, the impact of field inhomogeneities within the drum can be minimized compared to stationary freeze-drying particles (for example, bottle-based drying and / or tray-based drying , which includes vibrated drying), since the drum-based drying of the particles is in permanent motion due to the rotation of the drum. As soon as the trajectories of the particles in the microwave field are at least in the order of the microwave wavelength, a general and substantially uniform particle heating occurs.
[0050] Generally, the freeze dryer modalities according to the invention can be flexibly customized to specific process requirements, for example, desired process regimes. Depending on the details of one or more process regimes that you want to run through the device, it may be sufficient to provide only one of the chamber or the drum with a wall of controllable temperature. In other applications, for example, in cases where the freeze dryer is intended to be used for a wide range of process regimes, both the drum and the chamber can be equipped with controllable temperature walls. In one example, the drum can be configured to provide additional or supplementary temperature control over that provided by the chamber.
[0051] Temperature control may include applying cooling, for example, before and / or during the loading of the drum with the particles. In addition or alternatively, temperature control may include applying heating, for example, during the lyophilization process and / or during a supplementary process such as sterilization.
[0052] Providing the chamber and / or the drum with a heating medium for heating a wall, for example, an inner wall (optionally an outer wall of the drum) provides several advantages, such as reduced mechanical stresses and / or shortened transition times for transition from one operational mode to another (for example, transition from freeze drying to cleaning and / or sterilization mode). Such transitions may involve hot steam applied to structures maintained during drying at temperatures around, for example, -60 ° C. The heating of, for example, inner walls of the chamber and / or the drum allows for the smooth adaptation of presently cold structures before applying steam to it and, thereby, allows to considerably shorten the time scales in comparison with passive heating after termination of the drying process. Similarly, an active cooling medium can considerably shorten cooling times after a cleaning process and / or a sterilization process that involves high temperatures. According to a specific example, a passive cooling time for a given configuration can be from 6 to 12 hours, which can be shortened to around 1 hour (or less) by active cooling of, for example, one or more chamber and / or drum walls.
[0053] The structural entities referred to in the present invention as transfer sections are described in the present invention as an option to provide the transfer of particles to the interior and / or exterior of the dryer by freezing under closed conditions, that is, under protection sterility and / or provision of containment conditions. A design approach that includes such entities allows for flexibility when integrating the freeze dryer with additional separate devices on a process line. A transfer section can provide: 1) isolation from an environment, that is, provide closed conditions; 2) desired process conditions, for example, through cooling; and 3) guide the flow of the product from one device to another. These (and other) tasks can be performed by different components of a transfer section. For example, a double-walled transfer section may comprise an airtight outer wall to provide closed conditions, which can be correspondingly connected to an outer wall of the vacuum chamber, while an inner wall of the transfer section comprises a funnel, tube , tubing or similar guide medium for the particles. The guide means can extend through the chamber wall or walls to the drum, with or without engagement with the drum. The assignment of tasks to different structural components in the freeze dryer and / or the transfer section in this way allows for a simplified and yet efficient design.
[0054] As the process volume is supplied mainly by the freeze dryer housing (vacuum) chamber, the freeze dryer devices according to the modalities of the invention can be flexibly adapted to one or more of the various types of cooling installations. unloading and unloading containers, in which the dry particles are filled. After unloading the particles from the drum, the particles can be filled directly under closed conditions provided by the chamber in the containers received in or anchored in the chamber. Alternatively, a transfer section can be provided to guide the particles through a separate product handling section for discharge and / or other product handling operations. The guide means for guiding the product flow from the drum to the containers and / or the transfer section can be flexibly provided within the process volume covered by the closed conditions provided by the stationary chamber.
The freeze dryer according to the invention can generally be used for drying a wide spectrum of particles such as granules or pellets of different sizes and / or size ranges. The freeze dryer according to the invention can be flexibly operated in a batch mode, for example, for freeze drying a batch of particles and / or can be operated in a continuous mode, for example, during a loading, the freeze dryer can continuously receive frozen particles from an upstream particle generation device, prevent the agglomeration of the received particles and provide appropriate cooling. This is just an illustration of the flexibility provided by one or more of the modalities of the present invention.
[0056] At least one of the chamber and the drum can be adapted for CiP and / or SiP, which simplifies cleaning and / or sterilization and contributes to short maintenance times between production cycles, etc. In that regard, the freeze dryer according to the invention can be specifically adapted for efficient cleaning / sterilization. For example, the drum, chamber, or both can be tilted for cleaning and / or sterilization by draining liquids and / or condensates from the respective devices. In certain embodiments, an opening in the confining wall of the process volume can be reused for drainage, for example, an opening for a connection to the condenser, thereby providing a simple yet efficient design.
[0057] Generally, the complete capacity for CiP / SiP allows a freeze dryer design in which the process volume can be kept permanently and hermetically sealed, that is, integrated, by simple means such as welded or bolted connections, which it allows a cost-effective design and good performance compared to devices that require manual intervention and / or disassembly for, for example, cleaning and / or sterilization purposes and are, therefore, correspondingly restricted in their design. Brief Description of the Figures
[0058] The additional aspects and advantages of the invention will become evident from the following description of particular modalities illustrated in the figures, in which:
[0059] Figure 1 is a schematic illustration of a first embodiment of a freeze dryer according to the invention;
[0060] Figure 2 is a schematic illustration of a second embodiment of a freeze dryer in a side view;
[0061] Figure 3 is a schematic cross-sectional view illustrating details of the freeze dryer of Figure 2;
[0062] Figure 4 illustrates the details of the vacuum chamber and the freeze dryer drum of Figure 3;
[0063] Figure 5 illustrates in part a process line comprising a freeze dryer according to the invention;
[0064] Figure 6 is a cross-sectional view of a third embodiment of a freeze dryer according to the invention; and
[0065] Figure 7 is a flow chart illustrating an operation of the freeze dryer of Figures 2, 3. Detailed Description of Preferred Arrangements
[0066] Figure 1 schematically illustrates the components of mode 100 of a freeze dryer, in which an assignment of functions to the components and their interconnected operation is indicated. The freeze dryer 100 can be used in a process line for the bulk production of freeze-dried particles under closed conditions. The freeze dryer 100 comprises a housing chamber 102 and a drum 104 and is connected with transfer sections 106 and 108 for a transfer of product P / 110 into and out of a process volume 112, respectively.
[0067] The task 114 of the housing chamber 102 consists of defining the process volume 112 and establishing / maintaining the process conditions such as pressure, temperature, humidity, etc., within desired values within the process volume 112 , which includes the housing chamber 102 which is equipped with means to control the appropriate process parameters accordingly in order to provide a desired process regime for volume 112 in a well-defined, reliable and repeatable manner.
[0068] In one embodiment, the housing chamber 102 is adapted to provide vacuum conditions for process volume 112, in which the "vacuum" is understood to denote a low pressure or an under pressure below an atmospheric pressure, as is known for the element skilled in the art. The vacuum conditions as used in the present invention can mean a pressure as low as 1 KPa (10 millibar), 0.1 KPa (1 millibar), 50 Pa (500 microbar) or 0.1 Pa (1 microbar). It should be noted that lyophilization can generally be carried out under different pressure regimes and can, for example, be carried out under atmospheric pressure. Many of the freeze dryer configurations described in the present invention, however, include a housing chamber that houses a rotating drum, in which the housing chamber is implanted as a vacuum chamber, since lyophilization can be efficiently carried out under vacuum. Therefore, the housing chamber 102 in Figure 1 is later denoted in the present invention as being a "vacuum chamber", although it is understood that a vacuum chamber is only one embodiment of a general housing chamber that can be considered suitable for implement the design concepts discussed in the present invention.
[0069] Generally, the housing (vacuum) chamber 102 operates to establish or maintain pre-defined process conditions in the process volume 112 by applying process parameters of the control of the same generally indicated as function block 114 in Figure 1 In reference to a "vacuum" process condition, the condition can be established / maintained by controlling equipment associated with vacuum chamber 102, such as a vacuum pump, according to the appropriate control parameters, where it can be there is some regulation of feedback from process conditions as measured in or in association with process volume 112 in order to define the process control parameters accordingly. The illustration of the optional sensor circuitry as well as the feedback regulation circuitry is omitted from Figure 1. A vacuum pump is just one of a plurality of equipment devices that could possibly be applied in or in association with the vacuum chamber 102 in Figure 1, however, the vacuum pump is also omitted from the figure for clarity.
[0070] In relation to a "temperature" process condition within process volume 112, in preferred embodiments, the temperature control means (heating and / or cooling) are provided in association with the vacuum chamber 102. The means Suitable temperature control systems may include the application of a cooling medium, heating medium, radiation heat (where the radiation can be microwave radiation, for example), electric heat, etc. to process volume 112, indirectly through an inner wall surface of vacuum chamber 102 and / or directly through application to the interior of vacuum chamber 102 (i.e., process volume 112). For example, the heating energy can be radiated directly into the process volume. The appropriate parametric control of heating and / or cooling means is preferably in function block 114.
[0071] In relation to a "moisture" process condition, that is, a water vapor content of process volume 112, a condenser can be provided (omitted in Figure 1) in association with vacuum chamber 102, that is is, in temporary or permanent communication with the process volume 112. For example, during a production cycle (ie, a drying of the "P" particles), in order to establish and maintain a process condition of a pre-value set to humidity in volume 112, one or more of process parameters 114 may be related to the operation of the condenser.
[0072] The tasks illustrated within box 114 in Figure 1 may refer not only to a vacuum chamber operation 102 during freeze drying, but also to other processes / operational modes. For example, the freeze dryer 100 can be operated in a loading or filling mode, in which the P particles are guided almost continuously from an upstream particle generator (for example, a spray freezer, tower granulation, etc.) through the transfer section 106 to the freeze dryer 100. The product therefore flows with the particle generation rate to the freeze dryer, that is, drum 104 is loaded with the particle generation. In the loading mode, the process conditions may comprise a similar pressure as in the upstream particle generator and / or may comprise a pressure in the order of an atmospheric pressure (and / or a pressure in the transfer section 106). A temperature in the process volume 112 can also be controlled similarly to a temperature in the particle generator (and / or a temperature in the transfer section 106). Depending on the details of the particle generation, in the loading mode, a humidity of the process volume 112 may or may not be actively controlled.
[0073] Functions 114 may additionally comprise the control of process parameters for a cleaning mode and / or a sterilization mode. In one embodiment, the freeze dryer 100 is equipped with one or more means such as cleaning / sterilization access points (for example, nozzles, heads with multiple nozzles, etc.) as well as one or more drainage means for implanting CiP and / or SiP for the vacuum chamber 102. It should be noted that such access points need not necessarily be arranged directly in the vacuum chamber; for example, means for directing a cleaning / sterilizing medium to structures such as an inner wall of vacuum chamber 102 can be arranged in association with drum 104 housed in chamber 102. Control of parameters related to the flow of cleaning medium / sterilization for access points can be part of functions 114. Similarly, the parameters related to the pressure control and / or temperature control means discussed above can also be actively controlled in the cleaning / sterilization mode and / or in a transition mode for the transition from one of the modes discussed above to another. For example, cooling the vacuum chamber after cleaning / sterilizing and / or heating the chamber 102 after a drying process can optionally be shortened by active temperature control.
[0074] It should be understood that functions 114 preferably include, but do not require, the execution of predetermined control schemes, procedures or programs that implement a specific process regime or processing through the definition of time sequences for parameters of relevant control.
[0075] In addition to the role or the task (task set, function block) 114 of controlling the process conditions in volume 112 in various operational modes, the vacuum chamber 102 has also associated with this the role 116 of separating or isolating the process volume 112 of an environment 118 of the volume 112. The functions related to task 116 can refer to at least one among protecting a sterility condition within the process volume 112 (which includes or not the P particles, for example, after or before loading) and provide containment into chamber 102, that is, to prevent any transfer of material from process volume 112 to environment 118, be it solid, liquid, gaseous, (drug) product or excipients, pollution or friction. In order to deploy task 116, chamber 102 may comprise a partially or completely hermetically closed wall 120. Wall 120 may essentially define process volume 112 as inside or within it. The wall 120 may comprise a single wall, a double wall or a combination thereof.
[0076] For example, in certain embodiments, the wall 120 is hermetically closed with a minimum of well-defined openings for a transfer of matter and internal energy into and out of the process volume 112 as well as mechanical support for structures facing the process volume 112. The openings in the wall 120 may comprise multiple transfer sections 106 and 108, the cleaning / sterilization medium access points mentioned above, one or more drain openings to remove cleaning and / or sterilization remnants and openings sensor. Function block 116 may comprise active control of valves and / or other sealing means arranged in or in association with one or more of the above openings and may also comprise functions related to the determination / capture if the desired closed conditions are, in fact, , established or maintained within process volume 112.
[0077] Turning to drum 104 and the various functions described above, it is observed that drum 104, in preferred modes, can be loaded with P particles in a loading mode in which certain modalities of it have already been discussed above. The particles can be loaded and held in the rotating drum 104 during a drying mode and subsequently unloaded from the drum / unloaded from the freeze dryer 100 in an unload / unload mode. Consequently, one of the tasks (roles, function blocks) assigned to drum 104 is task 122 of receiving and loading the particles P transferred to the freeze dryer 100 via transfer section 106. Task 122 can, for example, be achieved by an appropriate drum design to receive and maintain the desired amount of particles. In addition, a slope of the drum can be actively controlled to allow one or more of loading, drying and unloading. For example, drum 104 can be tilted from a general predefined position to discharge the particles and can later be moved back to the predefined position. The active functions of paper 122 may also comprise capturing bulk properties which include detecting a level of loading and / or detecting a degree of particle agglomeration as well as capturing particle properties such as temperature or humidity.
[0078] Function block 124 in Figure 1 illustrates that drum 104 may further comprise or be equipped with one or more means to assist in controlling process conditions in process volume 112 during one or more of the various operating modes of the dryer by freezing 100. In principle, the control of process conditions can be attributed to one or both of the vacuum chamber 102 and the drum 104, since both are in direct contact with the process volume 112. However, it is contemplated that for many applications, the vacuum chamber 102 can take most of the process condition control (function block 114) while the assisting drum 104 (function block 124), if required, as process parameter control equipment correspondent can generally be preferably arranged in or in association with the stationary chamber instead of the cost-effective rotating design drum.
[0079] The additional process condition control functions 124 can therefore be seen as optional. For example, the rotating drum 104 can optionally be equipped with means to control pressure or humidity in process volume 112. In this regard, it is noted that the internal volume of drum 126 can be maintained in permanent communication with the external volume 128 (both volumes 126 and 128 are understood to form process volume 112) in relation to the transfer of material and energy in such a way that, for example, pressure, temperature and humidity conditions generally balance in volumes 126 and 128 Although the present invention is not limited to any particular mechanisms or theories of operation, it is contemplated that, in principle, maintaining the drum and chamber in open communication would not hinder pressure and / or humidity control through the drum, however , this may not generally be a preferred option.
[0080] Task 124 may comprise a (supplementary) temperature control within process volume 112. For example, in some embodiments, one or more means of heating and / or cooling may be arranged in or otherwise associated with to the drum 104 in order to assist the corresponding temperature control means (function 114) of the vacuum chamber 102. For example, the heating medium can be provided to assist in heating the process volume 112 and / or the particles P and / or cooling means can be provided for additional cooling during a loading phase. It is contemplated that the temperature control means in the drum 104 can replace the corresponding means in the chamber 102.
[0081] The support for efficient drying of particles P is indicated as an extra paper 130 of drum 104 in Figure 1. In this regard, it is observed that one or more advantages related to the principles of design as discussed in the present invention can also be achieved through the use of a particle carrier comprising one or more stationary or vibrating trays to receive particles filled in bottles or as in bulk. However, an optional design option is considered with a view on efficiency in terms of drying times, drying results, production costs, etc., employing a rotating drum as the particle carrier. For this reason, component 104 is called drum 104, although it is understood that, in general, other particle carriers may additionally or alternatively be employed depending on circumstances such as, for example, batch size, drying time and efficiency desired drying time and permissible moisture content of the particles after drying, etc.
[0082] Additional examples of functions included in task 130 comprise that the drum can be specifically adapted to support a large surface area of the product during drying, which may include an appropriate rotation speed of the drum as well as additional measures that support a revolution and efficient mixing of the particles. In this respect, typical rotation speeds during a freeze-drying process include, but are not limited to, between about 0.5 to 10 revolutions per minute (rpm), preferably between 1 to 8 rpm, while the speed rotational speed during loading in a mode can be set around 0.5 rpm.
[0083] As an additional example, a control function refers to maintaining the high product surface area by preventing particle agglomeration during loading, which, in turn, can be achieved, for example, through maintenance drum 104 in rotation (slow) during loading. The control of process conditions according to paper 124 is also contemplated for additionally supporting efficient drying. Therefore, some measures can be arbitrarily attributed to one or the other tasks 124 and 130; this may refer, for example, to the application of heat to drum volume 126.
[0084] It should be noted that any function related to providing closed conditions for process volume 112, such as protecting the sterility of particles P is preferably assigned to chamber 102 with paper 116. Such assignments allow drum 104 to be designed to be in open communication with the camera 102 with the corresponding advantages discussed in the present invention.
[0085] Transfer sections 106 and 108 have assigned tasks 132 and 134, respectively, to provide a transfer of particles into and out of process volume 112 under closed conditions, that is, under sterility protection and / or containment. Tasks 132 and 134 can comprise functions similar to what has been described in relation to task 116 of vacuum chamber 102. For example, transfer sections 106 and 108 can be designed to provide an airtight separation between an interior 107 and 109 of sections 106 and 108 and an environment such as environment 118 in order to protect sterility and / or containment. The interiors 107 and 109 can then be additionally adapted to tasks 136 and 138 of conducting the product and guiding the product flow into / out of the process volume 112. The provision of closed condition for a separate operation of the dryer by freezing 100 can also belong to tasks 132 and 134, which can be implanted by one or more sealing means adapted to establish a tight seal of the interiors 107 and 109 of transfer sections 106 and 108, resulting in a cut of any flow of product and, in addition, prevent any transfer of material into or out of process volume 112 along interiors 107 and 109.
[0086] Transfer sections 106 and 108 can optionally also be assigned to a task 140 and / or 142 of applying "process" conditions appropriate to interiors 107 and 109 of sections 106 and 108. For example, according to task 140, the transfer section 106 can be adapted to control an interior temperature 107 by means of appropriate cooling means. For transfer section 108, an active cooling mechanism may no longer be required in such a way that task 142 may not comprise temperature control functions. With respect to a cleaning / sterilization process, tasks 140 and 142 may comprise applying a cleaning / sterilization medium to interiors 107 and 109 through appropriate piping and cleaning / sterilization medium access points. Similar control functions can also be included in papers 114 and 124 for the chamber and drum, respectively, which makes the freeze dryer 100 to have viability for CiP / SiP.
[0087] It should generally be understood that part or all of, for example, tasks 114, 124, 140 and 142 can be performed through the execution of pre-defined control schemes, procedures or programs that specify the timing sequences for triggering relevant control parameters, thereby implementing a specific desired process regime.
[0088] Figure 2 is a side view of an embodiment 200 of a freeze dryer comprising a vacuum chamber 202 and condenser 204 interconnected by a pipe 206 equipped with valve 207 to control chamber 202 and condenser in a controlled manner 204 of each other. A vacuum pump can optionally be supplied in association with condenser 204 or tube 206. A transfer section 208 is provided to charge the freeze dryer 200 with frozen particles. The transfer section 208 can be connected or connectable in a manner associated with a device separate from a process line and / or a container or other storage device for storing particles to be processed under closed conditions.
[0089] In various embodiments, both the vacuum chamber 202 and the condenser 204 are generally cylindrical in shape. Specifically, the vacuum chamber 202 can comprise a cylindrical main section 210 terminated with cones 212 and 214, which can be permanently and fixedly mounted on the main section 210 (as shown in the example form for cone 212), or can be mounted removable mode, as shown as an example by cone 214 mounted on a plurality of screw fasteners 216 in main section 210. In some embodiments, transfer section 208 is permanently connected to end cone 214 to guide a product flow into the vacuum chamber 202 under closed conditions. Each of the main section 210 and the cone 214 of the vacuum chamber 202 comprises a port 218 and 220, respectively, for a product discharge from the vacuum chamber 202 that can be reached at least in part by gravity (optionally aided by a or more active driving mechanisms).
[0090] Figure 3 illustrates a cross-section of the freeze dryer 200 of Figure 2 showing aspects related to vacuum chamber 202 in more detail. Specifically, the chamber 202 houses a rotating drum 302, in which the rotation support of it is omitted in Figure 3 for clarity. Drum 302 is preferably generally cylindrical in shape with a cylindrical main section 304 terminated by cones 306 and 308. Drum 302 is adapted to receive frozen pellets through transfer section 208.
[0091] An opening 310 is provided in the cone 308. Through the opening 310, the internal volume 312 of the drum 302 is preferably in open communication with the external volume 314 inside the vacuum chamber 202. Therefore, the process conditions such as pressure, temperature and / or humidity tend to equalize between volumes 312 and 314; thus, even if there are differences in the process conditions between both volumes in an ongoing process, for example, due to the heating applied only inside or just outside the drum, where volumes 312 and 314 can be understood as forming the volume process 316 of chamber 202.
[0092] Similarly, as described in reference to the high level modality 100 of Figure 1, also in the freeze dryer in modality 200 illustrated in Figures 2 and 3, the vacuum chamber 202 was assigned the task of providing closed conditions for process volume 316 confined within / defined by a wall 318 of chamber 202, that is, to protect sterility and / or provide containment in relation to an environment 320. Wall 318 is implanted as a hermetically sealed wall with any opening therein being hermetically sealed or sealable in relation to the environment 320. Tube 206 as well as condenser 204 are also hermetically sealed.
[0093] Additionally, in some embodiments, the vacuum chamber 202 is adapted to provide functions to achieve the process conditions within the process volume 316 according to a desired process regime through the control of appropriate process parameters. In this regard, the wall chamber 318 can, for example, be equipped with one or more cooling / heating means, a set of sensor circuits to capture process conditions within the process volume 316, cleaning / sterilizing means, etc. (and / or support means such as support arms to support one or more of the means mentioned above), as illustrated by connection ports 322 and 323 for corresponding piping / cabling. The wall 318 can be a single wall or it can be provided with a double wall. Regarding the control of pressure conditions, a vacuum pump to evacuate the process volume 316 to a desired under pressure may be operating through the pipe 206, but it is nevertheless also related to a vacuum chamber "equipment" 202.
[0094] In addition or alternatively, the heating medium can be supplied according to other modalities. For example, in addition to or as an alternative to the heating medium provided for heating the inner wall surfaces of the vacuum chamber 202 and / or the drum 302, a magnetron can be provided for the generation of microwave radiation, which it is then guided by a wave guide tube to the drum 302. The tube can pass through a wall of the vacuum chamber and the process volume 316 to enter, for example, the opening 310 of the drum 302. According to some modalities, the heated drum and / or vacuum chamber walls can be omitted if microwave heating is available.
[0095] In a preferred embodiment, the transfer section 208 has double walls with the outer wall 324 which provides closed conditions if desired within an inner volume 326. The outer wall 324 can be permanently connected with the wall 318 of the vacuum chamber 202 as an aspect that contributes to providing closed conditions. The inner wall 328 forms a loading funnel that extends through the inner volume 326 and into the process volume 316 of the vacuum chamber 202. As closed conditions are provided by the outer wall 324, a sterile product can be conducted through the funnel loading 328 for chamber 202.
[0096] More specifically, in certain embodiments, the loading funnel 328 projects towards the drum 302, which is therefore directly loaded through the funnel 328. The cone 308 and the opening 310 are preferably adapted in such a way that a load The desired particle size can be received and loaded into the rotating drum 302. Additionally, the adaptations of the drum 302 to carry the particles can comprise controlling an inclination of the drum 302 and can further comprise measurements as known to the skilled artisan. The opening 310 can be designed in such a way that the loading funnel 328 can extend into the drum 302 without any engagement therewith. Although the present invention is not intended to be limited to any particular mechanism, it is contemplated that none of such engagement (e.g., sealing) of the stationary funnel 328 with the rotation cone 310 is required, since it is not the drum 302, but the chamber 202 which controls the process conditions for the inner portion of the drum 312 of the process volume 316; consequently, a sealing coupling to provide the closed conditions is required only between the transfer section 208 (more precisely, its outer wall 324) and the stationary vacuum chamber 202, simplifying and / or providing more flexibility for the freeze dryer design. 200.
[0097] As drum 302 is contained in process volume 316, it can be flexibly adapted to assist in providing desired process conditions within process volume 316. Additional cooling means and / or heating means can, for example, optionally be supplied in association with the drum wall 330.
[0098] Figure 4 illustrates the wall sections 318 of the vacuum chamber 202 as well as the wall 330 of the drum 302. In the embodiment illustrated with Figure 4, the wall of the vacuum chamber 318 is a double wall comprising the outer wall 402 and the inner wall 404 with the inner wall surface 406 facing process volume 316. The inner wall surface 406 is preferably temperature controllable by one or more cooling means and heating means. Specifically, a set of cooling circuits 408 is provided which is shown in Figure 4 as comprising a pipe system 410 that extends at least part of the internal volume 403 within the double wall 318. The pipe system 410 is connected between a internal flow of the cooling medium 412 and an external flow of the cooling medium 414. Piping 410 can enter and leave the double wall 318 through one of the ports 322 already illustrated in Figure 3. Piping 410 can be externally connected with additional equipment such as a cooling medium reservoir, pumps, valves and control circuitry for cooling process volume 316 as required for a prescribed process regime. In particular, the control circuitry and / or the cooling circuitry 408 can be adapted for cooling the inner wall surface 406 during loading of the drum 302 with the particles.
[0099] In the embodiment illustrated in Figure 4, the double wall 318 is additionally equipped with a set of heating circuits 416 implanted in an exemplary manner by one or more heating coils 418 with a set of corresponding power supply circuits 420. The source of power can be optionally controlled by the set of control circuits for heating process volume 316 and 314 as required for a prescribed process regime. For example, the control circuit set and / or the heating circuit set 416 can be adapted for heating the inner wall surface 406 during a freeze drying process, a cleaning process and / or a sterilization process .
[00100] The control circuitry mentioned above may comprise circuitry 422 which includes sensor equipment 424 disposed on the inner wall 404 to capture process conditions within process volume 316 and 314 and connected via liners 426 to components remote control of the process control circuitry. Sensor equipment 424 can include, for example, sensor elements to capture conditions such as pressure, temperature and / or humidity and the like.
[00101] In preferred embodiments, sterilization equipment 428 is provided which includes tubing 429 within wall 318 (typically, for cleaning and sterilization, separate equipment can be provided, however, only one system is illustrated in Figure 4). Sterilization tubing 429 provides a supply of sterilization medium to sterilization medium access points 430, where, for example, steam can be used as a sterilization medium. Access point 430 can be implanted as a multiple nozzle head 432 with a plurality of nozzles in which some of the nozzles 434 can be directed to the inner wall surface 406 for sterilization and other nozzles 436 can be directed to a external surface 438 of wall 330 of drum 304 for sterilization thereof. A system for providing a means of cleaning the interior of the process environment 316 and 314 can be implanted in a similar manner as described here for the sterilization equipment 428.
[00102] Turning to the drum 304, the wall 330 of the same can also be implanted as a double wall with the outer surface 438 of the outer wall 440 of the same directed towards the inner wall surface 406 of the inner wall 404 of the vacuum chamber 202, while the inner wall 442, more precisely, the inner wall surface 444 thereof, defines the inner volume 312 in relation to the drum 304, which, however, is part of the common process volume 316.
[00103] Still in additional embodiments, the drum 302 may additionally comprise an internal wall surface of controllable temperature 444 as specified below. The double wall 330 can contain heating equipment 446 shown as being deployed by heating coils 448 and corresponding power supply 450 in Figure 4, which can be adapted for (for example, additional) heating of the inner wall surface 444 during a process freeze drying, cleaning process and / or sterilization process. In addition, the double wall 330 contains cooling equipment 452 which includes piping 454 to guide a cooling medium along at least portions of the interior 441 of the double wall of the drum 312. The cooling equipment 452 can be adapted for cooling (additional ) of the inner wall surface 444 facing the inner volume 312 of the drum 302 during loading of the drum 302 with the particles.
[00104] A cooling medium employed in the system 408 for cooling the inner wall surface 406 of the housing / vacuum chamber 202 may, for example, comprise, but are not limited to, nitrogen (N2) or a mixture of nitrogen / air or a brine / silicone oil mixture. In addition to or alternatively to heating equipment 416 illustrated in Figure 4, for example, heating coils as commonly known in the field can be employed for heating. In one embodiment, the temperatures of the inner wall surface of the housing / vacuum chamber are controllable within a range of about -60 ° C to + 125 ° C. A temperature control associated with drum 302 can be similarly provided. as previously discussed for housing / vacuum chamber 202. In addition or alternatively, the use of a cooling and / or gas heating medium is possible and included by the person skilled in the art. The electrical heating medium to be applied within double walls 318 and / or 330 of the housing / vacuum chamber 202 and / or drum 302 may additionally or alternatively comprise metal sheets that allow the supply of uniform heat as well as, of other mode, devices and / or materials of similar function.
[00105] The control circuitry for controlling the operation of the freeze dryer 200 may comprise sensor equipment 456 arranged on the inner wall 442 to capture the process conditions within the internal volume of the drum 312, where the equipment 456 comprises elements sensor 458 connected via sensor liners 460 to central control components of the control circuitry. The temperature probes can also optionally be provided inside the drum in proximity to the product being dried and can, for example, be provided in the main section 304 of the drum 302 and / or in the terminating cones 306 and 308.
[00106] In preferred embodiments, the double wall 330 additionally contains cleaning / sterilization equipment generally referred to as number 461. A plurality of access points for cleaning and / or sterilizing means 462 can provide such cleaning / sterilization means as steam for process volumes 316 and 314. Access point 462 can be deployed as a multi-nozzle head 464 comprising nozzles 466 directed towards the outer wall surface 438 and comprising nozzles 468 directed towards the inner wall surface 406 of the wall 318 of the vacuum chamber 202 for cleaning / sterilizing it. In addition, sterilization equipment 461 also preferably comprises heads with multiple nozzles 470 directed to the internal volume 312 and 316 in the drum 302 for cleaning / sterilizing the inner wall surface 444 of the double wall of the drum 330. One or more means of cleaning / sterilization can be conducted in any case to the access points 462 and 470 through the pipeline 472. It is observed that the nozzles 436 of the sterilization system 428 associated with the wall 318 of the vacuum chamber 202 on the one hand, and the nozzles 468 of the sterilization system 460 associated with the wall 330 of the drum 302 implant a specific aspect of a system for SiP for a freeze dryer comprising a housing chamber that houses a rotating drum.
[00107] It is generally observed that the drum 302 comprises portions of single wall and portions of double wall. For example, drum 302 may comprise single wall cones 306 and 308 (see, for example, Figure 3) and may comprise a main section provided with double wall 304.
[00108] Figure 5 illustrates an exemplary embodiment 500 of a process line that includes a freeze dryer 502 comprising a rotating drum 504 housed in a vacuum chamber 506. Various properties of the freeze dryer 506 may be similar to those of the dryer by freeze 200 illustrated in Figures 2 and 3. However, in Figure 5, transfer sections 508 and 510 are illustrated by connecting the freeze dryer 502 to process devices 512 and 514 of line 500.
[00109] In a preferred embodiment, the internal volume 516 of the drum 504 is in communication through the opening 518 with the external volume 520 confined within the double walls 522 of the vacuum chamber 506, the internal volume 516 and the external volume 520 forming the volume of process 524 of the freeze dryer 502. The wall 522 that confines the entire process volume 524 is hermetically sealed and therefore is allowed to be supplied for processing under closed conditions, that is, protection from sterility and / or containment in with respect to an environment 526 of the freeze dryer 500.
[00110] Transfer section 508 is provided to guide a flow of product from the spray chamber 512 to the freeze dryer 502, where the spray chamber 512 is an exemplary embodiment of a particle generator and is only schematically shown in Figure 5. The sprinkler chamber 512 can be incorporated as any type of sprinkler and / or granulation device known in the field that includes, for example, a sprinkler / granulation chamber, and / or tower, and / or a tunnel cooling / freezing, and the like.
[00111] The transfer section 508 preferably comprises the double wall 528 with the outer wall 530 and the inner wall 532. To guide the product flow from the spray chamber 512 to the freeze dryer 502 (similar to task 136 of Figure 1), the inner wall 532 of the double wall 528 of the transfer section 506 forms a loading funnel that extends to the drum 504 without engaging it. The outer wall 530 of the double wall 528 is adapted to provide the closed conditions (see task 132).
[00112] In order to achieve closed end-to-end conditions for the production of freeze-dried particles in process line 500, among other resources, the outer wall 530 is preferably in a hermetically sealed assembly connection with the spray chamber 512 and with the freeze dryer 502. Specifically, the outer wall 530 of the double wall 528 is mounted with the outer wall 534 of the double wall 522 of the vacuum chamber 506, where the assembly contributes to the hermetic closing of both internal volumes , that is, process volume 524 and transfer volume 536 within transfer section 508. In addition to being connected to provide comprehensive closure for the entire process line 500, it should be noted that the freeze dryer 500, section transfer devices 508 and additional devices 512, 514 / transfer sections 510 of process line 500 are separately adapted for operation under closed conditions, for example For example, by supplying the hermetically closed vacuum chamber 506 in the case of freeze dryer 500, or by supplying the hermetically closed outer wall 530 in the case of transfer section 506. The conditions closed from end to end for the line process 500 are achieved without any additional insulator.
[00113] As shown in Figure 5, transfer section 508 is adapted for gravity transfer of frozen particles from the spray chamber 512 to the freeze dryer 500. Although not shown in detail in Figure 5, the double wall 528 of transfer section 508 can be adapted to provide the desired process conditions on transfer volume 536 (see task 106 in Figure 1). For example, the inner wall 532 may comprise a temperature-controlled inner wall surface 538. Specifically and in a manner similar to what has been described in the example above for the double walls 318 and 330 of the vacuum chamber 202 and the rotating drum 302, respectively, in Figure 4, the double wall 528 may contain cooling equipment for cooling the inner wall surface 538 during at least one product transfer from the spray chamber 512 through the transfer section 508 to the freeze dryer 500, and / or may comprise heating equipment for heating the inner wall surface 538 during at least one cleaning and / or sterilization of the transfer section 508. The corresponding cooling and / or heating can also be applied in order to shorten the time scales for adapting transfer section 508 to the desired process conditions, that is, minimizing cooling times or heating required to limit mechanical stress in a transition between processes, for example, in a transition from a production process to a cleaning / sterilization process or vice versa. Similarly, as shown in Figure 4, transfer section 508 can also be adapted for CiP / SiP.
[00114] In some embodiments, transfer section 508 comprises valve 540 for reliably separating the freeze dryer 502 from the sprinkler chamber 512 configurably. In a closed state, valve 540 can provide closed conditions for both devices 502 and 512 connected to the transfer section 508, that is, the internal flow section 542 and the external flow section 543 protruding into the drum 504 are hermetically closed and therefore form a closed blind tube from the perspective of each of a process volume within the spray chamber 512 and a process volume 524 of the freeze dryer 502, respectively.
[00115] The transfer section 510 connects the freeze dryer 502 with the following discharge section 514. In short, the transfer section 510 is observed for sharing several structural, functional and design aspects as seen in transfer section 108 of the Figure 1. The transfer section 510 comprises a double wall 544 with the outer wall 546 permanently and mechanically mounted in the vacuum chamber 506 on one side and the discharge section 514 on the other side in order to provide a closed connection in this with regard to protecting sterility and / or provide containment. The inner wall 548 forms a tube into which the freeze-dried particles are guided from the process volume 524 and 520 of the freeze dryer 502 to the process volume 550 provided by the discharge section 514.
[00116] To discharge the particles from the freeze dryer 502 after terminating a freeze drying process, the freeze-dried particles can be discharged from the drum 504 according to one or more of the various techniques in the field. For example, with or without rotation in progress, the drum 504 can be tilted by the corresponding control of support stacks 552. The discharge guide means 554 schematically illustrated are provided to guide the freeze-dried particles from the opening 518 of the drum 504 through process volume 520 of vacuum chamber 504 to transfer section 510. Guide means 554 and / or inner wall 548 of transfer section 510 may comprise a tube extending to process volume 520 , optionally with an outlet / supply duct and / or hopper. In one example, the guide means may comprise a continuous structure that forms a tube in a section close to the opening 518 of the drum 504 and that forms an open conduit or channel in a section close to the opening 555 to guide the particles into the section of transfer 510.
[00117] The transfer section 510, in particular the inner wall / tube 548 is adapted for gravitational transfer of particles to the discharge section 514. The transfer section 510 also comprises a valve 560 for configurably separating process volumes 524 and 550 with each other.
[00118] One or both of the discharge section 514 and the transfer section 510 may comprise guide means 556 to guide the flow of product in containers 558 such as vials, Intermediate Box Containers ("IBCs"), etc., under closed conditions. The discharge section 514 can be further adapted to provide closed conditions for the product for processes such as filling.
[00119] In some embodiments, transfer section 510 is not adapted for cooling internal transfer volume 562, since cooling of freeze-dried particles may not be necessary. However, as discussed for transfer section 508, heating equipment and optionally also cooling equipment can, however, be provided to shorten the time periods required for temperature adaptation between different processes. The entire process line 500 can be adapted for CiP / SiP, as illustrated, by incorporating one or more access points for cleaning / sterilizing medium 564.
[00120] Figure 6 is a cross-sectional view of an additional embodiment 600 of a freeze dryer according to the invention. In these embodiments, the freeze dryer 600 comprises a vacuum chamber 602 which houses a rotating drum 604, in which the construction and functionality of these components in many respects will be similar to those previously described in other embodiments in the present invention. In contrast to modality 502 illustrated in Figure 5, the freeze dryer 600 is adapted for direct product discharge, that is, product filling in containers 606 can be carried out under closed conditions within process volume 603 inside the chamber of vacuum 602, such that the flow of bulk product 607 continues through process volume 603 and ends in containers 606.
[00121] In certain embodiments, a sterilization chamber 608 double door system can be loaded with one or more IBCs 606 through sealable door 610. Chamber 608 optionally comprises an additional sealable door 612 which opens allowing the transfer of IBCs between vacuum chamber 602 and sterilization chamber 608. After loading IBCs 606 from the environment through port 610 to chamber 608, IBCs 606 can be sterilized by means of sterilization equipment 616. After sterilization of IBCs 606 , door 612 is opened and IBCs 606 are moved to vacuum chamber 602 by means of a traction system 618. When closed, door 612 is configured to maintain sterility and / or containment for process volume 603 supplied by vacuum chamber 602.
[00122] In some embodiments, the rotating drum 604 can be tiltable and / or can be equipped with a schematically indicated peripheral opening 620 that can be controllable for opening for unloading a batch of product after drying. The traction system 618 can then move filled IBCs 606 back into chamber 608 to the appropriate sterile seal for IBCs 606 before discharging them from chamber 608. Proper sealing of filled IBCs 606 can also be performed alternatively in the vacuum chamber 602.
[00123] The additional modalities also provide one or more means to sterilize the IBCs 606 inside the vacuum chamber 602, which can then, for example, be sterilized before the start of a production cycle and by establishing sterile conditions within process volume 603. Such a configuration can be advantageous in the case where the containers required to receive the entire production cycle can be stored entirely within the vacuum chamber before the beginning of the cycle, that is, before the establishment of closed conditions. This could require that one or more means be provided within the process volume established by the vacuum chamber 602 for sealing the containers after filling under continuous closed conditions, for example, within the process volume. While this can have the added cost of complexity for the freeze dryer, on the other hand, you can save extra devices by direct-discharging and / or save one or more insulators for discharge and filling. The general advantages of using the process volume provided by the housing chamber (vacuum chamber) for direct discharge / filling, depend on the chamber that is adapted to control the desired process conditions in any way.
[00124] In yet another modality, the process line comprises an anchoring installation arranged in the housing / vacuum chamber for final containers. For example, such an anchoring facility is deployed as a modified transfer section such as the 508 and 510 illustrated in Figure 5. The containers are anchored directly over a discharge tube that projects into and / or out of the chamber housing (vacuum chamber). In this regard, only the sterility of the interior of the containers needs to be ensured in advance of filling. Sterility needs to be maintained while the containers are in the anchored state, that is, from the anchorage to the undocking / sealing of the containers.
[00125] In relation to the cleaning / sterilization of a freeze dryer according to the invention and in that respect referring again to Figure 2, the freeze dryer 200 illustrated therein is arranged in table 222 through support structures 224. The Table 222 provides a tilt angle 226 of the freeze dryer 200 with respect to a horizontal orientation. A non-evanescent tilt of chamber 202 and / or condenser 204 can, for example, be used to implement a self-draining procedure in relation to cleaning and / or sterilization processes. In a preferred embodiment, one or more cleaning means and / or sterilization means or condensates introduced in the vacuum chamber 202 can be drained through the connection pipe 206 to the condenser 204, in which any drain can leave the freeze dryer 200 through port 228. In other modalities, the condenser is mounted horizontally (which could mean that the condenser does not have self-draining), while only the vacuum chamber can be mounted with a permanent or temporary / adjustable slope.
[00126] In other embodiments, instead of draining through a pipe 206, the vacuum chamber 202 additionally or alternatively comprises a drain port. As the drain requirement would be released, pipe 206 could be more flexibly designed.
[00127] The inclination angle 226 is preferably permanently or temporarily arranged or optionally the frame 222 can be adapted for movement through an adjustable inclination range 226, for example, between 0 ° and 45 °. A temporary / adjustable tilt 226 may be preferable in some embodiments in relation to product discharge via ports 220 or 218. In the case of an adjustable or adjustable tilt, connections to other devices such as transfer section 208, but potentially also the pipe 206 are properly flexible or configured in such a way that they are also very suitably changeable / adjustable.
[00128] As shown in Figure 3, the drum 302 can also be arranged similarly, in relation to a horizontal line 332, with a non-evanescent inclination angle 334, thus allowing the internal volume 312 of the drum 302 to be implanted as self-draining in relation to cleaning and / or sterilization means, sterilization condensates, etc. The drum 302 is configured in such a way that the remnants of a cleaning / sterilization process such as liquids and condensates leave the drum 302 to enter the chamber 202. The remnants can then leave the vacuum chamber 202 through a pipe 206 , as described above. As shown in Figure 3, the slope 330 of the drum 304 and the slope 226 of the vacuum chamber 202 can be chosen to be generally and mutually opposite to each other, i.e., the drum and the chamber are tilted in opposite directions. This is envisaged for providing greater design flexibility that includes particularly compact freeze dryer designs. The drum 302 can be permanently tilted by the given angle of inclination 330 or the inclination 330 can be adjustable, such that, for example, the drum 302 is horizontally aligned during freeze drying and is only selectively inclined, for example, to drainage of cleaning / sterilization remnants. Generally, the present invention provides flexible design concepts regarding self-draining capabilities of the freeze dryer. This aspect of the invention is covered by an important aspect to implement CiP / SiP concepts.
[00129] Figure 7 illustrates with flowchart 700 an exemplary embodiment 700 of a freeze dryer operation 200 of Figures 2 and 3. Generally, the freeze dryer operation 200 refers to a process for the bulk production of particles freeze-dried under closed conditions (see Figure 7, 702).
[00130] In step 704, cleaning and / or sterilization of at least one freeze dryer 200 is / are performed, in particular, this may include cleaning and / or sterilizing the entire inner wall surface 406 (Figure 4) of the vacuum chamber 202 that confines the process volume 316 (see Figure 3) and of the drum 302 with the outer wall surface 438 and the inner wall surface 444 (Figure 4). In order to prepare a subsequent production cycle, for example, in order to maintain sterility after sterilization, normally any cleaning and / or sterilization is preferably carried out under closed conditions of the vacuum chamber 202. Generally, as one of the related aspects to the provision of airtight closure or "closed conditions" for a process volume and / or the product processed therein, such airtight closure includes the sealing of any openings in the wall (s) that abut the process volume. These openings may include doors, drilling holes, etc., which are provided for one or more of at least the following: nozzles, sensor circuitry such as, for example, temperature probes, assemblies for sensor elements, a drum holder, etc. The openings also include the opening (s) provided for mounting transfer sections such as section 208, which can be provided on the inner walls of the vacuum chamber 202 and / or the inner / outer walls of the drum 302 It is observed that for a hermetic closure concept any energy supply, cooling / heating medium, cleaning / sterilization medium, etc. for the internal drum 302 it also needs to be considered as necessary and eventually transversal to the walls of the vacuum chamber 202 of the environment 320 and adequate supplies for the maintenance of "closed conditions" need to be taken into account in the design concepts.
[00131] In further reference to step 704, cleaning and / or sterilization may comprise controlling the temperature, for example, of the inner wall surface 406 of the vacuum chamber 202 and / or of the outer wall surfaces 438 and inner 444 of the drum 302. For example, one or more of the wall surfaces can be (pre-) heated in order to reduce their mechanical stress when steam is applied for sterilization purposes and / or to support the sterilization process itself. Remnants of any cleaning / sterilization process can be removed based on a self-draining ability of the drum and / or the vacuum chamber as illustrated by way of example in Figures 2, 3 or by other suitable means.
[00132] In step 706, the frozen particles are loaded into drum 302 of the freeze dryer 200. The particles can be received from any particle generator adapted to produce the frozen particles such as pellets, granules, etc. A continuity of the hermetic closing under conditions as established in step 704 preferably is ensured in the process volume 316 of the freeze dryer 200. For example, the maintenance of the closed conditions within the process volume 316 can be determined at regular time intervals ( for example, 1, 2, 3, 4, 5, 10, 20, 30, 40, 50, 60 and units of time between each other, which include seconds, minutes, hours and days, etc.). Production cycle 700 can be interrupted if any violation of closing conditions (or other process conditions or specifications) is detected, which includes, but is not limited to, unwanted opening operation of sealed valves, transfer sections, etc.
[00133] In preferred embodiments, during a loading step 706, at least the process volume portion 312 internal to the drum 302 can be controlled in order to provide ideal conditions for the particles received therein. For example, in addition to keeping the particles in a frozen state, in the case of a charging process that continues for a period of time of a particle generation in an upstream particle generator, one of the corresponding requirements can prevent particle agglomeration received before drying.
[00134] Consequently, the loading step 706 can generally comprise an active temperature control of the process volume 316 by cooling the walls 318 and 330 of the vacuum chamber and / or the drum. For example, as the walls may have been heated to high temperatures during the CiP / SiP 704 stage, in order to shorten their cooling times, active cooling of the vacuum chamber and / or drum walls can be performed before starting to load the particles. In an additional example, active cooling can be employed to reduce cooling times after sterilization from 6 to 12 hours (or more) to 1 hour (or less). A cooling can continue in order to provide an ideal temperature at least within the internal volume 312 of the drum 302 to receive the particles therein and to minimize the agglomeration of the particles.
[00135] In some embodiments, in order to provide the desired cooling, the walls 318 of the vacuum chamber 202 can be cooled accordingly. In this regard, drum 302 can be equipped with additional cooling equipment, and the drum can properly contribute to cooling. Depending on the amount of cooling required, the details of the freeze dryer configuration and its control regime, active cooling can alternatively be performed by (walls 330 of) drum 302, while (walls 318 of) the vacuum chamber 202 remains passive.
[00136] As an additional measure to provide efficient cooling for the charged particles and / or in order to prevent their agglomeration, the loading step 706 may comprise providing a rotation of the drum 302. For example, the drum can be held in continuous or discontinuous rotation and / or can be rotated constantly or with varying rotation speeds. According to an example, drum 302 can be rotated continuously at a constant speed which is generally slower than the rotational speed during drying. One or more predetermined rotation patterns for the drum can be applied and / or the drum can be rotated in response to a determination of process conditions such as actual drum load, moisture (i.e., water vapor content) and temperature within process volume 312, 314, and 316, etc.
[00137] In step 708, the particles loaded in the rotating drum are freeze-dried. The vacuum chamber 202 is in charge of providing closed conditions for the product. The protection of sterility and / or the provision of containment conditions may comprise that the transfer section 208 is sealed in relation to the upstream particle generator. In addition, freeze drying may comprise that a vacuum is established, which comprises predefined low pressure conditions within the process volume 314 of the vacuum chamber 202 through the action of vacuum pump 207 and as the drum 302 which carries the particles, the internal portion of drum 312 of process volume 316 is also in open communication. In preferred embodiments, water vapor evaporation from particles due to sublimation is extracted from communication with process volume portions 312 and 314 due to to the action of condenser 204 and vacuum pump 207.
[00138] In order to establish and / or maintain the desired process conditions during drying, in addition to the condenser 204 which extracts water vapor, the vacuum pump maintains the pressure at a desired vacuum level, etc., also the equipment heating element provided, for example, within the walls 318 of the vacuum chamber 202 and / or the walls 330 of the drum 302 can be controlled to actively heat the process volume 316 which includes the particles to be dried to reach temperatures at a level wanted. Depending on the details such as the loading of the drum 302, the intensity of the sublimation process in progress, etc., it may be sufficient that, for example, only the walls 330 of the drum 304 are heated, for example, only an internal surface 444 of the same. In an alternative embodiment, the drum is not equipped with a heating medium in order to limit the complexity of the drum design; in that case only the vacuum chamber, for example, an internal wall surface of the same, can be operated to heat the confined process volume during lyophilization (and / or still other heating mechanisms, such as microwave heating, can be provided). Such a configuration is possible since the process volume portions 312 and 314 internally and externally with respect to the particle drum 302 are in communication with each other. However, heating performed by the drum may, for some modalities, be more efficient in order to reach a desired temperature for the particles to be freeze-dried.
[00139] During freeze drying, drum 304 can be optionally rotated in order to maximize the product surface available for the direct release of water vapor in process volume 312. For the rotation patterns to be applied during drying , basically similar considerations need to be performed as discussed above for the loading step. However, a rotation speed can, in some modalities, be maintained at a higher speed than in the loading step. In one example, the drum is maintained at a continuous and constant speed of rotation during freeze drying. In one embodiment, the freeze dryer is equipped with a rotating drum of variable speed according to the adaptations of a drive unit for the drum and / or a control procedure, in which at least two different rotation modes are used. provided, namely, a first (e.g., continuous, slow) mode of rotation to be applied during a loading of particles and a second (continuous, faster) mode of rotation to be applied during freeze drying of the particles. Still in additional modalities, the drum and / or its control is adapted to provide discontinuous rotation movements (with start and stop) or multiple speeds.
[00140] In another mode, the speed of rotation is controlled according to, for example, the current status of the lyophilization process. For example, by changing the drum rotation speed, the product surface available for direct evaporation can be increased or decreased, which, in turn, is considered to influence process conditions such as humidity and temperature in the process volume. . As a result, the speed of rotation becomes a process parameter that is optionally available to control a lyophilization process.
[00141] In step 710, freeze drying of the particles is terminated, for example, as it has been detected that the humidity of the particles has decreased to a desired level. During a freeze dryer particle discharge, vacuum chamber 202 remains responsible for maintaining the closed conditions for the product, until the entire bulk product has been moved to a separate discharge section / station (see Figure 5 ) or until the particles have been filled directly into the final containers and these are sealed inside the vacuum chamber or removed from the vacuum chamber through a door in a separate sealing chamber (see Figure 6) or insulator.
[00142] An active temperature control may or may not be required in the unloading step, as the dried particles do not normally require cooling after drying. However, after the discharge has been completed, heating can be applied to match the conditions within process volume 316 of vacuum chamber 202 with an environment prior to, for example, removal of filled (and sealed) containers from the vacuum chamber 202.
[00143] In step 712, process 700 is terminated. This can ensure that closed conditions do not need to be maintained any longer. Active heating can be carried out using heating equipment associated with vacuum chamber 202 and / or drum 302, for example, in order to prepare a subsequent cleaning / sterilization process on short timescales. As indicated by arrow 714, after cleaning / sterilization, the freeze dryer 200 can be immediately involved in a next production cycle. In addition or alternatively, maintenance operations such as checking the sensor circuitry and other control equipment, etc., can be performed at that time.
[00144] According to the particular embodiments of the invention, a freeze dryer comprises a housing with an internal rotation drum. The housing, implanted, for example, as a vacuum chamber, is adapted to provide closed conditions and, therefore, the freeze dryer can be operated to produce a sterile product in a non-sterile environment. In some embodiments, the freeze dryer may additionally comprise completely contained loading and unloading means. An inclined loading tube can optionally reach the drum to continuously load particles such as micropellets during a particle generation process such as granulation, spray freezing, etc., in the rotating drum to keep the product moving inside during loading / filling.
[00145] The freeze dryer modalities as discussed in the present invention can beneficially be used for freeze drying, for example, free flowing sterile frozen particles such as bulk. The use of a rotating drum to receive the particles allows significantly reduced drying times compared to, for example, tray-based and / or bottle-based dryers, as with an increased mass transfer product surface and heat can be accelerated. The heat transfer does not need to occur through the frozen product and the layers for diffusing water vapor are smaller compared to, for example, drying in bottles, where stops may be required. No adaptation to specific flasks / stops allowing a passage of steam to be required, for example, due to the fact that no flasks / stops are used. Homogeneous drying conditions for the entire batch can be provided.
[00146] The supply of temperature-controlled wall surfaces in particular for cooling is contemplated, for example, by decreasing the demand for sterile cooling media such as sterile liquid nitrogen or silicone oil, thereby contributing to the good ratio of cost-effectiveness of the freeze dryer and / or a process that includes the freeze dryer.
[00147] The freeze dryer can be adapted for CiP / SiP, for example, the housing can be steam sterilizable. The vacuum housing / chamber and / or the drum can be tilted / tilted in order to withstand the draining of liquids / condensates and / or the discharge of the product. To discharge the product, the housing / vacuum chamber may comprise guiding / discharging the elements to guide the particles after discharging the drum into a final container or through a transfer section that includes a discharge funnel for a separate discharge section .
[00148] The modalities of a freeze dryer as described in the present invention allow an operation in a non-sterile environment for the manufacture of a sterile product. This avoids the need for the use of an insulator to achieve closed conditions, which implies that the freeze dryers according to the invention are not limited in relation to available insulator sizes. The corresponding additional benefits include decreased analytical requirements. Costs can be considerably reduced by maintaining compliance with the requirements of GMP, Product Laboratory Practice ("GLP"), and / or Clinical Product Practice ("GCP") and international equivalents.
[00149] Although, in preferred embodiments, the insulator (s) is / are not required for closed operation, in preferred embodiments, a freeze dryer according to the invention clearly constitutes a separate and well-defined process device dedicated to the freeze drying task under closed conditions, which is seen in contrast to highly integrated devices specifically adapted to deploy multiple tasks within a device, for example, particle generation and drying. For example, if connected, for example, via transfer sections as described in the present invention to a process line, the freeze dryer can be adapted for separate operations under closed conditions, which includes at least one among freeze drying, cleaning freeze dryer and freeze dryer sterilization. The freeze dryer according to the invention can therefore be flexibly employed and / or optimized for freeze drying as desired. Optimizations can refer, for example, to the supply and design of cooling and / or heating equipment in association with the housing / vacuum chamber and / or the drum.
[00150] The products to be freeze-dried can be based on virtually any formulation that is also suitable for conventional freeze-drying processes (for example, shelf type), for example, monoclonal antibodies, other protein-based APIs ( Active Pharmaceutical Ingredients), DNA-based APIs, cell / tissue substances, vaccines, APIs for solid oral dosage forms such as APIs with low solubility / bioavailability, oral rapid dispersion dosage forms such as ODTs, oral dispersion tablets, adaptations filled with sticks, etc.
[00151] The freeze dryer modalities according to the invention can be used for the generation of sterile, lyophilized and uniformly calibrated particles such as pellets or micropellets as in bulk. The resulting product can be free-flowing, dust-free and homogeneous. Such a product has good handling properties and could easily be combined with other components, where the components may be incompatible in a liquid state or just stable for a short period of time and not suitable for conventional freeze drying.
[00152] Although the present invention has been described in relation to various modalities thereof, it should be understood that this description is for illustrative purposes only.

权利要求:
Claims (8)
[0001]
1. Process line (500) for the production of freeze-dried particles under closed end-to-end conditions, the process line (500) comprising a freeze dryer (502) for the bulk production of freeze-dried particles under closed conditions, the freeze dryer (502) comprising a rotating drum (504) for receiving the frozen particles; and a stationary vacuum chamber (506) which houses the rotating drum (504), and for the production of the particles under closed conditions the vacuum chamber (506) is adapted for closed operation during the processing of the particles; the drum (504) is in open communication with the vacuum chamber (506); characterized by the fact that at least one transfer section (508) being provided for a product transfer between a separate device (512) from the process line (500) and the freeze dryer (502), the freeze dryer (502 ) and the transfer section (508) being separately adapted for closed operation, the transfer section (508) comprising a double wall structure (528) including an outer wall (530) and an inner wall (532) with a temperature-controlled internal wall surface (538).
[0002]
2. Process line (500) according to claim 1, characterized in that a first transfer section (508) being provided for a product transfer from a separate device (512) to produce frozen particles for the dryer by freezing (502), the first transfer section (508) comprising a loading funnel that projects into the open drum (504) without engaging it.
[0003]
Process line (500) according to claim 1 or 2, characterized in that a second transfer section (510) being provided for a product transfer from the freeze dryer (502) to a separate device ( 514) to discharge the freeze-dried particles.
[0004]
Process line (500) according to any one of the preceding claims, characterized in that the vacuum chamber (506) comprises a temperature-controlled internal wall surface (406).
[0005]
Process line (500) according to claim 4, characterized in that the vacuum chamber (506) comprises a double-walled housing.
[0006]
Process line according to any one of the preceding claims, characterized in that the drum (504) comprises a temperature-controlled internal wall surface (444).
[0007]
7. Process (700) for the bulk production of freeze-dried particles under closed conditions carried out using a process line as defined in any one of claims 1 to 6, characterized by the fact that the process comprises at least the following process steps (706, 708, 710): loading (706) frozen particles into the drum (504) of the freeze dryer (502); freeze drying (708) the particles in the rotating drum (504) which is in open communication with the vacuum chamber (506) of the freeze dryer (502); and discharging (710) the particles from the freeze dryer (502); the vacuum chamber (506) of the freeze dryer (502) being operated under closed conditions during the processing of the particles.
[0008]
Process (700) according to claim 7, characterized in that it comprises a step of controlling a temperature of a wall (318, 330) of at least one of the vacuum chamber (506) and the drum ( 504).

类似技术:

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US20200116428A1|2020-04-16|Heating device for rotary drum freeze-dryer

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AU2005263465A1|2006-01-26|Sterile freezing, drying, storing, assaying and filling process | |

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法律状态:
2018-12-11| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2020-01-28| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2020-12-08| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2021-01-19| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 04/10/2012, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

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EP11008058.7A|EP2578975A1|2011-10-05|2011-10-05|Rotary drum freeze-dryer|

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EP11008058.7|2011-10-05|

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PCT/EP2012/004167|WO2013050161A1|2011-10-05|2012-10-04|A process line for the production of freeze-dried particles|

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