Flexible manufacturing system

• US 10,294,658 B2
• Filed: 12/22/2009
• Issued: 05/21/2019
• Est. Priority Date: 12/23/2008
• Status: Active Grant

• Current Assignee: Xoma (US) LLC (Xoma Corp.)
• Original Assignee: Xoma (US) LLC (Xoma Corp.)
• Inventors: Scannon, Patrick J., Bernard, Frank, Tenerowicz, Robert S., Dadson, Jr., Alfred C.
• Primary Examiner(s): Savani, Avinash A
• Assistant Examiner(s): Becton, Martha M
• Application Number:
  US13/129,073
• Publication Number:
  US 20110258837A1
• Time in Patent Office: 3,437 Days
• Field of Search: 454187
• CPC Class Codes: B23P 25/00 Auxiliary treatment of workpieces, before or during machining operations, to facilitate the action of the tool or the attainment of a desired final condition of the work, e.g. relief of internal stress
• CPC Class Codes: C02F 1/001 Processes for the treatment of water whereby the filtration technique is of importance C02F1/44 takes precedence; construction of filters in general B01D24/00 - B01D41/00
• CPC Class Codes: E04B 1/343 Structures characterised by movable, separable, or collapsible parts, e.g. for transport movable roof parts E04B7/16; floatable buildings B63B; small prefabricated buildings, transportable as a whole, E04H1/12; small garages E04H6/02; tents or canopies, in general E04H15/00
• CPC Class Codes: E04B 2001/0053 Buildings characterised by their shape or layout grid
• CPC Class Codes: E04H 5/02 Buildings or groups of buildings for industrial purposes, e.g. for power-plants or factories buildings forming part of cooling plants E04H5/10
• CPC Class Codes: G05B 19/4188 characterised by CIM planning or realisation
• CPC Class Codes: G05B 2219/31338 Design, flexible manufacturing cell design
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
• CPC Class Codes: Y10T 29/49 Method of mechanical manufacture
• CPC Class Codes: Y10T 29/4998 Combined manufacture including applying or shaping of fluent material
• CPC Class Codes: Y10T 29/51 Plural diverse manufacturing apparatus including means for metal shaping or assembling
• CPC Class Codes: Y10T 29/53096 including means to provide a controlled environment
• CPC Class Codes: Y10T 29/534 Multiple station assembly or disassembly apparatus

Abstract

A flexible, multi-product, multi-technology, expandable facility for manufacturing products, such as biologicals, pharmaceuticals, or chemicals, and manufacturing processes using elements of such a facility.

Claims

1. A unitary structure adapted to be disposed within a housing, comprising:

at least one controlled air, sealable, sterilizable cleanroom having an entry point and an exit point;

a cleanroom entry portion coupled to and selectively isolated from the cleanroom, the cleanroom entry portion for controlling personnel flow to the cleanroom via the entry point;

a cleanroom exit portion coupled to and selectively isolated from the cleanroom and separated from the cleanroom entry portion, the cleanroom exit portion for controlling personnel flow from the cleanroom via the exit point;

means for permitting movement of the cleanroom within the housing; and

a mechanical system room that, when connected to the cleanroom, is fixed relative to the cleanroom, the mechanical system room comprising;

at least two air handling units that provide air to the cleanroom with at least Class 100,000 air purity, the air handling units connected to the cleanroom via one or more supply outlets, wherein a pressure differential is formed between the cleanroom and the exterior of the structure; and

at least two power supplies that provide power to electrical outlets in the cleanroom, wherein the at least two power supplies are connectable to one or more external electrical power sources,

wherein when one of the at least two air handling units breaks down, the other of the at least two air handling units provides air to the cleanroom without interruption, and

wherein when one of the at least two power supplies breaks down, the other of the at least two power supplies provides power to the electrical outlets in the cleanroom without interruption.

2. The structure of claim 1, further comprising a control system for controlling a manufacturing process performed in the cleanroom, wherein the control system comprises one or more sensors.

3. The structure of claim 1, further comprising one or more outlets adapted to supply the clean room with at least one of sterile water, non-sterile water, purified water, steam, wastewater, and gas.

4. The structure of claim 3, further comprising one or more duplicate systems for supplying the cleanroom with at least one of sterile water, non-sterile water, purified water, steam, wastewater, and gas to ensure no loss of productivity.

5. The structure of claim 1, further comprising equipment fixed to the structure, the equipment comprising at least one of a centrifuge, a hood, a tank, a chromatography column, a bioreactor, a refrigerator, a freezer, an incubator, a biosafety cabinet, a vacuum system, and a freeze drier.

6. The structure of claim 1, wherein the at least one controlled air, sealable, sterilizable cleanroom comprises first and second controlled air, sealable, sterilizable cleanrooms, the first cleanroom being serviceable without interrupting one or more manufacturing processes being performed in the second cleanroom.

7. The structure of claim 1, wherein a first controlled air, sealable, sterilizable cleanroom can be swapped out for a second controlled air, sealable, sterilizable cleanroom.

8. The structure of claim 1, wherein the structure comprises at least one of one or more reinforced floors or one or more suspension systems.

9. The structure of claim 1, wherein the one or more supply outlets are adapted to vary the internal pressure in the cleanroom, thereby varying the pressure differential between the cleanroom and the exterior of the structure.

10. The structure of claim 9, wherein the internal pressure can be varied to be greater than, less than, or equal to a pressure of the exterior of the structure.

11. The structure of claim 1, wherein the cleanroom is provided with at least Class 10,000, 1,000, 100 or 10 air purity.

12. The structure of claim 1, wherein the cleanroom comprises bioprocess equipment, the bioprocess equipment comprising at least one of culture media, water, solvents, and disposables.

13. The structure of claim 1, wherein the cleanroom comprises at least one of a work table, a work surface, cabinetry, surveillance equipment, bags, office items, and chairs.

14. The structure of claim 1, wherein the one or more supply outlets are sealable.

15. The structure of claim 1, wherein the cleanroom further comprises one or more sealable corridors to transfer materials to and from the cleanroom.

16. The structure of claim 1, wherein the structure is adapted for transport via land, sea or air.

17. The structure of claim 1, wherein the cleanroom is isolated from other portions of the structure such that the structure complies with GMP manufacturing guidelines.

18. The structure of claim 1, wherein the structure is portable.

19. The structure of claim 1, further comprising a clean connect area disposed between the cleanroom and the mechanical system room.

20. The structure of claim 19, wherein the clean connect area facilitates movement between the cleanroom and the mechanical system room.

21. The structure of claim 19, wherein the clean connect area connects the cleanroom and the mechanical system room.

22. The structure of claim 1, wherein the mechanical system room is removably connected to the cleanroom.

23. The structure of claim 1, further comprising a vertical wall separating the cleanroom and the mechanical system room.

24. The structure of claim 1, wherein the means for permitting movement of the cleanroom is arranged under the cleanroom.

25. The structure of claim 1, wherein the means for permitting movement of the cleanroom comprises rails, wheels, or tracks.

26. The structure of claim 1, wherein the means for permitting movement of the cleanroom comprises an air cushion arranged under the cleanroom.

27. A facility adapted to be disposed within a housing, comprising:

at least one controlled air, sealable, sterilizable cleanroom having an entry point and an exit point;

a cleanroom entry portion coupled to and selectively isolated from the cleanroom, the cleanroom entry portion for controlling personnel flow to the cleanroom via the entry point;

a cleanroom exit portion coupled to and selectively isolated from the cleanroom and separated from the cleanroom entry portion, the cleanroom exit portion for controlling personnel flow from the cleanroom via the exit point;

means for permitting movement of the cleanroom within the housing;

a support room adjacent the cleanroom;

a vertical wall separating the cleanroom and the support room;

at least two air handling units in the support room that provide air to the cleanroom with at least Class 100,000 air purity, the air handling units connected to the cleanroom via one or more supply outlets, wherein a pressure differential is formed between the cleanroom and the exterior of the structure; and

at least two power supplies that provide power to electrical outlets in the cleanroom, wherein the at least two power supplies are connectable to one or more external power sources,

wherein when one of the at least two air handling units breaks down, the other of the at least two air handling units provides air to the cleanroom without interruption,

wherein when one of the at least two power supplies breaks down, the other of the at least two power supplies provides power to the electrical outlets in the cleanroom without interruption.

28. The facility of claim 27, wherein the means for permitting movement of the cleanroom is arranged under the cleanroom.

29. The facility of claim 27, wherein the means for permitting movement of the cleanroom comprises rails, wheels, or tracks.

30. The facility of claim 27, wherein the means for permitting movement of the cleanroom comprises an air cushion arranged under the cleanroom.

31. The facility of claim 27, wherein the means for permitting movement of the cleanroom comprises means for permitting movement of the cleanroom relative to the support room.

32. A unit adapted to be disposed within a housing, comprising:

at least one controlled air, sealable, sterilizable cleanroom having an entry point and an exit point;

a cleanroom entry portion coupled to and selectively isolated from the cleanroom, the cleanroom entry portion for controlling personnel flow to the cleanroom via the entry point;

a cleanroom exit portion coupled to and selectively isolated from the cleanroom and separated from the cleanroom entry portion, the cleanroom exit portion for controlling personnel flow from the cleanroom via the exit point;

means for permitting movement of the cleanroom within the housing;

a mechanical system room that, when connected to the cleanroom, is fixed relative to the cleanroom; and

a vertical wall separating the cleanroom and the mechanical system room, wherein the mechanical system room comprises two or more redundant systems, the redundant systems comprising;

at least two air handling units that provide air to the cleanroom with at least Class 100,000 air purity, the air handling units connected to the clean room via one or more supply outlets, wherein a pressure differential is formed between the cleanroom and the exterior of the unit; and

at least two power supplies that provide power to electrical outlets in the cleanroom, wherein the at least two power supplies are connectable to one or more external power sources,

wherein when one of the at least two air handling units breaks down, the other of the at least two air handling units provides air to the cleanroom without interruption, and

wherein when one of the at least two power supplies breaks down, the other of the at least two power supplies provides power to the electrical outlets in the cleanroom without interruption.

33. The unit of claim 32, wherein the means for permitting movement of the cleanroom is arranged under the cleanroom.

34. The unit of claim 32, wherein the means for permitting movement of the cleanroom comprises rails, wheels, or tracks.

35. The unit of claim 32, wherein the means for permitting movement of the cleanroom comprises an air cushion arranged under the cleanroom.

36. A method of making a unitary unit adapted to be disposed within a housing, the method comprising:

building at least one controlled air, sealable, sterilizable cleanroom, the cleanroom having an entry point and an exit point, and the cleanroom comprising means for permitting movement of the cleanroom within the housing;

connecting a cleanroom entry portion to the cleanroom, the cleanroom entry portion selectively isolated from the cleanroom, the cleanroom entry portion for controlling personnel flow to the cleanroom via the entry point;

connecting a cleanroom exit portion to the cleanroom, the cleanroom exit portion selectively isolated from the cleanroom and separated from the cleanroom entry portion, the cleanroom exit portion for controlling personnel flow from the cleanroom via the exit point; and

connecting a mechanical system room to the cleanroom, wherein when the mechanical system room is connected to the cleanroom, the mechanical system room is fixed relative to the mechanical system room, the mechanical system room comprising;

at least two air handling units that provide air to the cleanroom with at least Class 100,000 air purity, the air handling units connected to the cleanroom via one or more supply outlets, wherein a pressure differential is formed between the cleanroom and the exterior of the unit; and

at least two power supplies that provide power to electrical outlets in the cleanroom from two sources, wherein the at least two power supplies are connectable to one or more external electrical power sources,

wherein when one of the at least two air handling units breaks down, the other of the at least two air handling units provides air to the cleanroom without interruption, and

wherein when one of the at least two power supplies breaks down, the other of the at least two power supplies provides power to the electrical outlets in the cleanroom without interruption.