Automated modular system and method for production of biopolymers

• US 10,569,249 B2
• Filed: 07/05/2018
• Issued: 02/25/2020
• Est. Priority Date: 09/25/2014
• Status: Active Grant

• Current Assignee: Synthego Corp.
• Original Assignee: Synthego Corp.
• Inventors: Dabrowski, Paul, Dabrowski, Michael, Gerlinghaus, Fabian, Pesch, Alex
• Primary Examiner(s): Wilson, Allan R
• Application Number:
  US16/027,982
• Publication Number:
  US 20180311637A1
• Time in Patent Office: 600 Days
• CPC Class Codes: B01J 19/0046 Sequential or parallel reactions, e.g. for the synthesis of polypeptides or polynucleotides; Apparatus and devices for combinatorial chemistry or for making molecular arrays synthesis methods per se C40B50/00
• CPC Class Codes: B01J 2219/00315 Microtiter plates
• CPC Class Codes: B01J 2219/00317 Microwell devices, i.e. having large numbers of wells
• CPC Class Codes: B01J 2219/00691 using robots
• CPC Class Codes: B01J 2219/00693 Means for quality control
• CPC Class Codes: B01J 2219/00702 Processes involving means for analysing and characterising the products
• CPC Class Codes: B01J 2219/00722 Nucleotides
• CPC Class Codes: B01J 2219/00759 Purification of compounds synthesised
• CPC Class Codes: G05B 19/4182 manipulators and conveyor only
• CPC Class Codes: G05B 19/4189 characterised by the transport system
• CPC Class Codes: G05B 2219/45092 Analysing or chemical synthesis robot, moving samples from station to station
• 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: Y10S 901/02 Arm motion controller

Abstract

The present invention provides an automated modular system and method for production of biopolymers including DNA and RNA. The system and method automates the complete production process for biopolymers. Modular equipment is provided for performing production steps with the individual modules arrange in a linear array. Each module includes a control system and can be rack mounted. One side of the array of modules provides connections for power, gas, vacuum and reagents and is accessible to technicians. On the other side of the array of modules a robotic transport system is provided for transporting materials between module interfaces. The elimination of the requirement for human intervention at multiple steps in the production process significantly decreases the costs of biopolymer production and reduces unnecessary complexity and sources of quality variation.

Claims

1. An automated production system comprising:

a production control system for scheduling and controlling production in an automated production; and

a plurality of stackable equipment modules for synthesizing biopolymers in accordance with pre-determined sequences under control of the production control system, wherein each equipment module of the plurality of stackable equipment modules comprises an interface feature connected to power.

2. The automated production system of claim 1, wherein the plurality of stackable equipment modules comprises a synthesizer module.

3. The automated production system of claim 1, wherein each equipment module of the plurality of stackable equipment modules is configured to be added or removed from the automated production system without interrupting the production in an equipment module of the plurality of stackable equipment modules remaining in the automated production system.

4. The automated production system of claim 1, comprising a plurality of synthesizers operating in parallel with the production control system, wherein the production control system distributes and schedules a synthesis process.

5. The automated production system of claim 2, wherein the synthesizer module comprises a plurality of independent channels such that a different synthesis can be performed in each independent channel of the plurality of independent channels.

6. The automated production system of claim 1, further comprising a quality control software that monitors input and output products.

7. The automated production system of claim 6, wherein the quality control software provides for closed loop control of the automated production system.

8. The automated production system of claim 6, wherein the quality control software provides for closed loop control of individual equipment modules in the plurality of stackable equipment modules of the automated production system.

9. The automated production system of claim 6, wherein the quality control software provides for closed loop control of individual channels of a synthesizer module of the automated production system.

10. The automated production system of claim 6, wherein the quality control software is a closed loop software that tunes or calibrates the automated production system, the plurality of stackable equipment modules, or channels of a synthesizer in response to a collected quality control data to enhance performance.

11. The automated production system of claim 10, wherein the quality control software performs continuous quality control.

12. The automated production system of claim 1, further comprising a customer interface interfacing with the production control system.

13. The automated production system of claim 1, wherein the production control system monitors and tracks materials moving through the automated production system.

14. The automated production system of claim 13, wherein the automated production system does not label intermediate products.

15. The automated production system of claim 1, wherein each equipment module of the plurality of stackable equipment modules has a dedicated control system and a communications interface, wherein the dedicated control systems and communications interfaces interact with the production control system.

16. The automated production system of claim 2, further comprising a continuously monitored supply of synthesis reagents and gases that are fed to the synthesizer module.

17. The automated production system of claim 1, wherein the production control system is configured to adjust operation of synthesis to not use a non-functional channel.

18. The automated production system of claim 5, wherein each independent channel of the plurality of independent channels is separately controllable.

19. The automated production system of claim 1, wherein the plurality of stackable equipment modules is arranged in a vertical stack.

20. The automated production system of claim 1, wherein the plurality of stackable equipment modules is in a rack.

21. The automated production system of claim 20, wherein the automated production system is configured to register a presence of an equipment module of the plurality of stackable equipment modules such that the production control system is configured to be notified of when an equipment module of the plurality of stackable equipment modules is online.

22. The automated production system of claim 20, wherein the plurality of stackable equipment modules is mounted in the rack.

23. The automated production system of claim 1, wherein the interface features are on top of each equipment module of the plurality of stackable equipment modules.

24. The automated production system of claim 1, wherein the plurality of stackable equipment modules is arranged in multiple arrays.

25. The automated production system of claim 24, wherein the multiple arrays are arranged back-to-back.

26. The automated production system of claim 1, wherein the plurality of stackable equipment modules is stacked vertically in multiple stacks, wherein stacks of the multiple stacks are adjacent to each other.

27. The automated production system of claim 1, wherein an equipment module of the plurality of stackable equipment modules is stacked upon another equipment module in the plurality of stackable equipment modules.

28. The automated production system of claim 1, wherein the plurality of stackable equipment modules further comprises interface features connected to network, fluid, vacuum, or gas.

29. The automated production system of claim 2, wherein the synthesizer module is an oligonucleotide synthesizer module.

30. The automated production system of claim 1, wherein each equipment module of the plurality of stackable equipment modules is an oligonucleotide synthesizer module, wherein the plurality of stackable equipment modules is stacked vertically, and wherein each equipment module of the plurality of stackable equipment modules is mounted in a rack.