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Updated: Sep 3, 2025
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A Cost-effective and Reliable Method to Predict Mechanical Stress in Single-use and Standard Pumps
Published on: August 5, 2015
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Evaluating shear in perfusion rotary lobe pump using nanoparticle aggregates and computational fluid dynamics.
Momen Amer1, Alex Vaca2, Marshall Bowden3
1Cell Culture Development, Biogen, 5000 Davis Drive, Research Triangle Park, NC, 27709, USA. momen.amer@biogen.com.
Bioprocess and Biosystems Engineering
|July 22, 2022
Summary
N-1 perfusion processes can cause cell damage due to pump shear stress. Computational fluid dynamics modeling identified high-shear zones and predicted geometry modifications to reduce shear stress, improving cell viability in biopharmaceutical manufacturing.
Area of Science:
- Biopharmaceutical Manufacturing
- Cell Culture Technology
- Process Engineering
Background:
- N-1 perfusion is a key technology for intensifying biopharmaceutical production.
- Unexpected cell damage was observed during large-scale N-1 perfusion runs.
- Reduced pump speed improved cell viability, indicating shear stress as a critical factor.
Purpose of the Study:
- Quantify shear stress in rotary lobe pumps used for N-1 perfusion.
- Validate a computational fluid dynamics (CFD) model for predicting shear stress.
- Evaluate the impact of pump geometry modifications on shear stress.
Main Methods:
- Utilized polymethyl methacrylate (PMMA) nanoparticles to measure shear stress in two pump sizes.
- Developed and validated a CFD model against experimental data.
- Simulated the effects of varying radial and mesh clearances on shear stress.
Main Results:
- Identified radial and mesh clearance zones as areas of maximum shear stress.
- The CFD model accurately predicted shear stress under various operating conditions.
- Predicted a 17% reduction in maximum shear stress by increasing clearances by 0.08 mm and 0.13 mm.
Conclusions:
- CFD modeling is a valuable tool for predicting and mitigating shear stress in rotary pumps.
- Optimizing pump geometry and operating conditions can prevent cell damage during N-1 perfusion.
- This approach facilitates cost-effective and efficient process scale-up in biopharmaceutical manufacturing.
