Scaling up a novel microfluidic process

Our client asked:

Our client is a high-tech start-up with a novel microfluidic process for encapsulating peptide and protein generics in spheres that enable controlled release of the drug. Sagentia Medical were asked to solve complex issues with the physics that were preventing them from scaling up small prototypes into a production-scale device.

The project story:

We analysed the issues from a number of angles:

• We reviewed scientific literature into the microfluidic processes and identified the key parameters that lead to successful production of spheres
• We identified new device designs that eliminated geometries where fluidic problems can occur
• We developed a mathematical model to predict the sensitivity of a scaled-up, parallel process to manufacturing tolerances

Results: deliverables and outcomes

• The project resulted in seven recommendations to guide the development process
• This was a short, sharp piece of work that helped our client surmount a critical obstacle
• They have now secured £2 million in funding, which will enable them to develop the scaled-up process