Systems and methods for inducing plug flow during fluid separation using air

A configurable automated blood component manufacturing system comprising:

• a durable hardware component comprising:
• a pump station with a plurality of pumps;
• a centrifuge mounting station and drive unit;
• an optical system associated with the centrifuge mounting station and drive unit;
• a microprocessor-based controller including a touchscreen for receiving operator input and displaying procedure parameters;
• a plurality of tubing clamps;
• a cassette nesting module including a plurality of valves and pressure sensors;
• and
• a single use fluid flow circuit comprising:
• a separation chamber configured to be received in the centrifuge mounting station;
• a fluid flow control cassette configured to be mounted in the cassette nesting module, the cassette having external tubing loops engageable with the pumps so that fluid flow through the cassette is controlled by actuation of the pumps, valves and clamps;
• a plurality of containers and an air access component in fluid communication with the cassette by respective tubing segments, with one or more of the tubing segments configured to be received in at least one of the tubing clamps;
• the air access component being adapted to receive air used to induce plug flow in at least one of the tubing segments;
• wherein the controller is pre-programmed to actuate flow of air from the air access component to induce plug flow during production of a fluid component;
• and
• wherein the controller is pre-programmed to automatically operate the system to perform one or more blood processing procedures selected by an operator by input to the touchscreen.