Systems and methods for manufacturing a silk fibroin solution and powders containing silk fibroin

A method of processing silk inputs to obtain silk fibroin, the method comprising the steps of:

• configuring at least two single reactor vessels in parallel;
• introducing a plurality of silk inputs to each single reactor vessel;
• introducing a solvent to each single reactor vessel;
• introducing a first compound to each single reactor vessel;
• introducing heat to the contents of each single reactor vessel to promote degumming of the silk inputs;
• removing at least a portion of the solvent and any degumming residue from each single reactor vessel;
• rinsing the degummed silk inputs in each single reactor vessel;
• introducing a second compound to each single reactor vessel to dissolve the remaining silk fibroin into solution;
• combining the contents of each single reactor vessel and directing them to a filtering step, wherein the filtering step substantially removes the second compound and produces a purified silk fibroin-based solution;
• and
• powderizing the purified silk fibroin-based solution to obtain the silk fibroin in a powder form.

A method of processing silk inputs to obtain silk fibroin, the method comprising the steps of:

• providing a single reactor vessel configured to receive silk inputs, extract silk fibroin therefrom, and produce a silk fibroin-based solution via degumming, rinsing, and dissolving processes therein, wherein the vessel comprises at least one inlet port and at least one outlet port;
• introducing a plurality of silk inputs to the single reactor vessel via the at least one inlet port so as to obtain a packing density of the silk inputs in the single reactor vessel of about 1% and about 30%;
• introducing a solvent to the single reactor vessel via the at least one inlet port;
• introducing a first compound to the single reactor vessel via the at least one inlet port;
• introducing heat to the single reactor vessel contents to promote degumming of the silk inputs;
• removing at least a portion of the solvent and any degumming residue from the single reactor vessel via the at least one outlet port;
• rinsing the degummed silk inputs such that the silk inputs are substantially free of sericin;
• introducing a second compound to the single reactor vessel via the at least one inlet port to dissolve any remaining silk fibroin into solution;
• and
• purifying the contents of the single reactor vessel by circulating the contents of the single reactor vessel through a tangential flow filtration module comprising at least one spiral wound membrane from about 1 diavolumes to about at least 12 diavolumes to substantially remove the second compound and produce a purified silk fibroin-based solution.