Process intensification in bioprocessing involves minimizing, concentrating, and simplifying methods and equipment to enable smaller, more efficient and higher quality bioprocessing.
"For perfusion, you don't really need exotic upstream equipment beyond robust cell retention devices."
Konstantin Konstantinov, Genzyme
Because XCell™ ATF technology minimizes cell shear and keeps cells in constant equilibrium with bioreactor contents, faster cell growth at higher densities can be achieved. This results in high cell density perfusion using the same simple mode of operation but with higher productivity. Benefits of concentrated perfusion include:
- Ultra-high cell densities of 100-200x106 cells/ml
- Cell viabilities of 90% and higher
- Requires 1-3 vessel volumes per day (vvd)
- Can be used to increase host cell density for virus production
N-1 perfusion refers to the intensification of cell growth in the step prior to the production bioreactor (N). This process intensification is done using perfusion in the N-1 bioreactor to attain high cell density and viability. This allows seeding the production bioreactor at a higher starting cell density and shortening the production bioreactor run time. This can dramatically increase the facility output without direct change to the core production process. A robust cell retention device is required to attain a high cell density inoculum for the production bioreactor.
High density (HD) cell banking is seed train optimization involving larger volume frozen seed banks, eliminating seed steps from vial and enabling banking of larger volumes up to 1 liter.
Cell culture growth factors play a critical role in media optimization, contributing to long-term growth and rapid proliferation of cell lines in serum-free media formulations.