More Product. Lower COGs.
How Perfusion Process Intensification in Upstream Cell Culture Overcomes Fed-Batch Limitations
As biologics pipelines grow more complex and manufacturers face mounting pressure to reduce cost of goods (COGs) without expanding headcount or facility footprint, traditional fed-batch processes in upstream cell culture are falling short. This BioProcess International Special Report shows how perfusion-based process intensification with XCell® ATF and KrosFlo® TFDF® technologies changes the equation by delivering measurably more product, with less operator burden, from smaller bioreactors.
Demand isn't slowing down
mAb volumes, viral vector programs, and CGT pipelines are all growing. Scaling fed-batch to meet that demand means more bioreactors, more space, more people.
COGS under pressure
Budget scrutiny is intensifying. Fed-batch ties up large bioreactors and long run cycles for yields that intensified processes achieve in a fraction of the space and time.
Do more with less
Teams are being asked to run more processes with the same or less headcount and without growing the facility footprint or adding more bioreactors.
What You'll Learn
This report builds the case for upstream process intensification from real-world examples and published results across three modalities.
- Why fed-batch inefficiencies are becoming a barrier to cost-competitive biologics manufacturing
- How automation and integrated process control reduce manual intervention, human error, and operator burden
- Scalability data from 0.5 L to 5,000 L in glass, stainless steel, and single-use bioreactor formats
- How KrosFlo® TFDF® enables continuous viral vector harvest with ~100% biomolecule transmission
10×
Yield per batch vs. fed-batch (mAb, CHO perfusion)
86×
More TU/L of bioreactor (lentiviral vector, TFDF)
3–10×
AAV production improvement across multiple serotypes
