Process Intensification


Bioprocess intensification is defined as a significant step increase in output relative to cell concentration, time, reactor volume or cost, resulting in improvements in productivity, environmental and economic metrics.

Bioprocess intensification usually involves a drastic change in equipment and/or process design e.g., moving from batch to continuous processing or integrating new process steps. The result is not only a considerable increase in productivity but a significant improvement in other environmental and economic metrics such as energy consumption, carbon footprint, OPEX and CAPEX. 

Benefits of process intensification in bioprocessing


  • Miniaturized plant size
  • Reduced CAPEX and OPEX
  • Distributed manufacturing
  • Faster from research to market 



  • Higher cell densities
  • Increased productivity
  • Improved product CQA
  • Wider process conditions
  • Continuous processing


  • Reduced energy use
  • Reduced waste
  • Reduced reagent usage
  • Smaller landscape footprint

Repligen solutions help overcome key challenges in process intensification, with hands-on process and implementation consultation from global Field Applications Specialists.

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Perfusion Cell Culture

Perfusion, a cornerstone of upstream continuous bioprocessing, has been practiced since the 1980s to maximize facility utilization, expand process flexibility and minimize costs. Today, novel cell retention devices and single-use technologies, with sophisticated control logic, simplify implementation.

N-1 Perfusion

A form of seed train intensification, N-1 perfusion refers to the intensification of cell growth in the seed train step (N-1) before the production bioreactor (N), achieving a more rapid and robust process while maintaining an existing Fed-Batch based production scheme.

Seed Train Intensification

Seed train intensification aims to generate ultra high-density cell cultures at optimal points during cell expansion using a robust cell retention device prior to the inoculation of the production bioreactor.

High Productivity Harvest

High Productivity Harvest (HPH) is a novel application developed by Repligen that enables the harvest of a Fed-Batch bioreactor in a fully sterile manner ready for processing on a capture column, eliminating both centrifugation and depth filtration.

XCell® ATF Systems

Simplify and intensify upstream bioprocessing. The XCell® ATF System, in single-use or stainless steel format, delivers high cell retention. High impact upstream solutions include N-1 perfusion, high productivity harvest, long-term perfusion and seed train intensification.

KrosFlo® TFDF® Systems

Game-changing TFDF® (Tangential Flow Depth Filtration) technology that simplify and intensify upstream viral vector bioprocessing, ideal for AAV, lentivirus, oncolytic, retrovirus, adenovirus, exosomes, and cells on microcarriers.