Concentrated Fed-Batch for Increased Productivity and Flexibility

Intensification With Flexibility for Higher Facility Throughput Requirement

Concentrated fed-batch (CFB) is the upstream process intensification that can have the greatest impact on productivity compared to standard fed-batch, producing up to four times the titer and 3-4 times higher throughput. Concentrated fed-batch is the ideal option for converting stainless-steel to single-use operations and for blockbuster drugs. Considering the increasing trend towards throughput of less than 500 kg per year, concentrated fed-batch offers the flexibility to have a multiproduct high throughput facility to satisfy productions of multiple drugs within the same single-use facility.

Ideal for higher throughput requirements

Perfusion enabled seed train options in Sartorius Biostat® RM/STR and ATF compatible production Biostat® STR result in high titer processes.

Almost 3-4 times the productivity as compared to fed-batch

Sartorius Biostat® STR bioreactors are ATF-compatible making it simpler for users to reach HCD for a high productive process

Ideal for converting large stainless steel facilities to single-use

Ideal single-use solutions in mixers, bags, tanks and filters for managing high volume of media required for concentrated fed-batch application

Lowest facility footprint in USP due to higher titers

Services for providing high titer cell line, media and media management tools along with flexible single-use solutions for seed train


Intensified Seed Train Options

Options for stirred tank and rocking motion bioreactors

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Media Management

For the larger volumes needed to increase cell density

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Process Control and Data Analytics

Ensuring quality, safety, and efficacy at all times

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Intensified Seed Train and Production Options

Concentrated Fed-Batch for Concentrated Impact

Up to 4x Productivity, Even in Small Volumes and Different Modalities

Concentrated fed-batch (CFB), combined with N-1 intensification in the seed train, achieves a 4-5 fold increase in productivity by running the production bioreactor in concentrated mode. The product and cells are returned to the bioreactor, hence concentrated, reaching high cell densities and titers, until the final harvest, which is performed in batch mode. The alternating tangential flow filter used in ultrafiltration mode is critical to remove spent media during that process. With up to 4 times titer over standard fed-batch and 3-4 times the throughput, CFB is an attractive alternative for both multiproduct single-use facilities or those with high drug demands.​

The Patented Rocking Motion Bag with Integrated Perfusion Membrane

A rocking motion perfusion system is an optimal solution consisting of a rocking motion single-use bag with an integrated perfusion membrane. Thanks to the unique design, a separate cell separation device is not required. Using the rocking motion perfusion bioreactor in the N-1 seed train step is a cost-effective way to establish intensified upstream seed train. This leads to increased productivity and potential reduction in seed train steps. ​

  • 25% reduction in costs per batch compared to a standard perfusion enabled stirred tank seed train.​
  • Increase titer by 30% or more​
  • Reduce upstream seed train days

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Effortless Change to Seed train Perfusion by Integrating ATF ​

Sartorius Biostat® STR  bioreactors are compatible with the XCell ATF® System (scalable to 5000 L), from Repligen. This alternating tangential flow (ATF) filtration system used in ultrafiltration mode retains cells leading to a higher cell density for production bioreactor inoculation. The combination of the bioreactors with the leading perfusion device in mAb production enables the implementation of a seed train step intensification in existing fed-batch operations.​

  • Increased Productivity per batch​
  • Almost double the titer for selected clones​
  • Reduce production bioreactor culture by ~40%

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Intensification Made Easier by Implementing Alternating Tangential Flow

During CFB processes, the Biostat® STR 2000 L bioreactor runs in concentrated mode with the implemented alternating tangential flow (ATF) system from Repligen. The ATF device operated in ultrafiltration mode to remove spent media while retaining cells and product in the bioreactor. This concentration of viable cell density (VCD) and product results in increased titers up to 4 times that of standard fed-batch.​

  • Increased facility throughput up to 4 times​
  • Increase productivity per batch with up to 4 times titer increase​
  • Potential shorter batches further increase throughput and flexibility​

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Media Management

Ensuring Media Quality and Stability Is Critical for Intensification

Concentrated Fed-Batch requires a larger amount of cell culture medium than in standard fed-batch. Ensuring consistent cell culture performance in intensified processes is dependent on the media design, quality, and stability. Consumables and equipment to handle these volumes are equally essential to support a smooth process flow. A reliable filter to avoid contamination and remove mycoplasma is also critical for successful intensified processes.

The Flexsafe® Pro Mixer Saves Time Without Compromising Control

Flexsafe® Pro Mixer is an efficient, single-use mixer for 50 L up to 3000 L. It provides the high levels of control that are essential for cGMP biomanufacturing.

  • Saves time with fast powder dissolution
  • Preserves quality of shear sensitive fluids through low shear mixing and high torque
  • Designed for rapid set-up and efficient changeover (in less than 10 minutes) reducing risk of damage and loss from product mishandling
  • Includes full material characterization and safety evaluation

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2D Single-Use Bags

Storage to Support the Media Volume Required for Concentrated Fed-Batch

With concentrated fed-batch running in perfusion mode, there is a greater demand for cell culture medium. It is for this reason that consumables and equipment to handle these volumes are essential for a smooth process flow. Sartorius Flexsafe® 2D Single-Use Bags ensure the stability and integrity of the medium, allowing excellent, reproducible cell growth. The superior strength of the  polyethylene film reduces risk of damage, while its flexibility enables consistent performance and easy handling. These ready-to-use bags have “plug and play” compatibility with Sartorius´ STR bioreactors.

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3D Single-Use Bags

Self-Deploying and Filling 3D Single-Use Bags for Pallet Tanks

Liquid medium must be prepared and safely stored to be ready whenever it is needed. To meet the significant cell culture media requirements of concentrated fed-batch and support smooth process flow, larger scale liquid storage is often required. Flexsafe® 3D Single-Use Bags, designed for storage applications in pallet tanks, are easy to use and allow excellent and reproducible cell growth. With a self-deploying accessory, the bag can be filled with no operator manipulation.

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Ensuring Quality and Safety of Cell Culture Medium

Companies are looking more and more for virus removal filters for media for risk mitigation purposes. Virosart® Media filters, provide high virus clearance safety and show superior capacities for media used for mAbs and recombinant proteins. ​

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Cost Efficient Media Filtration with High Mycoplasma Retention

Sartopore® 2 XLM sterile filters are used for cost-efficient media filtration with outstanding high throughput. They feature a 30% larger surface area and optimized pre-filter layers which results in a higher flow rate and higher throughput. The Sartopore® 2 XLM is an advanced 0.1 µm rated filter with high mycoplasma retention.

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The Missing Link in Your PI Plan

Explore the implications of media management in an intensification strategy in this webinar featuring Sartorius experts

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Featured Asset

Whitepaper: Intensifying Upstream Processing - Implications for Media Management

This whitepaper provides the tools and information needed to consider process intensification (PI) options while evaluating the implications of media management. This comprehensive overview of the media journey and how increased volumes associated with PI can be effectively managed is followed by an exploration of the feasibility of different PI scenarios in both new and existing facilities.

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Process Data Analytics

Assurance Through Multivariate Data Analytics

Customers rely on enhanced data analytics for process intensification. This is due to the increased complexity of processes, operations, and data, as well as the total cost of risk.  Multivariate Data Analysis (MVDA) extracts meaningful information from large data sets. It enables scale-up and batch-to-batch comparison investigations to improve the quality, safety, and efficacy of a drug product.

SIMCA® Ensures Process Health and Manufacturing Success

SIMCA® is an advanced data analytics solution to gain actionable information from large quantities of data, ensuring consistent processes and product quality. SIMCA® analyzes incoming raw materials and determines how they may affect cell growth, viability, productivity, and quality – which is critical for concentrated fed-batch. This robust multivariate engine will compare batch-to-batch quality and identify sources of any variation, accessible through an intuitive interface and easy-to-read interactive visualizations.

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SIMCA®-Online Integrates Real-Time Monitoring and Controls

Multivariate real-time monitoring is important, especially in intensified processes. While SIMCA® creates a digital fingerprint of a process as reference, SIMCA®-online uses real-time measurements to assess operations based on this fingerprint – essentially verifying if the current batch fingerprint matches or not. If there are derivations from the reference, the process can be adapted immediately. This automated corrective action keeps quality consistent, maximizes efficiency and reduces costs.

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Related Assets

Whitepaper: Intensifying Upstream Processing and the Implications for Media Management

PDF | 4.4 MB

Success Story: Increased Productivity With Concentrated Fed-Batch

PDF | 319.0 KB

A Look Into the Future of Bioprocessing

PDF | 869.9 KB

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