Dynamic Perfusion Delivers Highest Productivity in Smallest Footprint
Upstream Intensification for Challenging Modalities and Molecules
Established manufacturers are looking to single-use, flexible solutions when building new facilities or modifying existing operations. Their goal is to increase productivity across different modalities including difficult-to-express molecules. Meanwhile, early-stage drug development companies are looking for low upfront investment for their lower throughput products. With smaller bioreactor requirements that deliver higher productivity per batch, dynamic perfusion can be the answer in both cases.
Versatile solutions for cell line, media management with single-use mixers, pallet tanks, bags, filters and Biostat® STR and RM bioreactors.
Biostat® STR single-use bioreactors, ATF-compatible, are ideal to reach high VCDs for increased productivity for your perfusion process
Biostat® RM perfusion enabled bioreactors (0.1-100L wv) reaching cell densities for high volume inoculation resulting in shorter seed train
Perfusion enabled seed train with Sartorius Biostat® RM and ATF compatible Biostat® STR bioreactor for high productive intensified solution
Dynamic Perfusion Shows Less Does Mean More
Up to 5x the Productivity in a 500 L Bioreactor
In dynamic perfusion, the product can be continuously harvested by microfiltration. This approach can be accomplished in smaller bioreactors, resulting in smaller footprint and as much as a 60% lower capex upfront investment. Productivity can be increased up to 5 times compared to standard fed-batch. while offering the flexibility to support multiple molecule pipelines, even for hard-to-express molecules.
A Cost Effective Upstream Intensification Option
Implementing rocking motion bioreactor, with integrated perfusion membrane, in the N-1 seed train step is the most cost-effective opportunity for seed train intensification for high inoculum fed-batch process. Using the RM bioreactor manufacturers can
- Reduce both capital and consumable investment by >30%
- Achieve high cell densities at lower volumes to inoculate production bioreactor
- Increase productivity and overall facility throughput by 30-50% thus decreasing overall COGS by up to 50%
Intensification Made Easier through Alternating Tangential Flow
During dynamic perfusion (DP), a smaller bioreactor such as the Biostat® STR 500 L bioreactor is running in perfusion mode with the implemented alternating tangential flow (ATF) system from Repligen. For DP, it is run in microfiltration mode. The product is harvested continuously for the next 15 -20 days, while fresh media is fed every day in the same ratio. As there is no cell bleeding performed, the viable cell density (VCD) increases, allowing higher productivity with up to 5-fold increase.
- Appropriate for multi-modality facility
- Increase productivity with up to 5 times
- Ideal for difficult to express molecules (bispecifics, multispecifics...)
Ensuring Media Quality and Stability Is Critical for Intensification
Consistent cell culture performance in intensified processes is dependent on the media design, quality, and stability. In dynamic perfusion, fresh medium and feeds are added continuously over 15-20 production days, thus requiring smart media strategies. Consumables and equipment to handle these volumes are essential to support a smooth process flow, while reliable filters to avoid contamination and remove mycoplasma are 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
2D Single-Use Bags
Storage to Support the Media Volume Required for Dynamic Perfusion
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´ Biostat® STR bioreactors.
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 – and in the case of dynamic perfusion, 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.
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.
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.
The Missing Link in Your PI Plan
Explore the implications of media management in an intensification strategy in this webinar featuring Sartorius experts
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.
Assurance Through Multivariate Data Analytics
Customers rely on enhanced data analytics for process intensification due to the complexity of operations, processes and data as well as the total cost of risk. Multivariate Data Analysis (MVDA) extracts meaningful information from large data sets, enabling 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 in dynamic perfusion. 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.
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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