Expediting Viral-Based Vaccines Development and Increasing Productivity

Part 1 Upstream Processing

We are all witness to the impact of the COVID-19 pandemic across the world, as it is bringing economies and life in general to a halt. In response to this pandemic, there are more than 90 vaccine candidates today that are in pre-clinical phase, with a few companies entering clinical trial phase I. We know that speed is of essence and that scale-up to large-scale production needs to be achieved by strategically balancing risks and speed.

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This presentation first describes how vaccine developers can accelerate their timelines and develop highly efficient vaccine processes by using high throughput fully automatic multi-parallel bioreactor testing tools such as Ambr®, DoE software, and single-use solutions able to operate with mammalian cells, insect cells, and avian cells.

Key Learning Objectives

  1. Upstream process intensification methods, scale up tools and real case data will be presented for both suspension and adherent cell culture in fed batch, concentrated fed batch or perfusion mode.
  2. In particular, we will show how intensifying the working cell bank and the seed train bioreactor with perfusion helps saving half of the consumable costs and reduces the main bioreactor cell expansion time by up to 40%. 
  3. Moreover, being able to achieve higher titers will be extremely important to keep scale up at a manageable level, which is critical during a pandemic situation.
  4. The author will finally show how coupling the production bioreactor with ATF, PAT tools and online multivariate process monitoring software can provide 10 to 50 times higher cell density and a the full automation and predictive control of the cell culture process performance.

Meet Our Experts

Piergiuseppe Nestola, PhD
Global Vaccine Technology Consultant

Piergiuseppe Nestola is a Global Vaccines Technology consultant at Sartorius Stedim Biotech where he is responsible for providing scientific leadership and identifying the best technologies and processes for the vaccine segment.

Prior to joining Sartorius, he worked for several years at Janssen Vaccines AG in Bern (CH) as a scientist and team leader in the process development group. In this role, he was involved in the development and scaling up of both viral vectors and protein-based vaccines.

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