Applications Vaccixcell

Roller Bottles to Closed System

Mass cultivation of cells has become important especially in the production of viral vaccines or for obtaining therapeutic proteins. Roller bottles are two-dimensional (2D) system commonly used for cultivation of adherent cells (anchorage-dependent cells) as it provides the same techniques as with traditional cell culture flasks.

VacciXcell’s tide motion bioreactor system is similar to the principle of roller bottle system, as it also alternately exposes the cells to aeration and nutrition. However, the tide motion system overcomes most of the disadvantages associated with the roller bottle system as well as other static cell culture system including space requirement, amount of labor, contamination risk and most importantly production capacity.

The first to Vaccixcell’s linearly scalable bioreactors are Celcradle™ which is a disposable bioreactor capable of high density cell culture for protein expression, virus and monoclonal antibody production. It is designed based on the concept of bellow-induced intermittent flow of media and air through porous matrices, where cells reside. Celcradle™ provides a low shear, high aeration, and foam-free culture environment which results to high density cell culture with high quality product yield, minimal downstream processing cost, minimal labor and space requirement and most importantly highly reproducible and linearly scalable results.

VacciXcell Hybrid Bioreactor offers best transferring processes and analytical methods from research and development sites to commercial manufacturing sites. In a start-up or R&D environment, determining which type of culture would yield the desired product the most is essential. The VacciXcell hybrid bioreactor gives its users exactly that option by being able to try out four (4) different types of culture namely: adherent culture using macrocarrier, adherent culture using microcarrier in a stirred tank environment, suspension culture and fermentation. By being able to do the design of experiment (DOE) using these four types of culture in one system, data gathering and analysis would be easier and more efficient, resulting in lower total cost and shorter process development period.

 

As costs of production become more and more expensive, existing facilities that employ the roller bottle system can thereby benefit from switching to TideCell® System for several reasons. The TideCell® System is VacciXcell’s tide motion bioreactor which is linearly scalable from laboratory to production scale with significant reduction of bioprocessing time and costs. The system can replace thousands of 850cm2 roller bottles for up to 20,000 pieces with small footprint. The TideCell® System is fully enclosed and automated which reduces the risk of contamination and increases the control of the production. The tide motion principle employed in the TideCell® system allows simple medium exchange and better medium consumption efficiency, which is a large cost in cell culture systems.

VacciXcell has successfully conducted the switch from the roller bottle system to the TideCell® system for multiple customers performing vaccine production for both human and animals.

Client cases of transferring from roller bottles to TideCell® system. Only these information can be displayed due to non-disclosure agreement (NDA) with clients.

 

A(H1N1) Influenza Vaccine

Compared Item Roller bottle TideCell
Performance Analysis
Scale 2 L, 850 cm2 per bottle 10 L
Carrier None 550 g
Max. cell density 1×108 1.5×1011
Culture days 6 6
Average Virus concentration 128~256  HA 512~1024 HA
Culture medium (cell culture) 200 mL 250 L
Virus production days 4 4
Culture medium (virus production) 200 mL 50 L
Equivalency 1,000 1
Cost Analysis (based on the same productivity)
Space 300 m2 3~6  m2
Labor 20~30 2
Culture medium 400 L (~USD4,000) 300 L (~USD 3,000)

 

Human H5N1 Vaccine

Compared Item Roller bottle TideCell
Performance Analysis
Scale 15 L, 3000 cm2 per bottle 10 L
Carrier None 550 g
Max. cell density 4~6×108 1×1011
Culture days 3 3
Culture medium (cell culture) 1.5 L 50 L
Virus production days 16 28
Culture medium (virus production) 6 L 720 L
Equivalency 443 1
Cost Analysis (based on the same productivity)
Space 100 m2 3~6  m2
Labor 10~20 2
Carriers   550 g
Culture medium 2,658 L (~USD26,580) 720 L (~USD 7,200)
Average Virus concentration 40 mil. RID/ml 200 mil. RID/ml

 

Human Hepatitis A Vaccine

Compared Item Roller bottle TideCell
Performance Analysis
Scale 2 L, 850 cm2 per bottle 2 L,  10 L,  20 L
Carrier None 110 g, 1100 g
Max. cell density 1×108 2×1010,  1×1011, 2×1011
Average Virus concentration 1 arbi. unit/bottle 80, 330, 700 arbi. unit/bottle
Culture days N/A N/A
Culture medium (cell culture) 4.2 L 50 L, 250 L, 500 L
Virus production days 21 21
Culture medium (virus production) 4.2 L 50 L,  250 L, 500 L
Equivalency 80, 330, 700 1
Cost Analysis (based on the same productivity)
Space 100 m2 3~6  m2
Labor 10~20 2
Culture medium 2,940 L (~USD29,400) 500 L (~USD 5,000)

 

Hog Cholera Vaccine

Compared Item Roller bottle TideCell
Performance Analysis
Scale 15 L, 3000 cm2 per bottle 10 L
Carrier None 550 g
Max. cell density 4~6×108 1×1011
Average Virus concentration 40 mil. RID/ml 200 mil. RID/ml
Culture days 3 3
Culture medium (cell culture) 1.5 L 50 L
Virus production days 16 28
Culture medium (virus production) 6 L 720 L
Equivalency 443 1
Cost Analysis (based on the same productivity)
Space 100 m2 3~6  m2
Labor 10~20 2
Carriers   550 g
Culture medium 2,658 L (~USD26,580) 720 L (~USD 7,200)

Related Products:

CelcradleTM
TideCell®
Hybrid Bioreactor