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Regarding suitability of Eppendorf bioprocess equipment in GMP-regulated applications, please reach out to your Eppendorf sales representative.
Bioprocessing in Vaccine Development
Types of vaccines
Biopharmaceutical drugs have revolutionized the treatment of a wide range of diseases and are increasingly used in nearly all branches of medicine, including vaccinations. Vaccines contain weakened or inactive components of a pathogen that trigger an immune response within the body. This teaches the immune system to recognize and establish a rapid and effective response against that pathogen in future infections. This process is critical to protecting populations from rapidly spreading or potentially fatal diseases. Vaccines come in a wide variety of forms and use either the full pathogen, subunits of it, or the genetic information for producing the antigen of choice.
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Read more about the different vaccine types
Vaccines come in a wide variety of forms, including:
- Live attenuated vaccines that use a weakened (attenuated) version of the pathogen e.g., the measles, mumps, rubella (MMR) vaccine
- Inactivated vaccines that use an altered or killed version of the pathogen that cannot replicate e.g., rabies vaccine
- Subunit vaccines and toxoid vaccines that use protein, polysaccharide, or the pathogen capside.g., hepatitis B vaccine
- DNA and RNA vaccines that use DNA or RNA that codes for antigens from the pathogen, e.g., some COVID-19 vaccines
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Watch this in-depth video for all the essential information about viruses, vaccinations, and vaccine development.
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Read about the advantages of bioreactors for vaccine production
Once research has shown the ideal candidate antigen for a specific vaccine development plan, it is crucial to find the means to produce this antigen at sufficiently high quantities to meet the growing global demands for new vaccines. In this phase, either the pathogen itself is produced, with additional steps for later inactivation or isolation of a subunit, or a recombinant protein derived from the pathogen. The use of cell culture in bioreactors offers a standardized, scalable, and cost-effective procedure for developing vaccines.
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To meet growing global demands for new vaccines, it’s important to be able to produce vaccines in an efficient and cost-effective manner. This is especially true for diseases with a high mutation rate and transmissibility. One method for vaccine production is the use of embryonated chicken eggs (ECE), which have limitations in terms of the availability of high-quality and specific pathogen-free (SPF) eggs, scalability, and potential health concerns including egg allergies.
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The use of cell culture systems offers a more scalable procedure for developing vaccines. Advances in bioprocessing mean that it is now possible to grow mammalian and microbial cells to high densities in bioreactors, allowing for the large-scale production of a variety of viral vectors, live attenuated vaccines, and several subtypes of vaccines. Bioreactors combine an optimizable environment with scalability, and a more standardized and automated process for vaccine development.
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Discover more advantages of vaccine development using mammalian cells
White Paper
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Get to know more about approaches and trends in vaccine development production
Infographic: Vaccine development workflow
The vaccine development journey involves several stages, from selecting lead candidates to process development, and manufacturing. Gain a better understanding of the vaccine development workflow, and learn about the problems and potential solutions of each stage.
ebook: Challenges in upstream bioprocessing
Vaccine manufacturers are facing the challenge of developing new products to serve unmet needs and fulfill the demands in an economically viable way. Read expert views and case studies on some of the hot topics in vaccine bioprocess development.
ebook: Cultivation of adherent and suspension cells
Discover application examples for the cultivation of adherent and suspension cells for vaccine development.
Panel discussion: Trends in vaccine development
Check out this video of experts discussing trends in vaccine development including automation.
Webinar: Stirred tank bioreactors in vaccine development
The use of cell culture in bioreactors offers a standardized, scalable, and cost-effective procedure for developing vaccines. Learn, how suspension cells were efficiently cultivated in bioreactors to produce AAV particles and COVID-19 spike-proteins in suspension culture.
Methods of vaccine development
Vaccines are critical to both human and animal health. They are becoming an ever more vital tool in the fight against disease as new diseases continue to emerge against a backdrop of increasing antimicrobial resistance. To meet growing global demands for new vaccines, it is important to be able to produce vaccines in an efficient and cost-effective manner. The use of cell culture in bioreactors offers a standardized, scalable, and cost-effective procedure for developing vaccines. Find out, how Eppendorf can support you in upstream bioprocess development and scale-up.
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Process development
The purpose of upstream bioprocess development is to reduce the overall manufacturing cost of vaccine development while maximizing the quantity and quality of the desired final product. Various cultivation parameters, such as the temperature, pH , DO , shear force, and nutrient supply can affect cell growth and protein expression levels. Thus, it is essential to evaluate each of these conditions and their interactions to determine the most effective conditions for your bioprocess.
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Learn more about how the Eppendorf solutions help you saving time in bioprocess development.
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Bioprocess scale-up
Bioprocess insight gained at small-scale can help to ensure a high level of success in your large-scale processes. Once the ideal conditions have been achieved, bioreactors can be used to effectively scale-up your culture from benchtop to pilot and industrial scales. Several scale-up strategies exist to ensure maximum efficiency and product quality is maintained.
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Learn more about scale-up strategies and how the Eppendorf bioprocess equipment can help streamlining scale-up.
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Process intensification
Process intensification, a methodology for reducing equipment, energy consumption, and waste generation while achieving higher quality products, can make a substantial contribution to further increasing process productivity and lowering production costs. One way to optimize your bioprocessing is fine-tuning the control of your bioprocess through Process Analytic Technology (PAT) which can help to improve reproducibility, reduce batch-to-batch variation, and increase yields and product quality. Another important consideration when intensifying the rate or increasing the yield is which operation mode to use for your bioprocess. A variety of strategies including batch, fed-batch, and continuous cultures exist to help you optimize batch quality and yield.
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Learn more about how to reduce batch-to-batch variability and increase yield.
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Learn more
Eppendorf bioprocess solutions for vaccine development
Scalable systems
Since vaccine development is a challenging and complex process, it's essential to carefully prepare your approach to if possible avoid potential issues. Crucial aspects to consider is how to optimize your process at small scale and how you will scale up your cell culture from the lab to pilot and industrial scales. Eppendorf offers a wide range of bioreactors from 60 mL to 2400 L to suit the needs from research to pilot production scale.
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The Eppendorf range of bioreactor systems:
- Small-scale: DASbox® Mini Bioreactor System and DASGIP® Parallel Bioreactor Systems
- Bench-scale: SciVario® twin , BioFlo® 120 , BioFlo® 320
- Pilot/production-scale: BioFlo® 720 , BioFlo® 510 / CelliGen 510 , BioFlo® 610 , BioFlo® Pro
Single-use bioreactors
The use of single-use bioreactors increases turn-around, eliminates the need for bioreactor cleaning, and decreases the risk of cross-contamination. Eppendorf offers a large portfolio of single-use bioreactors for use in vaccine development. Regardless of the cells you employ to make vaccines, there are single-use bioreactors created specifically for your needs, for example:
- Microbial cells: BioBLU® f Single-Use Bioreactors (65 mL to 3.75 L)
- Cell Culture: BioBLU® c and p Single-Use Bioreactors (100 mL to 40 L)
- Cell Culture: BioFlo® 720 control station compatible with Thermo Scientific® HyPerforma® Single-Use Bioreactors (50 L to 2000 L)
Cell culture in perfusion
In perfusion mode, cells are retained inside the bioreactor while the medium is constantly exchanged. Like this the cell medium compositions remains more stable during the process which potentially favours a more consistent product quality. This means that toxic by-products need to be removed while the cells are retained in the bioreactor. The retention method varies depending on whether the cell line can be grown in suspension or needs to adhere to a growth matrix.
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Eppendorf offers solutions for upstream bioprocessing in perfusion:
- Bioreactor systems connectable to filtration devices for cell retention
- Bioreactor systems connectable to Cell-Lift impeller and decanter column
- Packed-bed bioreactors filled with Fibra-Cel® Disks
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Cultivation of adherent cells
Some cell types used in vaccine development, including Vero cells, are anchorage-dependent cells requiring a growth matrix to adhere to in order to be cultivated in stirred-tank bioreactors. There are two main approaches to ensure these cell types are retained correctly:
- Microcarriers: beads in suspension to which adherent cells can attach and grow in bioreactors
- Packed-bed bioreactors: bioreactors with a fixed bed of Fibra-Cel® Disks on which the cells are immobilized
Find out more about the cultivation of anchorage-dependent cells in Eppendorf bioreactors!
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Discover the Eppendorf bioreactor portfolio!
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How our customers use our products
Find some examples of how our customers use Eppendorf bioprocess equipment for vaccine process development.
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A selection of our customers
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