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Bioprocessing in Vaccines

Solutions for vaccine process development through production

In these exceptional and unprecedented times, many companies and organizations are eagerly working to advance the development of a vaccine in the context of the current COVID-19 crisis.

New bioprocess technologies such as single-use equipment and process automation open up novel possibilities for quality control and validation. This is especially important in GMP regulated environments such as in the development and manufacturing of new influence vaccines. When facing a pandemic outbreak, the need to smoothly develop new processes and quickly scale-up to clinical production volumes is key to efficiently develop new vaccinations.

Eppendorf, your expert partner in bioprocessing, contributes with its bioprocess solutions and services.

Challenges in vaccine 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. Upstream bioprocessing is an important piece of the puzzle. Read expert views and case studies on some of the hot topics in vaccine bioprocess development.

Vaccine research and process development

Modifying vaccines in response to changes by the respective virus or agent is a constant challenge for vaccine manufacturers. Hence, process development is a key element in the creation of improved, more rapid, and lower-cost methods for production.

Viral Vector Production


Continuous cultivation techniques and perfusion have the potential to increase the efficiency of biopharmaceutical manufacturing processes. They can help increasing product titers while decreasing production volumes needed.

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Vero cells are anchorage-dependent cells that are widely used as a platform for viral vaccine production. In stirred-tank bioreactors, they are grown ordinarily on microcarriers. Fibra-Cel®disks are an alternative attachment matrix because they provide a three-dimensional environment that protects cells from damaging shear forces. The cultivation of Vero cells in benchtop single-use and glass bioreactors with a packed bed made of Fibra-Cel disks has been tested.

Kamal A. Rashid, PhD, Director of the Biomanufacturing Education and Research Center, and Research Professor, Worcester Polytechnic Institute, reports on the cultivation of CHO cells in the BioBLU® 5p Single-Use Vessel in perfusion mode. The packed-bed basket technology, developed by Eppendorf, provides a shear-free environment for the production of animal cells.

Single-use technology

Single-use bioreactors are routinely used in biopharmaceutical R&D and biologics manufacturing. They have the potential to reduce turn-around times and the risk for contaminations and make validations easier. One potential problem of single-use systems, however, is the release of chemical compounds into the culture medium. Standardized tests help investigating the effects of leachables and extractables (L&Es) on cell growth.

Microbial vaccine development

Recent surveys see an increasing demand of microbial expression systems in the biopharmaceutical industry. Their advantages are obvious: Bacterial hosts are easy to cultivate, grow fast, and media are less expensive than complex cell culture media. A growing range of single-use fermentors has the potential to diminish labor costs, shorten turn-around times, and make validation easier.

BIOASTER® Technology Research Institute (TRI) is working to develop a microbial technology platform to improve safety and efficacy of vaccines and to develop diagnostic tools. They use DASbox® Mini Bioreactor System equipped with BioBLU Single-Use Vessels in order to enhance their process development efforts.

Charlotte Mignon, Research Engineer at BIOASTER, discussed her motivation on the job, what her research is about and how she spends her free time in an interesting interview.