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Process Intensification

MORE. FASTER.

Bioprocess intensification is defined as a significant step increase in output relative to cell concentration, time, reactor volume or cost, resulting in improvements in productivity, environmental and economic metrics.

By modality By unit operation By product

Bioprocess intensification usually involves a drastic change in equipment and/or process design e.g., moving from batch to continuous processing or integrating new process steps. The result is not only a considerable increase in productivity but a significant improvement in other environmental and economic metrics such as energy consumption, carbon footprint, OPEX and CAPEX. 

Benefits of process intensification in bioprocessing

BUSINESS

  • Miniaturized plant size
  • Reduced CAPEX and OPEX
  • Distributed manufacturing
  • Faster from research to market 

 

PROCESS

  • Higher cell densities
  • Increased productivity
  • Improved product CQA
  • Wider process conditions
  • Continuous processing

ENVIRONMENT

  • Reduced energy use
  • Reduced waste
  • Reduced reagent usage
  • Smaller landscape footprint

Repligen solutions help overcome key challenges in process intensification, with hands-on process and implementation consultation from global Field Applications Specialists.

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Leader in Upstream Process Intensification 

Watch the webinars on history, potential, applications

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Evolution of upstream intensification: Optimizing perfusion processes with PAT

The PAT landscape in upstream intensification, the benefits of this approach, and the scale-up from benchtop to manufacturing is discussed.

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Viral vector N-1 intensification reduces seed train vessel number, media volume and time

This webinar discusses similar efficiency gains for three different viral vectors (lentivirus, AAV8 and AAV9) through intensification using KrosFlo® TFDF® Technology that resulted in reduce train vessel number, N-1 vessel size, media volume and time.

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Where and When to Apply Upstream Process Intensification Technologies

15+ years of published application data, implementation in the largest number of commercial processes and proven scaling from 1 L to 5000 L differentiate XCell ATF® Technology from all other upstream intensification methods. Considerations for when and why to apply XCell ATF® Technology in order to meet specific productivity goals will be discussed.

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Perfusion Cell Culture

Perfusion, a cornerstone of upstream continuous bioprocessing, has been practiced since the 1980s to maximize facility utilization, expand process flexibility and minimize costs. Today, novel cell retention devices and single-use technologies, with sophisticated control logic, simplify implementation.

N-1 Perfusion

A form of seed train intensification, N-1 perfusion refers to the intensification of cell growth in the seed train step (N-1) before the production bioreactor (N), achieving a more rapid and robust process while maintaining an existing Fed-Batch based production scheme.

Seed Train Intensification

Seed train intensification aims to generate ultra high-density cell cultures at optimal points during cell expansion using a robust cell retention device prior to the inoculation of the production bioreactor.

High Productivity Harvest

High Productivity Harvest (HPH) is a novel application developed by Repligen that enables the harvest of a Fed-Batch bioreactor in a fully sterile manner ready for processing on a capture column, eliminating both centrifugation and depth filtration.

XCell® ATF Systems

Simplify and intensify upstream bioprocessing. The XCell® ATF System, in single-use or stainless steel format, delivers high cell retention. High impact upstream solutions include N-1 perfusion, high productivity harvest, long-term perfusion and seed train intensification.

KrosFlo® TFDF® Systems

Game-changing TFDF® (Tangential Flow Depth Filtration) technology that simplify and intensify upstream viral vector bioprocessing, ideal for AAV, lentivirus, oncolytic, retrovirus, adenovirus, exosomes, and cells on microcarriers.