{"id":41740,"date":"2023-05-31T19:05:00","date_gmt":"2023-05-31T19:05:00","guid":{"rendered":"https:\/\/www.alicat.com\/?p=41740"},"modified":"2026-01-06T23:06:12","modified_gmt":"2026-01-06T23:06:12","slug":"verringerung-des-platzbedarfs-von-bioreaktoren","status":"publish","type":"post","link":"https:\/\/www.alicat.com\/de\/articles\/reducing-bioreactor-footprint\/","title":{"rendered":"Geringerer Platzbedarf f\u00fcr Bioreaktoren"},"content":{"rendered":"

[et_pb_section fb_built=”1″ _builder_version=”4.24.2″ _module_preset=”default” custom_css_free_form=”@media (max-width: 375px) {|| .et-db #et-boc .et-l .et_pb_post_content_0_tb_body {|| width:100% !important;|| }}” locked=”off” global_colors_info=”{}” theme_builder_area=”post_content”][et_pb_row _builder_version=”4.27.4″ _module_preset=”default” custom_padding=”2em||0px||false|false” global_colors_info=”{}” theme_builder_area=”post_content”][et_pb_column type=”4_4″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}” theme_builder_area=”post_content”][et_pb_heading title=”Fast Global Vaccine Delivery via Reduced Bioreactor Footprint” _builder_version=”4.27.4″ _module_preset=”default” custom_css_free_form=”selector h1 {|| text-wrap: pretty;||}” global_colors_info=”{}” theme_builder_area=”post_content”][\/et_pb_heading][et_pb_image src=”https:\/\/www.alicat.com\/wp-content\/uploads\/2023\/05\/articles-fast-global-vaccine-delivery.webp” align=”center” force_fullwidth=”on” _builder_version=”4.27.5″ _module_preset=”default” custom_margin=”1.5rem||||false|false” hover_enabled=”0″ custom_css_free_form=”selector img {|| object-fit: cover;||}” locked=”off” global_colors_info=”{}” theme_builder_area=”post_content” module_id=”article-hero-image” sticky_enabled=”0″][\/et_pb_image][et_pb_divider color=”#2A3B47″ divider_weight=”2.5px” _builder_version=”4.27.4″ _module_preset=”default” height=”0px” custom_margin=”3rem||3rem||true|false” global_colors_info=”{}” theme_builder_area=”post_content”][\/et_pb_divider][\/et_pb_column][\/et_pb_row][et_pb_row _builder_version=”4.27.4″ _module_preset=”default” custom_padding=”0px||0px||true|false” locked=”off” global_colors_info=”{}” theme_builder_area=”post_content”][et_pb_column type=”4_4″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}” theme_builder_area=”post_content”][et_pb_text _builder_version=”4.27.4″ _module_preset=”default” custom_margin=”||2rem||false|false” global_colors_info=”{}” theme_builder_area=”post_content”]Global vaccine distribution is critical to the eradication of deadly diseases. In 1980, after an intensive vaccination campaign, the World Health Assembly declared smallpox eradicated<\/a>. As of 2020, there are fewer than 500 new cases of polio each year in the world.<\/p>\n

In the United States, 14 diseases<\/a> which used to be deadly (such as diphtheria and measles) are now nearly eliminated. However, they are much more prevalent in countries that have been unable to carry out rigorous vaccination campaigns.<\/p>\n

Inability to carry out these vaccination campaigns is most often due to the prohibitively high costs of the vaccines. When vaccines are manufactured more cheaply, they can be distributed globally at much lower costs \u2014 furthering disease eradication everywhere.[\/et_pb_text][et_pb_heading title=”Plant footprint correlates closely with manufacturing costs” _builder_version=”4.27.4″ _module_preset=”default” title_level=”h3″ global_colors_info=”{}” theme_builder_area=”post_content”][\/et_pb_heading][et_pb_text _builder_version=”4.27.4″ _module_preset=”default” custom_margin=”||2rem||false|false” global_colors_info=”{}” theme_builder_area=”post_content”]<\/p>\n

Space is a precious commodity, particularly in GMP cleanroom facilities. Reducing the footprint of bioreactors and various other pieces of equipment can have far\u2011reaching benefits \u2014 ultimately cheaper and more widespread distribution of vaccines.<\/p>\n

In any context, reducing footprint reduces the overall cost of goods, leading to more efficient and cost\u2011effective setups. For upstream setups, bioreactor footprint can be greatly reduced through engineering innovative methods to increase cell density, resulting in greater yields from the same setup \u2014 and more doses of a vaccine produced without increasing costs.<\/p>\n

[\/et_pb_text][et_pb_heading title=”Process intensification: increasing productivity with reduced equipment usage” _builder_version=”4.27.4″ _module_preset=”default” title_level=”h3″ global_colors_info=”{}” theme_builder_area=”post_content”][\/et_pb_heading][et_pb_text _builder_version=”4.27.4″ _module_preset=”default” custom_margin=”||2rem||false|false” global_colors_info=”{}” theme_builder_area=”post_content”]<\/p>\n

The goal of process intensification is to increase productivity while reducing necessary plant size. This means lower capital investments required for new facilities, lower lifetime overhead costs, and all-around lower cost of goods \u2013 while maintaining or even increasing outputs from the facility.<\/p>\n

In bioreactors, process intensification can be achieved by increasing the cell density in the reactor medium. Traditionally, cell cultures were grown on 2D surfaces, and scale\u2011up simply required increasing the amount of surface area available for the cells to adhere to.<\/p>\n

This method can achieve a cell density of 20 million cells\/mL, and requires a large manufacturing footprint: the number of incubators and biosafety cabinets needs to scale with the culture size. This system also requires many skilled operators to monitor the cultures.<\/p>\n

Newer technologies such as microcarriers have enabled scientists and manufacturers to reach significantly higher cell densities in much smaller footprints. In 2014, the Pall iCELLis<\/a> achieved 100 million cells\/mL<\/a>, and this keeps increasing. Currently, Univercells is using a grant from the Gates Foundation<\/a> to increase the density up to an impressive 250 million cells\/mL \u2014 with the goal of lowering vaccine manufacturing cost enough that they can deliver polio vaccines to low and middle income countries at a cost of only $0.15 per dose.<\/p>\n

[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row custom_padding_last_edited=”on|phone” _builder_version=”4.27.4″ _module_preset=”default” background_color=”#F6F6F6″ width_tablet=”” width_phone=”” width_last_edited=”on|phone” custom_padding=”3rem|3rem|3rem|3rem|true|true” custom_padding_tablet=”3rem|3rem|3rem|3rem|true|true” custom_padding_phone=”2rem|2rem|2rem|2rem|true|true” custom_css_free_form=”selector .et_pb_text_inner {|| margin-bottom: 0;||}” border_radii=”on|15px|15px|15px|15px” border_width_all=”3px” border_color_all=”#2A3B47″ locked=”off” global_colors_info=”{}” theme_builder_area=”post_content”][et_pb_column type=”4_4″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}” theme_builder_area=”post_content”][et_pb_heading title=”Case study: Sartorius uses process intensification to accelerate vaccine development” _builder_version=”4.27.4″ _module_preset=”default” title_level=”h3″ title_text_color=”#2A3B47″ global_colors_info=”{}” theme_builder_area=”post_content”][\/et_pb_heading][et_pb_text _builder_version=”4.27.4″ _module_preset=”default” text_text_color=”#2A3B47″ text_font_size=”15px” global_colors_info=”{}” theme_builder_area=”post_content”]<\/p>\n

In a July 2020 white paper, Sartorius looked at process intensification as a method by which to accelerate vaccine development in response to COVID\u201119. They noted that, globally, there are many more 2,000 L bioreactors sitting idle at any time than there are 20,000 L, GMP\u2011compliant bioreactors. These smaller bioreactors are flexible, and can be integrated into moveable skids which allow for rapid product changeovers. The white paper stated, \u201cutilizing an intensified cell culture process\u2026 to produce 10\u00a0\u2013\u00a020 doses of vaccine\/mL, [makes] it possible to perform 2,000 L runs and produce sufficient vaccine for small scale trials.\u201d<\/p>\n

[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row _builder_version=”4.27.4″ _module_preset=”default” custom_padding=”||0px||false|false” global_colors_info=”{}” theme_builder_area=”post_content”][et_pb_column type=”4_4″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}” theme_builder_area=”post_content”][et_pb_heading title=”Scaling out (not up) can maximize the efficiency of existing facilities” _builder_version=”4.27.4″ _module_preset=”default” title_level=”h3″ global_colors_info=”{}” theme_builder_area=”post_content”][\/et_pb_heading][et_pb_text _builder_version=”4.27.4″ _module_preset=”default” custom_margin=”||2rem||false|false” global_colors_info=”{}” theme_builder_area=”post_content”]<\/p>\n

Scaling out bioreactor facilities refers to increasing the output from smaller reactors \u2014 without needing to scale up to production\u2011scale reactors. This is done either by simply increasing the number of smaller bioreactors or by increasing the cell density within a single, smaller reactor.<\/p>\n

Scaling out<\/a> is often easier and more feasible than scaling up from 2,000 L bioreactors to 10\u00a0\u2013\u00a020,000 L reactors. This is primarily because it allows for large\u2011scale culture growth (and vaccine production) without requiring the facilities designed for (very expensive) large\u2011scale bioreactors.<\/p>\n

A key advantage of scaling out a process is that it allows for the continued use of single\u2011use bioreactors (SUBs)<\/a>. SUBs are cheaper, more flexible, and can achieve significantly more uptime than multi\u2011use reactors \u2014 but they generally have a maximum capacity of about 2,000 L. Increasing the number of SUBs in a facility while also increasing their achievable cell density can successfully bridge the 10x gap in capacity between a SUB and a production\u2011scale bioreactor.<\/p>\n

This results in reducing the necessary footprint of commercial\u2011scale bioreactors, and may be particularly useful for phase 3 vaccine trials, which require production of a large number of doses but still have uncertain outcomes. The ability to meet production needs for clinical trials without requiring the current (huge) level of capital expenditures could therefore allow a greater number of biologics to make it to clinical trials \u2014 resulting in a greater number of new vaccines making it to the market faster, allowing us to combat new or rare diseases more effectively than was previously possible.<\/p>\n

[\/et_pb_text][et_pb_text _builder_version=”4.27.4″ _module_preset=”default” text_font=”|700|||||||” custom_margin=”||2rem||false|false” global_colors_info=”{}” theme_builder_area=”post_content”]Learn more: Efficient scale-up is key to low-cost drug delivery $<\/span><\/a>[\/et_pb_text][\/et_pb_column][\/et_pb_row][\/et_pb_section]<\/p>\n","protected":false},"excerpt":{"rendered":"

Global vaccine distribution is critical to the eradication of deadly diseases. In 1980, after an intensive vaccination campaign, the World Health Assembly declared smallpox eradicated. As of 2020, there are fewer than 500 new cases of polio each year in the world. In the United States, 14 diseases which used to be deadly (such as […]<\/p>\n","protected":false},"author":7,"featured_media":44420,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"_et_pb_use_builder":"on","_et_pb_old_content":"","_et_gb_content_width":"1400","content-type":"","_searchwp_excluded":"","footnotes":""},"categories":[112],"tags":[],"class_list":["post-41740","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-bioreactors-fermenters"],"acf":[],"yoast_head":"\nReducing Bioreactor Footprint - Alicat Scientific<\/title>\n<meta name=\"description\" content=\"Optimize biologics development with these efficient scale-up strategies, equipment redundancy, single use bioreactors, CDMO partnerships, and more.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.alicat.com\/de\/artikel\/verringerung-des-platzbedarfs-von-bioreaktoren\/\" \/>\n<meta property=\"og:locale\" content=\"de_DE\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Reducing Bioreactor Footprint\" \/>\n<meta property=\"og:description\" content=\"Optimize biologics development with these efficient scale-up strategies, equipment redundancy, single use bioreactors, CDMO partnerships, and more.\" \/>\n<meta property=\"og:url\" content=\"https:\/\/www.alicat.com\/de\/artikel\/verringerung-des-platzbedarfs-von-bioreaktoren\/\" \/>\n<meta property=\"og:site_name\" content=\"Alicat Scientific\" \/>\n<meta property=\"article:publisher\" content=\"https:\/\/www.facebook.com\/alicatscientific\/\" \/>\n<meta property=\"article:published_time\" content=\"2023-05-31T19:05:00+00:00\" \/>\n<meta property=\"article:modified_time\" content=\"2026-01-06T23:06:12+00:00\" \/>\n<meta property=\"og:image\" content=\"https:\/\/www.alicat.com\/wp-content\/uploads\/2023\/05\/articles-fast-global-vaccine-delivery.webp\" \/>\n\t<meta property=\"og:image:width\" content=\"900\" \/>\n\t<meta property=\"og:image:height\" content=\"523\" \/>\n\t<meta property=\"og:image:type\" content=\"image\/webp\" \/>\n<meta name=\"author\" content=\"Alicat Scientific\" \/>\n<meta name=\"twitter:card\" content=\"summary_large_image\" \/>\n<meta name=\"twitter:label1\" content=\"Written by\" \/>\n\t<meta name=\"twitter:data1\" content=\"Alicat Scientific\" \/>\n\t<meta name=\"twitter:label2\" content=\"Est. reading time\" \/>\n\t<meta name=\"twitter:data2\" content=\"4\u00a0Minuten\" \/>\n<script type=\"application\/ld+json\" class=\"yoast-schema-graph\">{\"@context\":\"https:\\\/\\\/schema.org\",\"@graph\":[{\"@type\":\"WebPage\",\"@id\":\"https:\\\/\\\/www.alicat.com\\\/articles\\\/reducing-bioreactor-footprint\\\/\",\"url\":\"https:\\\/\\\/www.alicat.com\\\/articles\\\/reducing-bioreactor-footprint\\\/\",\"name\":\"Reducing Bioreactor Footprint - 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