Constructive improvement of the ultrasonic separation device ADI 1015

Area of Science:

• Biotechnology
• Cell Culture Engineering
• Bioprocess Optimization

Background:

• Ultrasonic separation devices are crucial for improving animal cell bioreactor cultures.
• Traditional ADI 1015 devices use peristaltic pumps, causing cell death and reduced viability due to continuous circulation.
• This limitation hinders achieving high cell densities in bioreactor systems.

Purpose of the Study:

• To modify the ultrasonic separation device configuration to enhance animal cell bioreactor performance.
• To mitigate cell death and viability reduction associated with conventional device operation.
• To achieve significantly higher viable cell densities in bioreactor cultures.

Main Methods:

• Reconfigured the ultrasonic separation device to eliminate continuous cell suspension circulation.
• Implemented a cyclical extraction and back-flushing process: 9 minutes of cell-free supernatant extraction followed by 1 minute of cell return.
• Tested the modified device with the shear-sensitive insect cell line High Five.

Main Results:

• Achieved cell densities ranging from 10^6 to 2.7 x 10^6 cells/ml with at least 90% viability.
• Maximal cell densities in the classical mode were significantly lower (0.76 x 10^6 cells/ml continuous, 10^5 cells/ml end-use).
• The modified configuration successfully prevented cell death and maintained high viability.

Conclusions:

• The modified ultrasonic separation device configuration significantly improves cell viability and density in bioreactor cultures.
• Eliminating continuous circulation and implementing a cyclical back-flush is key to overcoming cell damage.
• This optimized approach enables higher cell densities, crucial for efficient bioprocessing.