Process intensification for Peste des Petites Ruminants Virus vaccine production

Area of Science:

• Biotechnology
• Vaccine Production
• Process Intensification

Background:

• Peste des Petites Ruminants Virus (PPRV) vaccine production using anchorage-dependent Vero cells is complex.
• Existing bioprocesses require significant development and optimization for scalability.

Purpose of the Study:

• To develop and implement a novel, scalable bioprocess for PPRV vaccine production.
• To intensify the production process using serum-free medium and microcarrier technology.

Main Methods:

• Vero cells were adapted to serum-free medium (SFM).
• Microcarrier technology in stirred-tank bioreactors (STB) was employed.
• In-situ cell detachment and perfusion methods were implemented for enhanced cell concentration and direct scale-up.

Main Results:

• Vero cells in SFM exhibited growth rates comparable to serum-containing cultures.
• In-situ cell detachment achieved efficiencies over 85%.
• Perfusion increased maximum cell concentration by up to 2.5-fold, enabling direct scale-up from 2 L to 20 L STB without a mid-scale platform.

Conclusions:

• The developed bioprocess is feasible and scalable for PPRV vaccine production.
• The process achieved high infectious PPRV titers (TCID50/mL = 5 × 10^6).
• This scalable platform can support the Peste des Petites Ruminants Global Eradication Program by enabling rapid, large-scale vaccine manufacturing.