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Related Concept Videos

Bioreactor Design and Operational System01:29

Bioreactor Design and Operational System

Bioreactors are engineered vessels designed to cultivate microorganisms under controlled conditions for industrial bioprocessing. They maintain sterility and allow precise regulation of pH, temperature, oxygen, and nutrient levels to optimize microbial growth and metabolite production. Bioreactors range from small laboratory units of 1 liter to industrial systems holding up to 500,000 liters, though only about 75% of their volume is actively used for fermentation. The remaining headspace...
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Scale-Up Processes

The scale-up of microbial fermentation processes is essential in industrial biotechnology, allowing the transition from laboratory-scale experiments to commercial-scale production while aiming to maintain product yield and quality. This process requires meticulous adjustment of equipment design, process parameters, and contamination control strategies to accommodate increasing culture volumes.At the laboratory scale, cultures are typically maintained in 1 to 10-liter glass or autoclavable...
Upstream Processing01:27

Upstream Processing

Upstream processing represents a critical phase in biomanufacturing, wherein biological systems such as microorganisms, mammalian cells, or insect cells are cultivated to produce therapeutic proteins, vaccines, enzymes, or other biologically derived products. This phase encompasses all steps from the selection and genetic manipulation of the production organism to the cultivation of cells in bioreactors under tightly controlled environmental conditions.Host Selection and Genetic OptimizationThe...
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Production of Pharmaceuticals

Industrial insulin production uses genetically engineered E. coli expressing a proinsulin gene controlled by a tryptophan promoter and containing a methionine linker for later cleavage. The cells also carry ampicillin resistance for selective growth. Seed cultures are stored at −80 °C and production begins by thawing a small amount to inoculate starter cultures, which are progressively scaled to a 50,000-L bioreactor. In the bioreactor, E. coli grow in nutrient-rich media under sterile, tightly...
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Vaccine Production

Vaccine production involves a sequence of upstream and downstream processes to generate a safe and effective immunological product. It begins with cultivating microorganisms, such as viruses or bacteria, to obtain antigenic material. For viral vaccines, mammalian host cells are grown in bioreactors and subsequently infected with the target virus. The virus replicates within the host cells, which are lysed to release viral particles. This lysate is then clarified through filtration or...
Poliomyelitis01:17

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Poliomyelitis is caused by poliovirus, a small, non-enveloped, positive-sense RNA virus of the Picornaviridae family and Enterovirus genus. Transmission occurs primarily via the fecal-oral route, often through ingestion of contaminated water or food. The virus initially replicates in the oropharynx and intestinal mucosa, particularly in lymphoid tissues such as the tonsils, Peyer’s patches, and regional lymph nodes. Primary viremia follows, allowing dissemination throughout the body.In most...

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Related Experiment Video

Updated: Jul 10, 2026

Process Optimization using High Throughput Automated Micro-Bioreactors in Chinese Hamster Ovary Cell Cultivation
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Sabin inactivated polio vaccine upstream process development using fixed-bed bioreactor technology.

Ahd Hamidi1, Marieke Willemsen1, Thomas Robert2

  • 1Batavia Biosciences B.V., Bioscience Park Leiden, Zernikedreef 16, 2333CL, Leiden, the Netherlands.

Vaccine
|March 4, 2025
PubMed
Summary
This summary is machine-generated.

Regional production of inactivated polio vaccines (IPV) using a novel microfacility enhances vaccine availability. This scalable process improves efficiency and reduces the manufacturing footprint for polio eradication efforts.

Keywords:
Equipment developmentFixed-bed bioreactorInactivated polio vaccineLow cost of goodsSabin attenuated poliovirusTangential flow filtrationVaccinessIPV

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Area of Science:

  • Vaccinology
  • Bioprocess Engineering
  • Infectious Disease Control

Background:

  • Polio eradication faces challenges in regions with limited healthcare infrastructure.
  • Ensuring a sustainable and equitable supply of inactivated polio vaccines (IPV) is crucial for the final stages of polio eradication.
  • Existing polio vaccine production methods face limitations due to biosafety requirements and cell line characteristics.

Purpose of the Study:

  • To develop a scalable and efficient regional manufacturing process for inactivated polio vaccines (IPV).
  • To overcome challenges associated with traditional polio vaccine production, including biosafety level 3 containment and Vero cell line adherence.
  • To create a cost-effective solution for regional vaccine production, supporting pandemic preparedness.

Main Methods:

  • Development of an IPV production process utilizing polio Sabin strains within a contained microfacility.
  • Integration of a tangential flow filter (TFF) with a fixed-bed bioreactor (150 m² surface area) to combine production and concentration steps.
  • Implementation of a fully disposable system for virus production, enhancing process efficiency and reducing footprint.

Main Results:

  • Achieved increased process efficiency and a reduced manufacturing footprint through bioreactor and TFF integration.
  • Demonstrated a scalable production process that is demand-driven and utilizes fewer resources.
  • Successfully developed a contained microfacility approach for safe and efficient IPV production.

Conclusions:

  • The developed scalable production process offers a cost-effective method for regional IPV manufacturing.
  • This approach addresses limitations in current polio vaccine production, facilitating equitable access and supply.
  • The technology is suitable for regional demand-driven production and pandemic preparedness efforts.