Facility

FACILITY

Introducing new technologies and methodologies into process development and manufacturing facilities should lead to improvements and efficiency gains in those facilities. The goals may vary for companies who could be at different stages of development, or who have diverse requirements for a range of therapeutic products in their pipeline.

However some goals will be similar to all companies independent of their size, product range or financial situation. Goals such as increasing protein expression, reducing cost of goods, and improving flexibility are all of interest.  The ATF™ System offers many opportunities for achieving these goals, whether through extremely high cell density cultures and protein yields, or through rapid low shear cell harvesting and subsequent downstream simplification.  But it is the combination of several improvements, some dramatic and some simple, that lead to a new paradigm in biologics manufacturing: a “factory of the future”.  This factory can be seen as a small, multiproduct, flexible but highly productive and intensified biomanufacturing facility – and the costs simultaneously reduced. It could be for multi-tonne antibody production, removing the need for large (or even medium) sized steel tanks, or for diverse vaccine manufacture able to have production ramped up quickly in response to local demand.

In assessing the impact of a product such as Refine’s ATF System, the direct improvement in one unit operation, such as achieving a ten fold improvement in bioreactor yield, needs to be understood within the larger manufacturing environment to ensure the specific gain translates to a real achievable outcome at large commercial scale.  An upstream success may cause a downstream bottleneck for example, and so Refine has extended the applications of the ATF System to enable capture the full benefits of process intensification.

Recognizing that there are different solutions to the same problem, and allowing flexibility in implementation can be important. Large scale perfusion is becoming mainstream, either for seed expansion and the n-1 step to allow higher inoculation densities or for the main production reactor itself. Concentrated Perfusion methods now allow 1g/L/day of protein to be routinely produced, meaning a single use 1000L bioreactor can produce 1kg per day – significantly more than many people expect. However, the continuous harvest produced is not always favored unless companies understand how to best utilize this higher productivity. Where a single concentrated harvest is preferred, a UF step allows a high cell concentration of over 100m cells/ml to produce a concentrated harvest of 20g/L and higher, depending on the cell specific productivity of the cell line.

Where can the ATF System make an impact on your process or facility?

Roll over each goal to show details.

Goal Process Development Manufacturing
Reduce timelines in development
- Only one cell culture media is required and development is simplified through spent media analysis
- High cell concentrations are easily achieved, removing the need to produce a high productivity cell line
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Simplify and reduce development experimental space
- The concentrated perfusion processes need little or no equipment optimization between cell lines and products
- Downstream development is reduced by the straightforward flow calculations in scale-up
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Increase number of manufacturing slots, with help from single use equipment
- No sterilization in place nor cleaning in place is needed
- Easy integration to all single use bioreactors
Increase process efficiency (volumetric productivity, yield etc)
- Greatly increased volumetric productivity
- Higher yield recovery and removal of centrifuge step
Apply new process knowledge across product platforms to leverage maximum gain
- Common operation and implementation in all unit operations
Reduce laboratory and factory floorspace for a given product output
- Reactor sizes are reduced up to 10 fold for any desired output required
- Small footprint plus removal of traditional primary recovery equipment
Achieve higher flexibility within a facility with minimal capital expenditure
- Choice of filters with different pore sizes allows separation, concentration, wash and diafiltration options for a wide range of proteins, viruses and novel therapeutic molecules

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