Bioprocess Operation Modes And Advanced Bioreactor Technologies

By Olga Rojewska and Marcin Tęczar

Cell culture in bioreactors is a cornerstone of modern biotechnology, enabling the controlled growth and proliferation of living cells for various applications, including the production of therapeutic proteins, vaccines, and stem cell cultivation. The success of this process relies on precisely monitoring and managing key parameters such as temperature, pH, dissolved oxygen, gas composition, mixing, and nutrient supply to ensure optimal cell growth, high viability, and consistent product quality.

Different cell culture methodologies, including batch, fed-batch, perfusion, and continuous culture, each have distinct advantages and challenges. Batch culture is straightforward and cost-effective but offers limited control and duration. Fed-batch systems boost productivity through periodic nutrient addition, while perfusion culture ensures high cell viability and product yield by continuously exchanging the medium. Although more complex and costly, perfusion and continuous systems are highly advantageous for industrial-scale applications.

The choice of bioreactor and mixing technology further influences outcomes. Stirred-tank reactors allow precise control but may introduce shear stress, orbital shaking reactors provide gentle mixing, and wave bioreactors facilitate efficient aeration with minimal agitation. Single-use bioreactors, despite generating more waste, offer significant benefits such as reduced costs, minimized contamination risks, and faster process transitions, making them particularly valuable for pharmaceutical companies and contract manufacturing organizations.