400L Multimodal Bioreactors for Avian Influenza Vaccine Production
Jan.15.2026
A major vaccine manufacturer addressed the need for large-scale production of avian influenza vaccines by establishing an upstream platform using nine 400L multimodal bioreactors capable of both microcarrier and suspension culture. This system is fully compatible with MDCK cell-based vaccine processes, enabling efficient and stable mass production through a unique "adherent-to-suspension" strategy.
Process Implementation
The equipment utilizes a microcarrier culture process divided into two key phases:
1.Cell Expansion Phase (Adherent Mode): Leveraging the large surface area of microcarriers, MDCK cells attach and grow rapidly. The three-dimensional structure provides ample space, ensuring high cell density and a viability rate of ≥95%.
2.Virus Production Phase (Suspension Mode): Once the cells have confluently grown on the microcarriers, the system switches to an optimized suspension control mode (or the cells are enzymatically detached to become suspension cells) for virus inoculation and propagation. By precisely regulating temperature, dissolved oxygen, and pH parameters, the optimal environment for viral replication is achieved.
Project Advantages
Massive Capacity: Operating nine reactors in parallel achieves a total single-batch throughput of 3600L, allowing flexible matching of simultaneous production requirements for multiple virus strains.
Increased Efficiency: Compared to traditional processes, the virus harvest cycle is shortened by 20%, and hemagglutination titers stably meet standards.
Safety & Compliance: Utilizing a cell substrate eliminates the risk of allergic reactions caused by egg protein residues.
Flexibility & Economy: The bioreactors' multimodal capability reduces process switching costs. The integrated upstream system enables fully closed operation, significantly lowering contamination risks and helping the enterprise efficiently respond to both emergency production needs and regular supply demands for avian influenza vaccines.
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