Fixed-Bed (Fibra-Disk) Bioreactors for Rabies Vaccine Production
Jan.15.2026
The client is a leading domestic biopharmaceutical enterprise specializing in the R&D and production of human rabies vaccines. To increase production capacity and ensure product uniformity, the company needed to establish a large-scale upstream cultivation system. We provided a comprehensive solution consisting of thirty 50L and four 150L fixed-bed (fibra-disk) bioreactors, along with a full set of upstream auxiliary equipment, perfectly suited for the high-density adherent culture of Vero cells.
Project Implementation
Cell Expansion Phase: The 50L bioreactor group is responsible for cell expansion. Leveraging the extremely high surface area of the fibra disk-like carriers, cells proliferate rapidly, effectively ensuring the stability of the seed batch quality.
Virus Production Phase: The 150L bioreactor group handles virus inoculation and large-scale cultivation. The system precisely controls critical parameters such as temperature, pH, and dissolved oxygen to provide the optimal environment for viral replication. The strong adhesion properties of the fibra disk carriers extend the cell survival cycle, enabling continuous harvesting of the viral fluid and significantly increasing the yield per unit volume.
Application Results
Since commissioning, the cell density (based on culture volume) has exceeded 1.2×10⁷ cells/mL, and the average viral titer has stabilized at 7.5 LogLD₅₀/mL. The batch-to-batch variation is less than 5%, fully complying with the standards of the Chinese Pharmacopoeia.
The annual production capacity of the entire system can support the manufacturing of 20 million doses of lyophilized rabies vaccine, representing a 40% increase in efficiency compared to traditional processes. Furthermore, the high-purity harvest reduces the difficulty of downstream purification, helping the customer achieve large-scale, high-quality vaccine production.
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