Large-Scale Production of PRRS and PCV Vaccines
Jan.15.2026
Project Background
A leading animal vaccine manufacturer focused on the prevention and control of Porcine Reproductive and Respiratory Syndrome (PRRS) and Porcine Circovirus (PCV). They needed to establish an efficient, large-scale vaccine production line. The core requirements were to increase viral titer, ensure batch-to-batch stability, and achieve fully closed-system control throughout the process. In response, we customized a microcarrier culture solution that perfectly matches the entire upstream workflow from seed expansion to large-scale viral cultivation.
Equipment Configuration
The core equipment includes four 20L, four 100L, and four 500L microcarrier bioreactors, supplemented by sixteen 1000L microcarrier bioreactors. The system is fully equipped with upstream support equipment (including media preparation systems, aseptic transfer systems, and online parameter monitoring systems), forming a stepped large-scale cultivation system to meet the needs of different production stages
Application Results
The project utilizes specific sensitive cell lines for different viruses (e.g., Marc-145 cells for PRRSV and PK-15 cells for PCV2) in a microcarrier culture process.
Process Flow: Seed cells are first expanded and acclimatized in 20L bioreactors, then scaled up stepwise through 100L and 500L reactors, and finally undergo large-scale viral propagation in 1000L reactors.
Precision Control: The equipment precisely controls temperature (33-38℃), pH (6.8-7.6), dissolved oxygen (40%-60%), and agitation speed to ensure cell densities reach over 5×10⁶ cells/mL.
High Yield: The final harvested viral fluid shows significantly improved titers, with PRRSV titers exceeding 10⁸.⁵ TCID₅₀/mL and PCV2 titers exceeding 10⁸.⁰ TCID₅₀/mL.
The fully automated and closed operation significantly reduces contamination risks, reduces batch-to-batch variation by 30%, and increases production capacity by 5 times compared to traditional processes. This helps the customer achieve efficient mass production and quality upgrading of vaccines.
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