Oncolytic Adenovirus Production Using 15L & 150L Fixed-Bed Bioreactors
Jan.15.2026
Client：A biopharmaceutical company specializing in cancer immunotherapy.
Challenges：The client needed to establish an efficient and scalable oncolytic adenovirus production process. Traditional adherent culture methods were limited in scale, yielded low viral titers, and suffered from poor reproducibility. The core requirement was to achieve a smooth transition from laboratory research to pilot-scale production.
Solution：
We deployed our 15L and 150L fixed-bed bioreactors equipped with Fibra-Disk carriers to establish a high-density HEK293 cell culture and viral amplification system.
A perfusion culture mode was adopted, with precise stage-specific control of serum concentration and glucose levels:
Cell Growth Phase: Glucose was maintained at 1-2 g/L to promote rapid cell proliferation.
Viral Production Phase: Glucose was controlled at 0.5-1.5 g/L to optimize viral replication.
Throughout the process, the system maintained an optimal environment with pH 7.0-7.4, temperature 37℃, and dissolved oxygen (DO) at 20-60%.
Results：
Results：
15L Scale: The peak cell density reached 1×10⁷ cells/mL (based on working volume), and the viral titer increased by nearly 2 orders of magnitude compared to traditional processes.
150L Pilot Scale: The process was scaled up smoothly with excellent reproducibility. Viral harvest was performed continuously for 5-6 days, yielding stable viral titers that fully met pilot production requirements.
This solution significantly reduced the complexity of downstream purification and established a solid core equipment foundation for the client's subsequent commercial production.
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