Suspension Culture for Influenza Vaccine Production
Jan.15.2026
Project Background
A vaccine manufacturer focused on the industrialization of cell-based influenza vaccines needed to establish an efficient and scalable suspension culture process. The goal was to replace the traditional egg-based production method to improve production efficiency and safety. We provided a complete solution including one 5L, one 25L, and one 125L suspension bioreactor, along with full upstream supporting equipment, to cover the entire workflow from seed expansion to virus production.
Application Solution
The project utilizes an MDCK cell suspension culture process with a three-stage scale-up strategy:
5L Bioreactor: Used for cell thawing and seed expansion to provide a highly active working seed culture.
25L Bioreactor: Achieves high-density cell culture. Key parameters such as pH, Dissolved Oxygen (DO), and temperature are optimized to bring the cells to an optimal physiological state, laying a solid foundation for viral replication.
125L Bioreactor: Serves as the core production unit where virus inoculation, propagation, and harvest are completed.
The equipment is equipped with a precise parameter control system that monitors and intelligently adjusts the culture environment in real-time, ensuring the stability of both cell growth and viral replication.
The equipment is equipped with a precise parameter control system that monitors and intelligently adjusts the culture environment in real-time, ensuring the stability of both cell growth and viral replication.
Project Results
Leveraging the efficient collaboration of the three-stage reactors and precise process control, the project achieved significant results:
High Yield & Quality: A cell density of ≥7×10⁶ cells/mL was achieved, with viral Hemagglutination (HA) titers stably meeting standards.
Process Advantages: Compared to traditional egg-based processes, the production cycle was shortened by 30%. This effectively avoids the risk of adaptive mutations of the virus in eggs and reduces the potential for allergic reactions caused by exogenous protein residues.
Agile Response: The equipment is easy to operate and supports rapid process validation and transfer, helping the enterprise quickly respond to seasonal demands and sudden public health emergencies for influenza vaccines.
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