Overcoming scale up challenges in viral vector production
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A major biopharmaceutical manufacturer faced inefficiencies and labor-intensive workflows in preparing and transferring media for perfused stirred-tank and rocker bioreactors. To streamline operations, the facility implemented Avantor’s custom in-line conditioning system, enabling real-time dilution and mixing of concentrated media and buffer components directly before delivery to bioreactors. The automated skid integrated hybrid single-use and stainless-steel components, surge tanks, static mixers, leak detection, and CIP capabilities, while reducing high-pressure WFI to acceptable levels for single-use materials. Seamless integration with the site’s automation platform ensured accurate dosing, continuous monitoring, and automatic batch record logging, minimizing human error and enhancing regulatory compliance. The solution significantly reduced preparation times, labor requirements, and operational risk, while improving data integrity and scalability, transforming media handling into an efficient, automated, and GMP-compliant process.
