AAV manufacturing: reaching high capacity with serum-free, scalable production

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Webinar Date/Time: Tue, Apr 11, 2023 11:00 AM EDT

Meet capacity challenges growing a suspension HEK293 cell line in serum-free conditions to produce an AAV-2 product in high quantities with a scale-X™ fixed-bed bioreactor.

Register Free: https://www.biopharminternational.com/bp_w/serum-free

Event Overview:

Adeno-associated viruses (AAVs) are a vector of choice for a wide range of therapeutic indications. Although early targets were for rare diseases, there is a shift towards higher prevalence indications such as cancers or common neurological disorders. This is combined with the high vector demand per dose sometimes exceeding 1015 vg, which means that manufacturing capacity will increasingly become a bottleneck as the clinical pipeline matures. Industry has taken a stance to address this challenge by developing upstream platforms in suspension adapted HEK293 cell lines in order to benefit from the large capacity offered by stirred tank bioreactors (STRs). However, intensifying and scaling-up STRs is complex, time-consuming can result is delays in the time to market.

Structured fixed-bed bioreactors offer an interesting alternative with a low-shear, well-controlled and homogeneous environment achieving high productivity, high product quality and cost-effectiveness in a reduced footprint for adherent and suspension cells. Univercells Technologies will present how the scale-X™ fixed-bed bioreactor technology is used grow a suspension HEK293 cell line in serum-free conditions to produce an AAV-2 product in high quantities, thereby providing an alternative to stirred tank reactor technology to meet the capacity challenge.

Key Learning Objectives:

Attend this webinar to discover more about:

  • Understanding the AAV market needs and production challenges
  • The benefits of process intensification and scale-up through biomass immobilization in fixed-bed technology versus stirred tanks for suspension cell lines
  • How cells can be grown at densities 10 to 30 times higher in a structure fixed-bed than in a stirred tank bioreactor while improving product quality and quantity
  • How the scale-X increases cell specific productivity more than 2-fold while decreasing HCP and HC-DNA concentrations resulting in a 24% reduction in cost of goods.


Alex Chatel
Senior Marketing & Product
Univercells Technology

Alex Chatel is a Senior Marketing & Product manager at Univercells Technologies, he is responsible for key developments and applications in the scale-X™ fixed-bed bioreactor technology. Prior to this, he held positions as an Enterprise Fellow at University College London, UK and as a Research Engineer at GlaxoSmithKline in Stevenage, UK. Alex has a broad bioprocessing expertise ranging from antibody products to viral vaccines and cell & gene therapies, both in upstream and downstream applications. Alex earned his Ph.D. in Biochemical Engineering from University College London, UK and his MEng in Chemical Engineering from The University of Manchester, UK.

Laura Siedler
Bioprocess Project Manager
Univercells Technology

Laura Siedler is Bioprocess Project Manager in the of Bioprocess & Field Services Team at Univercells Technologies. Her mission is to support the seamless adoption and establishing of the scale-X systems and the NevoLine Upstream platform for viral vector production. Laura acquired 2.5 years of experience in supporting customers in technology adoption, process optimization and upscaling. She earned her MS. in Molecular and Applied Biotechnology from the RWTH Aachen University, DE.

Register Free: https://www.biopharminternational.com/bp_w/serum-free