Dr. David Flitsch, Application and Project Manager at Kuhner Shaker introduced Kuhner Shaker’s orbitally shaken bioreactors, which represent an innovative way of scaling up bioprocessing while maintaining consistent hydrodynamics across scales.
Traditional scale-up processes typically face challenges such as varying aeration, mixing methods, and mechanical stress that impact cell viability and product quality. Meanwhile, orbitally shaken bioreactors address these issues by offering a gentler and surface-aerated system that minimises stress for various cell types. These cells include mammalian, plant, and insect cells.
These bioreactors use single-use gamma-irradiated bags and portable designs for smaller units to streamline processes and reduce contamination risk. Flitsch added: “As I said, these bioreactors are working with single-use bags, so there’s no stirrer or additional mixing device inside, that reduces the risk of damaging the bag.”
The bioreactors are scalable up to 2,500 litres and deliver better mixing times and power inputs compared to traditional shake flasks. To demonstrate the bioreactors' capabilities, Flitsch introduced a case study by ProBiogen who wanted to scale up their animal herpes virus production from a batch shake flask to a controlled fed-batch orbital shaken bioreactor. The results showed higher cell viability and yields.
Flitsch stated, "You can see it's a proper system to scale up from shake flask to a more controlled environment and then even apply the fed-batch and have both higher viability at harvest time and also the number of viable cells did strongly increase in that example.”
Beyond the biopharmaceutical field, these bioreactors have proven valuable in various industries including cultured meat production. Flitsch added that this
machinery is capable of mixing delicate molecules like mRNA which is prone to damage.
Overall, orbitally shaken bioreactors offer a streamlined, consistent, and scalable solution for diverse bioprocessing needs. Flitsch concisely addressed challenges in traditional scale-up methods while expanding their utility across emerging applications.
