The Importance of Monitoring Cell Culture Numbers in Bioreactors

The Importance of Monitoring Cell Culture Numbers in Bioreactors

In the field of bioprocessing, bioreactors are used to culture cells in large quantities for the production of therapeutic drugs and vaccines. Monitoring the number of cells in these bioreactors is crucial to ensure optimal yield and avoid contamination. In this article, we will explore the reasons why monitoring cell culture numbers is important and how it can improve the bioprocessing industry.

Why Monitoring Cell Culture Numbers is Important

In bioprocessing, the cell culture process is the foundation upon which the production of biosimilars, vaccines, and cell therapies relies. The accurate and precise count of live cells is essential to ensure optimal yield, quality, and purity of cell cultures. Maintaining a stable cell line is crucial to prevent genetic drift and the loss of product quality over time.

Moreover, monitoring cell numbers and concentration can prevent batch-to-batch variability. Changes in the cell number can impact production variables such as metabolism, pH, and nutrient availability, affecting product quality, quantity, or both. Additionally, measuring and managing the cell number can help identify any potential issues early on and prevent losses in production.

Methods of Monitoring Cell Culture Numbers

There are several methods used to monitor cell culture numbers in bioreactors. The oldest, still widely used, is the hemocytometer method, which involves manually counting cells under a microscope. This method is accurate but time-consuming and requires a skilled operator.

Another method is flow cytometry, which enables high-throughput cell counting and analysis of cell characteristics such as viability, morphology, and cell cycle phase. The technique is precise, efficient, and automated, allowing for real-time monitoring.

Another method that allows for real-time cell culture monitoring is based on measuring the capacitance or permittivity of the bioreactor contents. The capacitance/permittivity measurement reflects the presence of charged or polarized particles (such as live and dead cells) in the culture, giving an indication of the cell number and viability in the bioreactor.

Examples of Successful Monitoring of Cell Culture Numbers

One example of successful monitoring of cell culture numbers is the development of human papillomavirus (HPV) vaccines. The team at GlaxoSmithKline was able to increase the yield of HPV vaccines by monitoring the cell number and adjusting the feeding strategy to fit with the culture’s growth rate, resulting in increased productivity and cost savings.

Another example is the optimization of the production of influenza vaccines at Novartis Vaccines and Diagnostics. By implementing flow cytometry methods and real-time monitoring, they were able to reduce variability between batches, maintain a stable cell line, and increase production yield.

Conclusion

Monitoring cell culture numbers is critical in bioprocessing. It allows for optimization of production processes, helps prevent contamination, and ensures consistent product quality and yield. Investments in monitoring technology can lead to improvements in production efficiency, cost savings, and the development of more effective vaccines and cell therapies. In summary, the ongoing monitoring of cell culture numbers is fundamental to the growth and success of the bioprocessing industry.

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