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Understanding the Vaccine Manufacturing Process
The manufacturing of vaccines is a complex, multi-step process that can vary significantly depending on the type of vaccine being produced. Here’s a closer look at the general stages of manufacturing vaccines and how the Applikon single-use AppliFlex ST and SUPR bioreactors play a pivotal role in each phase.
1. Research and development
Vaccine research and development is the initial phase where antigens that elicit an immune response are identified. This stage involves extensive laboratory research to understand the pathogen's biology and how the immune system responds to it. The Applikon AppliFlex ST bioreactor aids in this phase by allowing for the cultivation of pathogens or cells under controlled and contained conditions, enabling the study and selection of effective antigens for the vaccine.
2. Seed stock preparation
Once the antigens have been identified, a seed stock of the virus or bacteria is prepared. This involves growing the pathogen in controlled conditions to produce a pure and stable culture that can be used for vaccine production. The Applikon AppliFlex ST bioreactor's precision ensures the seed stock's optimal growth environment, maintaining the culture's viability and purity. Thanks to the single-use approach, sterility, prevention of cross-contamination and safety for the user are guaranteed.
3. Antigen production
The core of the vaccine manufacturing process is antigen production. This step may involve growing the pathogen (for live attenuated or inactivated vaccines) or expressing the antigen in a recombinant system (for subunit vaccines). The Applikon SUPR single-use production bioreactor provides a controlled environment for growing these cultures. The single-use bioreactor is gamma-sterilised and easy to use thanks to the Click-n-Go bag loading. The single-use bioreactor reduces the risk of cross-contamination, protects the user from contact with the culture and enables fast production with reduced turnaround times, ensuring the efficient production of high-quality antigens.
4. Isolation and purification
After antigen production, the next step is the isolation and purification of the antigen from the culture medium. This is crucial for ensuring the vaccine's safety and efficacy. The Applikon SUPR bioreactor facilitates the controlled environment necessary for the growth of the culture, which is then subjected to various purification methods to isolate the antigen.
5. Formulation and adjuvant addition
The purified antigen is then mixed with adjuvants, stabilizers, and preservatives to form the final vaccine. This formulation process is essential for enhancing the vaccine's effectiveness and longevity. Although the Applikon bioreactors are primarily involved in earlier stages of vaccine production, the data and insights gained from its use are critical in determining the optimal conditions for vaccine formulation.
6. Clinical trials
Before vaccines can be made available to the public, they must undergo rigorous clinical trials to test their safety, efficacy, and potential side effects across different population groups.
7. Large-scale production
Once approved, vaccines enter large-scale production, where large scale bioreactors like the Applikon SUPR 1000 are used to meet global demands. The flexibility and scalability of these bioreactors make them ideal for adjusting production volumes based on demand.
The Role of the Applikon Single-Use Bioreactors in Vaccine Production
The Applikon single-use bioreactors are key player in the vaccine production process, offering several advantages:
- Versatility: The customizable AppliFlex ST supports various options to do vaccine research in lab-scale, accommodating different types of vaccines, including viral, bacterial, and subunit vaccines.
- Precision control: The bioreactor allows for meticulous control over the environmental conditions, crucial for optimizing the growth of the antigen-producing organisms or cells.
- Scalability: Thanks to the scalable design of the Applikon single-use bioreactors, the AppliFlex ST and SUPR offer a scalable platform from 500mL to 1000L (from 2025). Designed for both research and production, it enables a seamless transition to larger manufacturing processes, facilitating the fast response to emerging health threats.
- Efficiency: Its advanced technology enhances the overall efficiency of vaccine manufacturing, reducing production times and costs while ensuring high-quality outcomes.
- Safety: In the production of vaccines, user safety is key. The Applikon single-use bioreactors offer the necessary safety for vaccine research and production.
Vaccines are essential in the fight against infectious diseases
The Applikon single-use bioreactors play a vital role in advancing vaccine research, development and production. Through its precision, versatility, safety and scalability, it empowers scientists and manufacturers to navigate the complex vaccine manufacturing process, from research to the production of vaccine antigens and the final formulation. As a key player in the viral vaccine production, the AppliFlex ST and SUPR single-use bioreactors exemplifies the cutting-edge technology that will continue to drive innovations in vaccine development and manufacturing. Discover more about how the Applikon single-use bioreactors can transform your vaccine production processes at AppliFlex ST single use bioreactors - Resea Biotec GmbH.
Feautured Products
SUPR single-use bioreactor
The SUPR single-use production bioreactor impresses with its simple, scalable and customer-friendly design. The cell culture reactor enables a seamless process transfer from R&D to production.
The SUPR bioreactor is available in the sizes 50L, 250L and 1000L.
AppliFlex ST GMP single-use bioreactor
The AppliFlex ST GMP is a configurable single-use bioreactor that meets all cGMP requirements for clinical production. The system simplifies Scale-Up, Scale-Down and Scale-Out. The fully closed system is customizable and reduces any risk of cross contamination.
The AppliFlex GMP is available in 500 mL and 3 L versions for both cell cultures and microbes.
V-Control
Developed in partnership with Emerson, V-Control is a process control platform designed as a 'one common-platform' solution for bioreactors from research to production.
V-Control offers a scalable software solution that overcomes the hurdles of scaling up.
Stainless steel bioreactors
Stainless steel bioreactors play a key role in the development and production biotech products. From bench to pilot to full production – the Applikon bioreactors simplify your scale-up through consistent design and scalable control solutions.
Our portfolio offers both standard systems for fermentation and cell cultures as well as customized systems.
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