The Factory of the Future... ...
The ATF™ System offers many opportunities for improving on traditional cell culture and cell separation processes. Whether through extremely high cell density cultures and protein yields, or through rapid low shear cell harvesting and subsequent downstream simplification. It is the combination of multiple improvements that lead to a new paradigm in biologics manufacturing: a "factory of the future". This factory will be small, yet
capable of multiproduct manufacture, and highly productive.
Some of the benefits & considerations of the ATF System on "The Factory of the Future":
- Yield: Upstream increases of 10-fold are achieveable, however this success may create downstream bottlenecks in purification.
- Process Design : Old methodoligies can be enhanced by leveraging such methods as Concentrated Perfusion which are capable of 1gm/liter/day. Thought needs to be given to the design of a facility that utilizes such strategies.
- Building Design : A concentrated fed-batch process can produce as much as 20gm/liter from a 1,000 liter bioreactor using the ATF. Previously, reactor volumes as large as 10,000 liters were required. The cost savings resulting from this intensified yield will have a major impact on all aspects of the facility.
Where can the ATF System make an impact on your process or facility?
Goal |
Process Development |
Manufacturing |
Reduce timelines in development
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- Only one cell culture media is required and development is simplified through spent media analysis
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- High cell concentrations are easily achieved, removing the need to produce a high productivity cell line
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n/a |
Simplify and reduce development experimental space
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- The concentrated perfusion or concentrated fed-batch processes need little or no equipment optimization between cell lines and products
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- Downstream development is reduced by the straightforward flow calculations in scale-up
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n/a |
Increase number of manufacturing slots, with help from single use equipment
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- No sterilization in place nor cleaning in place is needed
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- Easy integration to all single use bioreactors
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Increase process efficiency (volumetric productivity, yield etc)
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- Greatly increased volumetric productivity
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- Higher yield recovery and removal of centrifuge step
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Apply new process knowledge across product platforms to leverage maximum gain
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- Common operation and implementation in all unit operations
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Reduce laboratory and factory floorspace for a given product output
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- Reactor sizes are reduced up to 10 fold for any desired output required
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- Small footprint plus removal of traditional primary recovery equipment
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Achieve higher flexibility within a facility with minimal capital expenditure
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- Choice of filters with different pore sizes allows separation, concentration, wash and diafiltration options for a wide range of proteins, viruses and novel therapeutic molecules
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