How Perfusion In Seed Train Bioreactors Can Simplify Upstream Processes

Running N-1 bioreactor operation in perfusion mode offers a route to intensify seed trains by generating high density, high viability inoculum that reduce pre production steps and shorten production bioreactor occupancy. By extending exponential growth beyond what is achievable in batch mode, perfusion enables high cell concentration inoculation or removal of intermediate seed stages. However, scalability, long term viability, and potential impacts on fed batch performance remain key industry challenges. In this presentation, we will demonstrate a scalable N-1 perfusion process from bench to production scale and describe how we achieved ~95% viability and exceeded 170 × 10⁶ cells/mL after 9 days of culture. We will also show that there was no impact on the subsequent fed batch runs seeded from these perfusion cultures compared to non-intensified seed train cultures.