Keeping your process consistent across the seed train

Consistent process conditions across scales

In practice, development, pilot and production systems are often built differently, which makes it difficult to maintain comparable process conditions. Differences in geometry, mixing and control systems can introduce variability that only becomes visible later in production.

Platforms such as the Applikon BioBench, BioPilot and BioProduction from Getinge are designed around a consistent engineering concept across scales. Building on more than 30 years of experience in bioreactor design, these systems apply the same process logic from lab to production, supported by advanced control technologies and integrated automation. This continuity helps ensure that parameters such as mixing, oxygen transfer and control strategies remain comparable during scale-up.

Designing out variability during scale-up

Maintaining process consistency requires more than matching volumes. Reactor design elements such as aspect ratio, agitation system and gas transfer configuration need to align with the biological process. Even small differences can influence cell behaviour or productivity.

Using a staged approach—from standardised development systems to modular pilot reactors and fully customised production vessels—allows process parameters to be defined early and translated into larger-scale equipment. Advanced engineering tools, validated design methods and long-standing application experience support this process, helping to reduce variability during scale-up and achieve more predictable performance in production environments.