Fed-batch performance profiles for mAb production using different intensified N − 1 seed strategies are CHO cell-line dependent

Recent optimizations of cell culture processes have focused on the final seed scale-up step (N − 1 stage) used to inoculate the production bioreactor (N-stage bioreactor) to enable higher inoculation cell densities (2–20 × 10⁶ cells/mL), which could shorten the production culture duration and/or increase the volumetric productivity. N − 1 seed process intensification can be achieved by either non-perfusion (enriched-batch or fed-batch) or perfusion culture to reach those higher final N − 1 viable cell densities (VCD). In this study, we evaluated how different N − 1 intensification strategies, specifically enriched-batch (EB) N − 1 versus perfusion N − 1, affect cell growth profiles and monoclonal antibody (mAb) productivity in the final N-stage production bioreactor operated in fed-batch mode. Three representative Chinese Hamster Ovary (CHO) cell lines producing different mAbs were cultured using either EB or perfusion N − 1 seeds and found that the N-stage cell growth and mAb productivities were comparable between EB N − 1 and perfusion N − 1 conditions for two of the cell lines but were very different for the third. In addition, within the two similar cell growth cell lines, differences in cell-specific productivity were observed. This suggests that the impact of the N − 1 intensification process on production was cell-line dependent. This study revealed that the N − 1 intensification strategy and the state of seeds from the different N − 1 conditions may affect the outcome of the N production stage, and thus, the choice of N − 1 intensification strategy could be a new target for future upstream optimization of mAb production.