Concurrent PRRSV Bioreactor Production Method
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Solution Overview
Problem
Current methods for producing live attenuated Porcine Reproductive and Respiratory Syndrome Virus (PRRSV) vaccines are inefficient and costly at commercial scales, requiring extensive cell line growth and multiple passage levels, which are time-consuming and resource-intensive.
Innovation Solution
A method for commercial-scale production of PRRSV involving concurrent seeding of mammalian cell lines permissive to PRRSV infection into bioreactors, with multiple harvesting steps and media replenishment, allowing for efficient propagation and harvesting of the virus, reducing the need for prior cell line growth and minimizing resources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional sequential methods are used for producing live attenuated PRRSV vaccines, then virus propagation can be achieved, but production time is excessive and resource consumption is high
Solution Approach 1:
The patent applies preliminary action by pre-seeding mammalian cell lines into bioreactors before virus introduction. This advance preparation of the cellular substrate eliminates the need for time-consuming cell growth phases during actual virus propagation, directly reducing production time while maintaining efficiency
Solution Approach 2:
The patent implements continuity of useful action through multiple sequential harvesting steps with media replenishment. Instead of single-phase production, the system continuously propagates and harvests virus across multiple cycles, keeping the production process constantly active and maximizing resource utilization throughout the cultivation period
2Reliability
If multiple passage levels are required for virus attenuation, then vaccine efficacy is improved, but the number of production steps increases and costs rise
Solution Approach 1:
The patent merges multiple production operations into a unified continuous process. By combining cell seeding, virus propagation, and multiple harvesting cycles within a single bioreactor system, it achieves the required virus attenuation through continuous passage while eliminating the need for separate, discrete production facilities or equipment for each passage level
3Quantity of substance
If extensive cell line growth is performed prior to virus infection, then sufficient substrate is available for virus propagation, but resource consumption and production time increase
Solution Approach 1:
The patent applies preliminary action by pre-seeding adequate quantities of mammalian cell lines into bioreactors before virus introduction. This advance preparation ensures sufficient cellular substrate is ready for immediate virus propagation, eliminating the need for time-consuming cell growth phases during actual production while maintaining adequate cell quantities
4Productivity
If traditional production methods are used, then virus can be propagated, but manufacturing costs are high and scalability is limited
Solution Approach 1:
The patent implements universality by using standardized bioreactor systems that can handle multiple functions: cell seeding, virus propagation, and sequential harvesting. This multi-functional approach allows the same equipment to scale from small to large production volumes, making the manufacturing process adaptable and cost-effective across different production scales
Solution Approach 2:
The patent implements continuity of useful action through multiple sequential harvesting steps with media replenishment. Instead of single-phase production, the system continuously propagates and harvests virus across multiple cycles, keeping the production process constantly active and maximizing resource utilization throughout the cultivation period
Data Source
AI summary
The present invention describes an efficient commercial scale production method for the preparation of PRRS virus.