Bioreactor Platform Enables Scalable Adherent Cell Culture

Green Elephant Biotech has introduced the Archimedes^® One Dynamic Adherence Bioreactor, developed in collaboration with Bürkert Fluid Control Systems. The platform is designed to address long-standing challenges in scaling adherent cell culture processes, particularly in cell and gene therapy manufacturing.

Challenges in Adherent Cell Culture Scaling
Adherent cell cultures are widely used in advanced therapies but remain difficult to scale. Traditional two-dimensional systems require extensive manual handling and multiple culture vessels, limiting efficiency and reproducibility.

Alternative approaches, such as suspension cultures or fixed-bed bioreactors, introduce trade-offs. Suspension systems often require adaptation of sensitive cell types, while fixed-bed systems can increase hardware complexity and operational costs.

The Archimedes^® One platform is designed to overcome these limitations by maintaining adherent growth conditions while enabling scalable and controlled production.

CellScrew Geometry and Perfusion-Based Cultivation
At the core of the system is the CellScrew^® geometry, which provides a high surface area for cell growth within a compact volume. This design supports perfusion-based cultivation, allowing continuous nutrient supply and waste removal.

The approach enables controlled expansion of adherent cells without transferring them into suspension or complex matrices, preserving biological characteristics while improving scalability.

Automated media distribution and integrated harvesting reduce manual intervention, supporting standardized and reproducible workflows.

Integrated Fluidics and Process Control
The system incorporates Bürkert’s fluidic and gas control technologies to regulate media flow and gas exchange. Precise control of process parameters such as pH, dissolved oxygen, and temperature is achieved through an integrated biocontroller.

This level of monitoring and control aligns adherent cell culture processes with the capabilities typically associated with suspension bioreactors, improving process consistency and reliability.

Automation and Workflow Efficiency
By integrating fluid management and automation, the platform reduces operational complexity in cell culture processes. Automated control of cultivation conditions and harvesting steps minimizes variability and supports higher throughput.

These capabilities are particularly relevant for contract development and manufacturing organizations (CDMOs) and therapy developers seeking to scale production while maintaining quality standards.

Development Collaboration and Market Introduction
The system was developed through a collaboration initiated at analytica 2024, where Bürkert identified Green Elephant’s technology. Bürkert subsequently became a strategic investor, supporting joint development of the platform.

An early access program is being launched to enable selected users to test the system in real-world production environments. This phase will generate application data and support validation ahead of broader commercial availability.

Relevance for Bioprocessing and Digital Supply Chains
The Archimedes^® One platform reflects broader trends in biomanufacturing toward automation, process standardization, and scalability. By integrating cultivation, fluidics, and control systems, the platform supports more efficient production workflows.

Within a digital supply chain, such systems enable better process traceability, data-driven optimization, and consistent product quality—key requirements for the industrialization of cell and gene therapies.

Edited by Romila DSilva, Induportals Editor, with AI assistance.