Xpansion® Multiplate Bioreactor System product photo Primary L

Xpansion® Multiplate Bioreactor System

Multiplate bioreactor for adherent cell culture

  • Closed and single-use to reduce risk of contamination
  • 2D multiplate design allows easy scale up from traditional multitray systems
  • Real-time control and monitoring ensures reproducibility and traceability
  • Single-use closed bioreactor, from vessel to sensors, reduces risk of contamination
  • Multiple sizes available to match the scale required
  • Compatible with Pall’s mPath™ benchtop bioreactor control tower

The Xpansion multiplate bioreactor system is a closed, single-use system that has been specifically designed for the scale-up of shear-sensitive, adherent mammalian cells under controlled conditions. It is suitable for multiple applications but is especially well suited for seed train operations for the iCELLis® bioreactor as well as for adherent stem cell culture..

The Xpansion bioreactor system was developed for efficient scale-up of traditional 2D cell cultures. The multiplate structure
is comprised of a large cell growth surface area (up to 122,400 cm2), while the compact design enables the elimination of the gas
phase between the plates. This gas phase is replaced by an automatically controlled aeration system via disposable pH and
dissolved oxygen (DO) sensors. Temperature monitoring and agitation control are also included.

The Xpansion bioreactor system provides a similar microenvironment to a multitray stack but in a much more compact space and with fully automated environmental control. The 80 cm high Xpansion 200 bioreactor provides the same cell growth area as a 4 m high stack of multitray vessels.

The 80 cm high Xpansion 200 bioreactor provides the same cell growth area as a 20 multitray vessels

System Overview

Single-Use Bioreactor with Stacked Multiplate Design

Standard Cell Environment Preservation

Similar to multitray stacks, cells adhere and grow on hydrophilized polystyrene plates and are harvested using a cell dissociation reagent.

An Xpansion bioreactor plate

Because of its design, the system maintains the same environment as T-flasks or multitray stacks, and processes designed on these systems are easily adapted to the Xpansion system.

Cell Culture Parameters (pH, DO) Control and Temperature Monitoring

The Xpansion bioreactor head plate includes ports for single-use, optical, non-invasive measurement of pH and DO. Depending on the DO and pH measurement, gas regulation is activated via the controller according to users’ requirements.

Temperature is measured for monitoring via a PT100 reusable sensor installed in a thermowell of the bioreactor. Heating is provided by placing the consumable in an incubator or warm room.

Aeration System

Gas aeration occurs depending on user-specified pH and DO set-points measured using the pH and DO sensors. Gas from the controller enters the bioreactor and passes through thin silicone tubing placed in the central column formed by stacking the plates where it diffuses into the surrounding medium. The gas inlet and outlet include pre-installed hydrophobic aeration filters.

The Xpansion bioreactor aeration system


Homogenization by Medium Circulation

Each plate contains 16 radial channels allowing medium to flow through and up the plates. The rotation of the impeller pushes the liquid upward, first vertically through the first plate channel, then horizontally over the plate, then up again to the second plate, etc.

Circulation of culture medium throughout the Xpansion bioreactor plates




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Description

Multiplate bioreactor for adherent cell culture

  • Closed and single-use to reduce risk of contamination
  • 2D multiplate design allows easy scale up from traditional multitray systems
  • Real-time control and monitoring ensures reproducibility and traceability
  • Single-use closed bioreactor, from vessel to sensors, reduces risk of contamination
  • Multiple sizes available to match the scale required
  • Compatible with Pall’s mPath™ benchtop bioreactor control tower

The Xpansion multiplate bioreactor system is a closed, single-use system that has been specifically designed for the scale-up of shear-sensitive, adherent mammalian cells under controlled conditions. It is suitable for multiple applications but is especially well suited for seed train operations for the iCELLis® bioreactor as well as for adherent stem cell culture..

The Xpansion bioreactor system was developed for efficient scale-up of traditional 2D cell cultures. The multiplate structure
is comprised of a large cell growth surface area (up to 122,400 cm2), while the compact design enables the elimination of the gas
phase between the plates. This gas phase is replaced by an automatically controlled aeration system via disposable pH and
dissolved oxygen (DO) sensors. Temperature monitoring and agitation control are also included.

The Xpansion bioreactor system provides a similar microenvironment to a multitray stack but in a much more compact space and with fully automated environmental control. The 80 cm high Xpansion 200 bioreactor provides the same cell growth area as a 4 m high stack of multitray vessels.

The 80 cm high Xpansion 200 bioreactor provides the same cell growth area as a 20 multitray vessels

System Overview

Single-Use Bioreactor with Stacked Multiplate Design

Standard Cell Environment Preservation

Similar to multitray stacks, cells adhere and grow on hydrophilized polystyrene plates and are harvested using a cell dissociation reagent.

An Xpansion bioreactor plate

Because of its design, the system maintains the same environment as T-flasks or multitray stacks, and processes designed on these systems are easily adapted to the Xpansion system.

Cell Culture Parameters (pH, DO) Control and Temperature Monitoring

The Xpansion bioreactor head plate includes ports for single-use, optical, non-invasive measurement of pH and DO. Depending on the DO and pH measurement, gas regulation is activated via the controller according to users’ requirements.

Temperature is measured for monitoring via a PT100 reusable sensor installed in a thermowell of the bioreactor. Heating is provided by placing the consumable in an incubator or warm room.

Aeration System

Gas aeration occurs depending on user-specified pH and DO set-points measured using the pH and DO sensors. Gas from the controller enters the bioreactor and passes through thin silicone tubing placed in the central column formed by stacking the plates where it diffuses into the surrounding medium. The gas inlet and outlet include pre-installed hydrophobic aeration filters.

The Xpansion bioreactor aeration system


Homogenization by Medium Circulation

Each plate contains 16 radial channels allowing medium to flow through and up the plates. The rotation of the impeller pushes the liquid upward, first vertically through the first plate channel, then horizontally over the plate, then up again to the second plate, etc.

Circulation of culture medium throughout the Xpansion bioreactor plates


Specifications
See datasheet for specifications.
Additional Information

Features and Benefits

Xpansion Bioreactor System
Scalable system
  • Available in a wide range of sizes to allow for scale up from lab scale to production
Same environment as multitray stack
  • Decreased process development time and risk
  • Less cost for process development and validation
  • Accelerate time to market
Compact and closed system
  • Reduced footprint
  • Reduced risk of batch failure due to contamination
  • Decreased operating cost
Controlled environment
  • Process reproducibility facilitates quality control
  • Supports cGMP compliance
  • Supports regulatory approval

mPath Control Tower and Pall Link Server
mPath control tower designed for operation with Pall Link - a SCADA software package
  • Capable of accessing data anywhere on any networked device including laboratory workstations,desktop computers or remote devices such as laptops, mobile phones and tablets
  • Operates as either a standalone network or integrated with site IT systems, compatible with multiple network security approaches (e.g. virtual private network [VPN]) and password protection to protect bioreactors from unauthorized access
  • Full alarm customization to alert for process or safety critical events
Ergonomic industrial design
  • Extensive human factors research to determine optimal placement of connections and control tower elements
  • Flexibility in operation – choose when and where to view data, choose how to design processes
  • Compact design to limit bench space requirements – small form factor and biocontainer hangers remove the need for scales and bottles
  • Elevated from bench for cleanability

See datasheet for documentation and certificates, and Pall quality standards.

Preventive Maintenance and Service Packages

The Xpansion bioreactor system is supported with extensive maintenance and service packages. Pall has a global network of technicians and engineers available to assist with installation, qualification, training, technical support, preventive maintenance and on-site repairs. Contact Pall to arrange to discuss any of these services.

Process Development Services

Pall Accelerator process development services provide customers with expert advice and support for the implementation of fully integrated single-use processing solutions into new or existing processes, including process optimization, equipment selection, transfer of existing processes, scale-up and troubleshooting advice. Details can be found in the Accelerator Process Development Services brochure (USD 3079).

Our teams are specialized in upstream and downstream processing and will gladly help find the right technology for any part of your manufacturing process. It is possible to combine the Xpansion bioreactor system with other products to meet any requirement in the upstream part of the process:

  • Media preparation
  • Buffer preparation
  • Media sterilization and aseptic transfer
  • Liquid transfer into the bioreactor (e.g. glucose, anti-foam, base, etc.)
  • Seed train solutions
  • Cell harvest and separation
  • Perfusion modules

Please contact Pall for a total solution discussion on your process.

Ordering Information
Description Part Number
Xpansion bioreactor system
System hardware – consists of Xpansion hardware,
mPath controller, control cables
XPNBRS
Pall Link server and SCADA software MPATHLINK
Harvest station
Mechanical cell detachment device for harvest
XPNHVST
Lift
Safe movement of bioreactor from package to incubator.
Highly recommended for XP100 and XP200
XPNLIFT
Consumables
Xpansion 10 bioreactor
Xpansion 50 bioreactor
Xpansion 100 bioreactor
Xpansion 200 bioreactor

XPN10
XPN50
XPN100
XPN200
Seeding manifold
2 L bottle with female MPCu connector used to transfer
cell suspension into seeding container
6100097S
Pooling manifold
Sterile 10 L bottle with female MPC connector used for
pooling reagent bottles
6100129
Application
Bioreactors - Adherent Cell
Segment
Cell Culture