What is ‘Upstream Bioprocessing’?

Upstream Bioprocessing covers the early stages of the bioprocess, where cells are isolated, grown, and prepared before moving into fermentation and downstream purification.

To understand the term clearly, it helps to first define bioprocessing itself. 

Bioprocessing simply describes a process that obtains living cells or components from microorganisms, such as enzymes, chloroplasts, or bacteria, to manufacture pharmaceuticals, vaccines, diagnostic agents, industrial enzymes, or chemicals.

It is a multidisciplinary field that combines the principles of biology, chemistry, and engineering to design, develop, and optimise processes for the production of these products. 

‘Cell Bioprocessing’ is the umbrella term that includes the two stages of bioprocessing: ‘Upstream Bioprocessing’ and ‘Downstream Bioprocessing’.

Upstream Bioprocessing refers to the initial stages of producing biological products, such as cell culture, fermentation, and purification. They are typically done on a large scale and are focused on maximising cell growth and product yield.

Downstream Bioprocessing refers to the later stages of producing biological products, such as purification, concentration, formulation, and packaging. These processes are often done at a smaller scale than Upstream.

Upstream Bioprocessing

The phrase ‘Upstream Bioprocessing’ describes the early stages of the bioprocess. This is where microbes, cells, and bacteria are grown, nurtured, and developed through a range of technologies and media.

In detail, those stages are:

1: Cell Isolation 

This is the process of separating a specific type of cell from a mixture of cells. Cell isolation is an important step in bioprocessing, as it allows for the cultivation of pure populations of cells.

2: Cultivation 

This refers to the growth of cells in a controlled environment, such as a bioreactor. This can be done in batch culture, where cells are grown in a single container, or in a continuous culture, where cells are grown in a steady-state system. The goal is to achieve optimal growth conditions for the cells to maximise production.

3: Cell Banking 

This is the process of storing cells for later use. The cells are typically frozen in liquid nitrogen or preserved in a cryopreservative. Cell banking allows for a supply of cells to be preserved, ready to be used on demand. It removes the need to create an entire upstream bioprocess workflow every time they are wanted.

4: Culture Expansion 

This is a way of increasing the number of cells in a culture through techniques such as cell splitting. This increases the yield of cells that are available for downstream processing.

After the Upstream Bioprocessing stage, the media will go on to the next stage of its product development journey: fermentation.

Fermentation

Despite its long history, fermentation continues to be a central part of bioprocessing. 

This part of the purification process that uses microorganisms, such as bacteria or yeast, to convert a substrate (such as sugars, starches, or organic acids) into useful products.

Fermentation can be used in the production of a wide range of products and media, such as enzymes, antibiotics, hormones, and proteins.

The goal of fermentation is to achieve optimal growth conditions for the microorganisms, and to maximise the production of the desired product.

Additionally, fermentation can also be applied to produce secondary metabolites, like antibiotics, pigments, and flavours. The process is commonly used in the industrial production of biofuels, food, beverages and, of course, biopharmaceuticals.

ALLpaQ bioprocess containment

ALLpaQ containers protect media through storage, transport, and handling as it moves along the supply chain.

Designed to reduce contamination risk, with smooth, removable panels for easier cleaning between uses, ALLpaQ bioprocess containers can be built around your 3D bag specifications and tubing routes rather than a fixed off-the-shelf shape. This also means that non-standard formats can typically be accommodated. 

Simply share your requirements, and we will confirm compatibility before production. 

The stackable, foldable design can also reduce warehouse footprint and return-shipment volume. As an ISO 9001 and 14001 accredited manufacturer, every container is fabricated under documented quality controls, with material traceability documentation available upon request. 

Discuss your requirements with our team or explore the full Genesis Shipping Container range, covering sizes from 50 to 1,000L. 

Further Reading

When they reach the desired density, the cultures or media are harvested, ready for the next part of the process. Read our guide to Downstream Bioprocessing to see what happens next.

Looking to compare containment options for your own upstream workflow? Contact us to discuss your requirements or read our guide to single-use bioprocessing to see where reusable containment fits alongside single-use bags.

Author

ALLpaQ

Packaging

ALLpaQ is the market leader in the design of innovative pharma containers and fluid management solutions.

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