Scale-up challenges in vaccine production
Once a new vaccine has been given the green light by the Food and Drug Administration (FDA) and other regulatory bodies, vaccine manufacturers are faced with the challenge of scaling up their processes.
This specific challenge became most evident during the high time of the Coronavirus disease when formulations were required in large scale as soon as they had passed phase 3 trials and adverse events could be ruled out.
But even beyond the pandemic, scaling remains an important topic. Once a formulation is approved, titers of raw material need to be bumped up. Raw material includes antibodies, RNA, various viral vectors, pathogens or adjuvants to boost immune response and increase the duration of antibody responses.
In addition to having to handle increased volumes of raw material, large scale vaccine platforms require an increasing amount of components, many of which are often provided by different suppliers. Any issues in the procurement of just a single component will stall the production of valuable vaccine doses, thus impacting the global health sector.
Furthermore, standardization is an essential aspect in scaling up vaccine manufacturing. The FDA approval and clinical phases rely on findings from small volumes. When scaling up the quantity of substances, minimizing deviations becomes imperative to guarantee both efficacy and, more importantly, safety. To attain the desired properties, scalable processes—from laboratory procedures to the handling of bulk drug substances—need to adhere to a certain degree of standardization. In addressing this challenge, the solutions from Single Use Support, ensure freezing curves that maintain uniformity or similarity for both small and large volumes.
Another significant aspect in scaling up production involves establishing a well-functioning supply chain for all essential components, with particular emphasis on ensuring the security of cold chain logistics.