Xpansion® Multiplate Bioreactor System product photo Primary L

Xpansion® Multiplate Bioreactor System

Multiplate bioreactor for cell-based product manufacturing

Features and Benefits

  • USP Class VI certified materials
  • Designed for adherent cell culture applications
  • Treatment for cells adherence
  • Single-use closed bioreactor, from vessel to sensors, reduces risk of contamination
  • 2-D multiplate design allows easy adaptation from traditional multitray systems
  • Integrated,disposable pH DO probes
  • Real-time control and monitoring ensures reproducibility and traceability
  • Reduced operations results in process simplification, flexibility, and assurance
CELL CULTURE SOLUTIONS
Pall has a comprehensive portfolio of advanced single-use solutions for cell culture applications

The Xpansion multiplate bioreactor is part of the Pall Life Sciences’ single-use bioreactor family, designed for shear-sensitive adherent cell applications, such as cultivation of stem cells.

The Xpansion multiplate bioreactor was developed for safe, large-scale production of traditional 2-D 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 which provides advanced gas diffusion. Control is automatic via disposable pH and dissolved oxygen (DO) sensors. Temperature monitoring and agitation control are also included. Xpansion bioreactors offer the capability of monitoring cell morphology and density through the use of an optional digital holographic microscope.

Xpansion System Components

The Xpansion system includes a single-use bioreactor, docking station and a controller.

Single-Use Bioreactor with Stacked Multiplate Design

Comprised of stacked hydrophilized polystyrene radial plates, the Xpansion bioreactor is designed to promote cell growth on the top of each plate; each plate has a hole in the center. The stacking of these plates forms the central column which allows circulation of the medium in the bioreactor and gas exchange.

The plates are covered by an outer tube, a head plate on the top and a base plate on the bottom. On the head plate, there are:
  • Six sensor connectors: pH, DO, and four optional sensors
  • Three viewing windows for use with optional holographic microscope
  • Two vent filters
  • Two gas filters (in and out) for aeration system
  • One thermowell port
  • One sampling port
In the bottom side of the bioreactor, there are:
  • Two fluid operation ports (e.g., inoculation, harvest, etc.)
  • One magnetic impeller


An Xpansion Plate


  The Xpansion Multiplate Bioreactor

Materials
 
1 Gas lines
(in & out)
C-Flex* tubing and silicone 3/16 in. ID, 0.2 μm hydrophobic filters (PTFE, polyester, polypropylene)
2 Vent.1 C-Flex 3/16 in. ID, 2 0.2 μm hydrophobic filters (PTFE,polyester, polypropylene)
3 Sampling port C-Flex 3/16 in. ID with needleless connector for sampling with luer syringe + oneway valve
4 Top part Clear polystyrene
5 Cell surface plates Cell culture plasma-treated clear polystyrene
6 Aeration support Polypropylene + polycarbonate
7 Aeration tubing Silicone 0.58 in. ID x 0.77 in. OD
8 Outer tube Polyvinyl chloride
9 Stirrer cover Clear polystyrene
10 Impeller Ultra-high-molecular-weight polyethylene
11 Bearing Polyether ether ketone
12 Bottom part Clear polystyrene
13 Liquid in/out tubing C-Flex Clear 374 Tubing 3/8 in. ID, CPC MPC male connector, 0.2 μm hydrophobic filters
Sealing material Resin
 

Docking Station

The bioreactor docks to a station that includes a magnetic drive stirring unit powering the magnetic impeller.

Control of agitation speed is integrated in the controller. The setpoint is defined via the screen on the front side of the controller.

Controller

The controller has measurement/control hardware and a gassing system with a digital control.

Features of the Xpansion controller include:
  • Graphic user interface with color display and touch screen operation with Administrator and Operator security levels
  • Integrated transmitters for temperature, disposable DO and pH sensors
  • Integrated control loops for DO and pH
  • Agitation control (speed range from 5 to 250 rpm)
  • Temperature monitoring
  • DO and pH sensor patches arrive precalibrated; data are transferred via a USB key to the controller
  • In-process DO and pH can be recalibrated
  • Trend display for up to four process values (pH, DO, T, gas flow rate)
Controller Gas Module
The controller is connected to the user’s gas supply line. Its “gas outlet” is connected to the “gas in” filter of the bioreactor. Gas composition to be injected in the bioreactor is regulated by controller solenoid gas valves. The flow rate of the mixed gas is adjusted by a massflow controller (0-200 mL/min). The controller gas module contains:
  • One gas diffuser outlet
  • Four solenoid valves of Air, N2, O2, and CO2
  • One Mass Flow Controller for mixed gas flow control
Data Management

The Xpansion system has one ethernet port for data communication/ acquisition. It can be linked to egraph (optional software and computer provided by Pall Life Sciences). egraph is installed on a host PC and provides data acquisition for all process values.


Xpansion Controller and Docking Station
Xpansion Controller and Docking Station

Controller

 
Height 50 cm (19.7 in.)
Depth 40 cm (15.7 in.)
Width 25 cm (9.8 in.)
Weight 15 kg (33 lbs.)
Power supply 100 – 240 VAC, 50 – 60 Hz
Interface Ethernet
USB host
Stirrer speed 5 – 250 rpm
Integrated measurement module Disposable DO sensor
Disposable pH sensor
Temperature
One point recalibration function Disposable DO sensor
Disposable pH sensor
Gas options O2
N2
CO2
Air
Temperature monitoring 0 – 50 ºC (32 – 122 ºF)
 

Gas Requirements

 
Gases Application Specification
Air pH control Compressed air – medical grade
Outlet pressure between 1 and 2 bars (14.5 – 30 PSI) 6 mm Festo connectors
CO2 pH control Pure CO2
Outlet pressure equivalent to air pressure 6 mm Festo connectors
Oxygen DO control Medical grade oxygen
Outlet pressure equivalent to air pressure 6 mm Festo connectors
Nitrogen
(optional)
DO control Medical grade nitrogen
Outlet pressure equivalent to air pressure 6 mm Festo connectors
 


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Description

Multiplate bioreactor for cell-based product manufacturing

Features and Benefits

  • USP Class VI certified materials
  • Designed for adherent cell culture applications
  • Treatment for cells adherence
  • Single-use closed bioreactor, from vessel to sensors, reduces risk of contamination
  • 2-D multiplate design allows easy adaptation from traditional multitray systems
  • Integrated,disposable pH DO probes
  • Real-time control and monitoring ensures reproducibility and traceability
  • Reduced operations results in process simplification, flexibility, and assurance
CELL CULTURE SOLUTIONS
Pall has a comprehensive portfolio of advanced single-use solutions for cell culture applications

The Xpansion multiplate bioreactor is part of the Pall Life Sciences’ single-use bioreactor family, designed for shear-sensitive adherent cell applications, such as cultivation of stem cells.

The Xpansion multiplate bioreactor was developed for safe, large-scale production of traditional 2-D 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 which provides advanced gas diffusion. Control is automatic via disposable pH and dissolved oxygen (DO) sensors. Temperature monitoring and agitation control are also included. Xpansion bioreactors offer the capability of monitoring cell morphology and density through the use of an optional digital holographic microscope.

Xpansion System Components

The Xpansion system includes a single-use bioreactor, docking station and a controller.

Single-Use Bioreactor with Stacked Multiplate Design

Comprised of stacked hydrophilized polystyrene radial plates, the Xpansion bioreactor is designed to promote cell growth on the top of each plate; each plate has a hole in the center. The stacking of these plates forms the central column which allows circulation of the medium in the bioreactor and gas exchange.

The plates are covered by an outer tube, a head plate on the top and a base plate on the bottom. On the head plate, there are:
  • Six sensor connectors: pH, DO, and four optional sensors
  • Three viewing windows for use with optional holographic microscope
  • Two vent filters
  • Two gas filters (in and out) for aeration system
  • One thermowell port
  • One sampling port
In the bottom side of the bioreactor, there are:
  • Two fluid operation ports (e.g., inoculation, harvest, etc.)
  • One magnetic impeller


An Xpansion Plate


  The Xpansion Multiplate Bioreactor

Materials
 
1 Gas lines
(in & out)
C-Flex* tubing and silicone 3/16 in. ID, 0.2 μm hydrophobic filters (PTFE, polyester, polypropylene)
2 Vent.1 C-Flex 3/16 in. ID, 2 0.2 μm hydrophobic filters (PTFE,polyester, polypropylene)
3 Sampling port C-Flex 3/16 in. ID with needleless connector for sampling with luer syringe + oneway valve
4 Top part Clear polystyrene
5 Cell surface plates Cell culture plasma-treated clear polystyrene
6 Aeration support Polypropylene + polycarbonate
7 Aeration tubing Silicone 0.58 in. ID x 0.77 in. OD
8 Outer tube Polyvinyl chloride
9 Stirrer cover Clear polystyrene
10 Impeller Ultra-high-molecular-weight polyethylene
11 Bearing Polyether ether ketone
12 Bottom part Clear polystyrene
13 Liquid in/out tubing C-Flex Clear 374 Tubing 3/8 in. ID, CPC MPC male connector, 0.2 μm hydrophobic filters
Sealing material Resin
 

Docking Station

The bioreactor docks to a station that includes a magnetic drive stirring unit powering the magnetic impeller.

Control of agitation speed is integrated in the controller. The setpoint is defined via the screen on the front side of the controller.

Controller

The controller has measurement/control hardware and a gassing system with a digital control.

Features of the Xpansion controller include:
  • Graphic user interface with color display and touch screen operation with Administrator and Operator security levels
  • Integrated transmitters for temperature, disposable DO and pH sensors
  • Integrated control loops for DO and pH
  • Agitation control (speed range from 5 to 250 rpm)
  • Temperature monitoring
  • DO and pH sensor patches arrive precalibrated; data are transferred via a USB key to the controller
  • In-process DO and pH can be recalibrated
  • Trend display for up to four process values (pH, DO, T, gas flow rate)
Controller Gas Module
The controller is connected to the user’s gas supply line. Its “gas outlet” is connected to the “gas in” filter of the bioreactor. Gas composition to be injected in the bioreactor is regulated by controller solenoid gas valves. The flow rate of the mixed gas is adjusted by a massflow controller (0-200 mL/min). The controller gas module contains:
  • One gas diffuser outlet
  • Four solenoid valves of Air, N2, O2, and CO2
  • One Mass Flow Controller for mixed gas flow control
Data Management

The Xpansion system has one ethernet port for data communication/ acquisition. It can be linked to egraph (optional software and computer provided by Pall Life Sciences). egraph is installed on a host PC and provides data acquisition for all process values.


Xpansion Controller and Docking Station
Xpansion Controller and Docking Station

Controller

 
Height 50 cm (19.7 in.)
Depth 40 cm (15.7 in.)
Width 25 cm (9.8 in.)
Weight 15 kg (33 lbs.)
Power supply 100 – 240 VAC, 50 – 60 Hz
Interface Ethernet
USB host
Stirrer speed 5 – 250 rpm
Integrated measurement module Disposable DO sensor
Disposable pH sensor
Temperature
One point recalibration function Disposable DO sensor
Disposable pH sensor
Gas options O2
N2
CO2
Air
Temperature monitoring 0 – 50 ºC (32 – 122 ºF)
 

Gas Requirements

 
Gases Application Specification
Air pH control Compressed air – medical grade
Outlet pressure between 1 and 2 bars (14.5 – 30 PSI) 6 mm Festo connectors
CO2 pH control Pure CO2
Outlet pressure equivalent to air pressure 6 mm Festo connectors
Oxygen DO control Medical grade oxygen
Outlet pressure equivalent to air pressure 6 mm Festo connectors
Nitrogen
(optional)
DO control Medical grade nitrogen
Outlet pressure equivalent to air pressure 6 mm Festo connectors
 
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