The XRS 20 Bioreactor System is a new single-use bioreactor system with unique agitation and control properties designed for the cultivation of mammalian cells in suspension culture under controlled conditions and suitable for applications ranging from general life sciences research to seed train operations and full GMP production at the 2 to 20 liter scale.
Comprised of three components (XRS 20 Platform, XRS 20 Controller, and Allegro™ XRS 20 Biocontainers), the XRS System produces superior performance (as measured by higher density, better cell viability, and higher expression levels) compared to competitor rocker systems because its unique Bi-Axial agitation produces shorter mixing times and higher mass transfer properties.
The XRS 20 Bioreactor System incorporates a number of other features to ensure easy operation, robust performance, and suitability for GMP operations:
XRS 20 Platform
Bi-axial agitation (rocking motion on two horizontal axes at 90 degrees separation)
Improved agitation properties: shorter mixing times and higher mass transfer rates
Fully enclosed platform with safety interlock
Improved operator safety, suitable for production environments, protects light sensitive culture media
Allegro XRS 20 Biocontainer
3 dimensional biocontainer design
Superior mixing (with bi-axial platform), robust in operation
Biocontainer with integrated optical sensors, integrated filters, pre-assembled tubing sets
True single use system, ease of installation, minimal turn-around time
Gas inlet and exhaust filters are integrity testable, sterilizing grade 0.2 μm
Improved suitability for GMP operations
Integrated bottom drain with rotary lift valve
Improved suitability for GMP operations, minimal hold up volume, ease of use
Multiple liquid addition ports:
Main liquid addition line with female CPC
Reagent line 1 with female luer
Reagent line 2 with female luer
Accessory port with female luer
Improved ease of use, easily handles fed batch operations, acid/base pH control feeds
Integrated single use pH and Dissolved Oxygen (DO) sensors
Ease of use and reduced probability of contamination
Integrated sampling port
Ease of use - Very low hold up volume (less than 5 mL), capable of sampling without stopping agitation
Single-use biocontainer built with Allegro film
Assurance of robustness, quality and supply, track record of use of film in GMP operations, validation guide available
Advanced, full function, small footprint controller with touchscreen interface
Easy to use, but with powerful control capabilities (below). Touchscreen simplifies setup, calibration, operation, alarms, trending and process data collection
3 thermal mass flow gas controllers
Accurate 3 gas mixing and flow control, programmable
Controls up to 32 control loops; stores 10 recipes and 8 process variables for trend graphing. Includes an industrial touchscreen monitor/user interface, 3 built-in pumps & connectors for all utilities & communications signals.
25.4 cm (10 in.) LED monitor
Digital display in 0.1 °C increments
From 8 °C above ambient temperature to 40 °C (ambient temperature defined as 10 to 30 °C)
P&I control for heating. Heating is assured via the heater mat and cooling via ambient temperature.
Platinum RTD probe
Digital display in 1 rpm increments.
1 - 35 rpm
-15° to +15° in both X and Y directions
Stepper motor controlled
0.2 μm disposable filter (integrated with biocontainer)
Silicone heater mat
Up to 3 gases (Air, O2, CO2, or Mixture), Thermal Mass Flow Control
Gas sparged into biocontainer headspace
0.2μm disposable filter (integrated with biocontainer)
Digital display in 0.01 pH increments
6 - 8 pH
Non-invasive optical pH probe
Digital display in 0.1% increments
0 - 200%
3-gas P&I control
Non-invasive optical DO probe
Assignable peristaltic pump Fixed speed (14 rpm) or variable duty cycle Available control modes: Off, On, Prime.
Pumps 2 & 3
Assignable peristaltic pumps Fixed speed (109 rpm) or variable duty cycle Available control modes: Off, On, Prime.
68.9 mbar (1 PSIG) maximum
100-240 VAC, 50/60 Hertz, Single phase, 13 amp
105-230 VAC, 50-60 Hertz, Single phase, 13 amp
Power Rating, Reactor Platform
20 kg (44 lb)
78 kg (171.6 lb)
Overall Dimensions XRS Control Cabinet
29.5 cm W X 40.6 cm D X 66.8 cm H (11.6 in. wide X 16 in. deep X 26.3 in. high)
Overall Dimensions Reactor Platform
90 cm W X 60 cm D X 62 cm H (35.4 in. wide X 23.6 in. deep X 23.6 in. high) Allow for the lid's 20cm overhang at the rear of the platform, and factor in an additional 37 cm to the overall height when the lids are open.
External Computer Connections
Ethernet port supplied for future connection to supervisory host computer
2 Cooper Bussmann S505-10-R 5 x 20 mm 10 A fuses
See Section 5.1 Instructions For Use USD 2875
Ambient Operating Conditions
10 – 40 °C, up to 80% relative humidity, non-condensing
Allegro XRS 20 biocontainer supplied as a complete, ready-to-use, single-use system
Bi-Axial Rocker for Better Mixing and Mass Transfer
The XRS bioreactor system rocks on two axes simultaneously (Bi-Axial agitation), producing a low turbulence, swirling pattern within the 3-dimensional XRS 20 Biocontainer. Under similar agitation conditions, the XRS system mixes almost 3 times faster than conventional rockers, and demonstrates much higher mass transfer properties as measured by kLa values.
Summary of best mixing times observed in pH equilibration studies, 20 liter working volumes with conventional pH probes1
Mixing Time (s)
Maximum speed and rock angle = 42 rpm, 10.4°
50 to 98 seconds3
75% Max speed, maximum long axis angle, 1/3 short axis angle = 30 rpm, 15° long, 5° short
Summary of mass transfer coefficients observed in 20 liter working volumes as measured with nitrogen purge and recovery2
KLa per Hour
Maximum speed and rock angle = 42 rpm, 10.4°
Maximum speed and angle = 40 rpmv, 15° long, 15° short
1 Mixing trial results from 3 repetitions for each device 2 Mass transfer results from 3 repetitions for each device 3 Times significantly different for edge/center measurements For additional details on mixing and mass transfer studies, contact email@example.com
Better Mixing, Better Cell Culture Performance
The superior mixing properties due to the design of the 3-D biocontainer and the bi-axial agitation leads to superior cell culture performance in mammalian suspension systems. With faster delivery of nutrients to the cellular micro-environment (and faster removal of metabolites), the XRS 20 System allows cells to attain higher densities, and with higher overall viabilities, leading to much significantly higher protein expression levels. In the batch culture example cited below, with identical media inputs and seeds, the Pall XRS Bioreactor System produced 18% higher cell densities, and 30% more antibody titer compared to conventional rocker technologies.
Summary of side-by-side growth and viability experiments (n=3) at 20 liter working volumes comparing conventional rocker system and Pall XRS 20 system. Simple batch culture of a CHO (Chinese hamster ovary) cell line expressing a monoclonal antibody.