AAV and LV vectors have safety and operational challenges with downstream purification, but requirements vary by vehicle type. As noted in Scientific Reports, AAVs generally require cellular lysis, which can leave behind contaminants from host cells. AAV vector production is also prone to incomplete and empty viral capsids, which can also carry contamination risks. On the other hand, LV vectors could require a more involved or restrictive processing workflow to reach desired yield and purity, according to research published in Cell.

Because of these and other concerns, researchers are increasingly deploying closed and semi-automated systems for bioburden and processing control. Automation tools embedded in these systems reduce manual processing and handling steps, which can mitigate AAV vectors' contamination risks and address LV vectors' workflow needs. Closed systems also can reduce environmental contamination risks.

Researchers are also looking at high-yield platforms for adherent cultures — including products like Corning CellSTACK® culture chambers and HYPERStack® vessels, which can make for more efficient scale-up, Cell Culture Dish says. These products, and the next generation fixed-bed bioreactors like Corning Ascent® Fixed Bed Reactor offer increased surface area to volume ratio in a smaller footprint, increasing scale potential and providing automated control in closed systems.