From Fed-Batch To Perfusion: Unlocking ROI And Capacity In Monoclonal Antibody Manufacturing

Fed-batch remains the traditional platform for upstream monoclonal antibody (mAb) production, but it is limited in cost efficiency, productivity, and facility utilization. As pipelines expand and competitive pressures mount, manufacturers need an upstream platform that delivers stronger process economics without compromising quality or timelines.

This white paper presents a detailed economic analysis comparing fed-batch and perfusion-based upstream production at both mid- and large-scale. Modeling shows that perfusion with XCell® ATF Systems achieves:

• Up to 24% lower cost per gram at commercial scale
• 5–10X higher volumetric productivity (space-time-yield)
• Smaller, more flexible facilities with reduced CAPEX and OPEX
• Improved product quality through stable culture conditions

Beyond modeling, the paper highlights real-world implementations that demonstrate how continuous perfusion enables faster development timelines, improved facility utilization, and dramatic reductions in production costs.

By maintaining higher viable cell densities over extended run times, perfusion empowers upstream teams to expand output without investing in larger bioreactors or additional infrastructure. For organizations seeking to move beyond fed-batch, this analysis shows how continuous perfusion can unlock capacity, improve economics, and strengthen competitiveness in a rapidly evolving therapeutic landscape.