{"id":24866,"date":"2026-06-23T07:00:00","date_gmt":"2026-06-23T07:00:00","guid":{"rendered":"https:\/\/cellura.io\/?p=24866"},"modified":"2026-06-22T07:42:44","modified_gmt":"2026-06-22T07:42:44","slug":"characterization-of-suspension-limits-in-the-softxs-low-shear-bioreactor-system","status":"publish","type":"post","link":"https:\/\/cellura.io\/fr\/characterization-of-suspension-limits-in-the-softxs-low-shear-bioreactor-system\/","title":{"rendered":"Characterization of Suspension Limits in the SoftXS\u2122 Low-Shear Bioreactor System"},"content":{"rendered":"\t\t
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Suspension Remains a Major Challenge in Modern Cell Culture<\/strong><\/h5>

Maintaining homogeneous suspension<\/strong> while preserving a gentle hydrodynamic environment<\/strong> remains one of the major challenges in suspension-based cell culture systems.<\/p>

Many biological structures used in research and biomanufacturing, including stem cells<\/strong>, organoids<\/strong>, immune cells<\/strong>, cell aggregates<\/strong>, and microcarrier cultures<\/strong>, are sensitive to mechanical stress.<\/p>

Conventional stirred-tank bioreactors typically rely on internal impellers to generate mixing, producing localized turbulence<\/strong>, shear gradients<\/strong>, sedimentation zones<\/strong>, and heterogeneous fluid environments<\/strong>.<\/p>

The SoftXS\u2122 platform<\/strong> was developed to overcome these challenges through an impeller-free inclined rotation system<\/strong> capable of generating continuous suspension under low-shear conditions<\/strong>.<\/p>

A Different Mixing Principle<\/strong><\/h5>

Unlike conventional stirred systems, SoftXS\u2122 operates without internal impellers<\/strong>.<\/p>

The combination of:<\/p>

  • Rotational speed<\/strong><\/li>
  • Tilt angle<\/strong><\/li>
  • Free-surface dynamics<\/strong><\/li>
  • Vessel geometry<\/strong><\/li><\/ul>

    generates chaotic advection<\/strong> and continuous particle resuspension<\/strong> throughout the culture volume.<\/p>

    This design enables:<\/p>

    • Homogeneous suspension<\/strong><\/li>
    • Continuous mixing<\/strong><\/li>
    • Reduced hydrodynamic stress<\/strong><\/li>
    • Absence of impeller-induced shear<\/strong><\/li>
    • Absence of localized turbulence<\/strong><\/li><\/ul>

      creating a more homogeneous and mechanically gentle environment for sensitive biological systems.<\/p>

      Demonstrating Predictable Suspension Across Scales<\/strong><\/h5>

      To evaluate suspension performance, fluorescent polyethylene microbeads with a density similar to biological aggregates were used as model particles.<\/p>

      Three particle populations were investigated:<\/p>

      • ~100 \u00b5m<\/strong><\/li>
      • ~400 \u00b5m<\/strong><\/li>
      • ~1300 \u00b5m<\/strong><\/li><\/ul>

        Experiments were performed using vessel volumes of 10 mL<\/strong>, 50 mL<\/strong>, and 250 mL<\/strong> under identical hydrodynamic conditions.<\/p>

        The results demonstrated:<\/p>

        • Homogeneous suspension maintained from 10 mL to 250 mL<\/strong><\/li>
        • Predictable scale-up behavior<\/strong><\/li>
        • Stable suspension without internal impellers<\/strong><\/li>
        • Consistent hydrodynamic performance across vessel formats<\/strong><\/li><\/ul>

          Larger particles required higher rotational speeds to overcome sedimentation, while smaller vessels required higher speeds to maintain equivalent suspension conditions.<\/p>

          Importantly, an H\/D ratio of 0.7<\/strong> minimized the critical suspension speed (Nc)<\/strong> required to achieve stable suspension.<\/p>

          Defining Homogeneous Suspension Operating Windows<\/strong><\/h5>

          The study identified three distinct operating regimes.<\/p>

          Homogeneous Regime<\/strong><\/h6>
          • Complete particle suspension<\/strong><\/li>
          • No visible sedimentation<\/strong><\/li>
          • Stable full-height mixing<\/strong><\/li><\/ul>
            Limit Regime<\/strong><\/h6>
            • Partial sedimentation<\/strong><\/li>
            • Reduced suspension efficiency<\/strong><\/li>
            • Transitional suspension behavior<\/strong><\/li><\/ul>
              Non-Homogeneous Regime<\/strong><\/h6>
              • Significant particle accumulation<\/strong><\/li>
              • Strong spatial heterogeneity<\/strong><\/li>
              • Incomplete suspension<\/strong><\/li><\/ul>

                These results demonstrate that suspension performance is primarily controlled by particle size<\/strong>, rotational speed<\/strong>, and vessel geometry<\/strong>.<\/p>

                Quantitative Validation Using Laser Imaging<\/strong><\/h5>

                To independently validate suspension homogeneity, the study combined laser-sheet imaging<\/strong>, coefficient of variation (CV) analysis<\/strong>, and particle counting<\/strong>.<\/p>

                Homogeneous operating conditions consistently exhibited:<\/p>

                • Low CV values (<15%)<\/strong><\/li>
                • Negligible sedimentation<\/strong><\/li>
                • Uniform particle distribution throughout the liquid column<\/strong><\/li><\/ul>

                  The analysis also demonstrated that CV alone is insufficient<\/strong> to fully characterize suspension quality, since some partially sedimented conditions may still display relatively low CV values.<\/p>

                  Combining CV analysis<\/strong> with particle counting<\/strong> therefore provides a more robust framework for defining true suspension homogeneity.<\/p>

                  Dynamic Mixing and Particle Tracking<\/strong><\/h5>

                  Single-particle tracking experiments confirmed the dynamic nature of the SoftXS\u2122 suspension mechanism.<\/p>

                  Tracked particles continuously explored the accessible reactor volume without prolonged confinement in localized regions.<\/p>

                  This behavior demonstrates:<\/p>

                  • Efficient temporal mixing<\/strong><\/li>
                  • Continuous spatial renewal<\/strong><\/li>
                  • Homogeneous environmental exposure throughout the reactor<\/strong><\/li><\/ul>

                    The results confirm that homogeneous suspension within SoftXS\u2122 is maintained through continuous dynamic recirculation<\/strong> rather than static particle distribution.<\/p>

                    Quantifying Hydrodynamic Shear Stress<\/strong><\/h5>

                    One of the most significant findings of the study was the characterization of the hydrodynamic shear environment generated by SoftXS\u2122.<\/p>

                    Using fluid-dynamics models derived from experimental Particle Image Velocimetry data, the study established a direct relationship between rotational speed and shear stress:<\/p>

                    Fsh = 0.077 \u00d7 \u03c9<\/strong><\/p>

                    Within the validated operating window required to achieve complete homogeneous suspension (70\u2013250 rpm<\/strong>), hydrodynamic shear stress remained exceptionally low.<\/p>

                    Most importantly:<\/p>

                    • Maximum calculated shear stress: 19.25 mPa<\/strong><\/li>
                    • Entire SoftXS\u2122 operating window remains below 20 mPa<\/strong><\/li><\/ul>

                      This is substantially lower than the shear environments typically reported for conventional stirred and vertical-wheel bioreactor systems.<\/p>

                      \"\"<\/p>

                      Figure 1.<\/strong> Hydrodynamic shear stress as a function of rotational speed. Comparison between SoftXS\u2122 and conventional suspension technologies demonstrates that complete homogeneous suspension can be achieved while maintaining shear stress below 20 mPa<\/strong> throughout the validated SoftXS\u2122 operating window.<\/p>

                      Direct comparison with conventional suspension technologies revealed significantly higher shear environments, highlighting the ability of SoftXS\u2122<\/strong> to combine homogeneous suspension<\/strong> with exceptionally low mechanical stress<\/strong>.<\/p>

                      Conclusion<\/strong><\/h5>

                      This study demonstrates that the SoftXS\u2122 platform<\/strong> enables robust<\/strong>, reproducible<\/strong>, and low-shear suspension<\/strong> across working volumes ranging from 10 mL to 250 mL<\/strong>, without the use of internal impellers.<\/p>

                      Three major outcomes emerge from this work:<\/p>

                      • Reproducible homogeneous suspension across all investigated scales<\/strong><\/li>
                      • Predictable hydrodynamic behavior governed by particle size and operating conditions<\/strong><\/li>
                      • Efficient low-shear mixing achieved through inclined rotation without impellers<\/strong><\/li><\/ul>

                        Quantitative laser-sheet imaging, particle tracking experiments, and hydrodynamic modeling collectively confirm that complete suspension<\/strong>, continuous dynamic mixing<\/strong>, and ultra-low shear stress (<20 mPa)<\/strong> can coexist within a single scalable bioreactor platform.<\/p>

                        These results establish SoftXS\u2122<\/strong> as a scalable and controllable low-shear bioreactor technology<\/strong> for applications requiring the gentle suspension of sensitive biological materials.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<\/div>\n\t\t","protected":false},"excerpt":{"rendered":"

                        Suspension Remains a Major Challenge in Modern Cell Culture Maintaining homogeneous suspension while preserving a gentle hydrodynamic environment remains one of the major challenges in suspension-based cell culture systems. Many…<\/p>\n","protected":false},"author":2,"featured_media":24872,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"content-type":"","footnotes":""},"categories":[290],"tags":[833,350,828,838,824,832,841,844,840,842,823,831,837,834,836,827,843,845,835,825,829,839],"class_list":["post-24866","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-recherche-fr","tag-bioprocess-engineering-2","tag-bioreacteur-softxs","tag-bioreactor-engineering","tag-cell-aggregates","tag-cell-culture-hydrodynamics","tag-cell-culture-mixing","tag-cell-manufacturing-2","tag-cellura-2","tag-chaotic-advection","tag-fluid-dynamics","tag-homogeneous-suspension","tag-hydrodynamic-shear-stress","tag-immune-cell-culture","tag-mammalian-cell-culture","tag-organoid-culture-2","tag-scalable-bioreactor","tag-scalable-cell-culture-2","tag-softxs-3","tag-stem-cell-culture","tag-suspension-bioreactor","tag-suspension-culture","tag-suspension-systems"],"yoast_head":"\nCharacterization of Suspension Limits in the SoftXS\u2122 Low-Shear Bioreactor System - 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