HEK293 is a widely used cell line in the fields of research and industry. It is assumed that these cells are sensitive to hydrodynamic stress. The aim of this research was to use particle image velocimetry validated computational fluid dynamics (CFD) to determine the hydrodynamic stress in both shake flasks, with and without baffles, and in stirred Minifors 2 bioreactors to evaluate its effect on the growth and aggregate size distribution of HEK293 suspension cells. The HEK FreeStyle^TM 293-F cell line was cultivated in batch mode at different specific power inputs (from 63 $\mathrm{W} {\mathrm{m}}^{-3}$ to 451 $\mathrm{W} {\mathrm{m}}^{-3}$), whereby $\approx 60 \mathrm{W} {\mathrm{m}}^{-3}$ corresponds to the upper limit, which is what has been typically described in published experiments. In addition to the specific growth rate and maximum viable cell density VCD${}_{\max }$, the cell size distribution over time and cluster size distribution were investigated. The VCD${}_{\max }$ of $(5.77\pm 0.02)·{10}^6$$\mathrm{cells}$$\mathrm{m}$${\mathrm{L}}^{-1}$ was reached at a specific power input of 233 $\mathrm{W} {\mathrm{m}}^{-3}$ and was $23.8\%$ higher than the value obtained at 63 $\mathrm{W} {\mathrm{m}}^{-3}$ and $7.2\%$ higher than the value obtained at 451 $\mathrm{W} {\mathrm{m}}^{-3}$. No significant change in the cell size distribution could be measured in the investigated range. It was shown that the cell cluster size distribution follows a strict geometric distribution whose free parameter p is linearly dependent on the mean Kolmogorov length scale. Based on the performed experiments, it has been shown that by using CFD-characterised bioreactors, the VCD${}_{\max }$ can be increased and the cell aggregate rate can be precisely controlled.

Scaling bioprocesses remains a major challenge. Since it is physically impossible to increase all process parameters equally, a suitable scale-up strategy must be selected for a successful bioprocess. One of the most widely used criteria when scaling up bioprocesses is the specific power input. However, this represents only an average value. This study aims to determine the Kolmogorov length scale distribution by means of computational fluid dynamics (CFD) and to use it as an alternative scale-up criterion for geometrically non-similar bioreactors for the first time. In order to obtain a comparable Kolmogorov length scale distribution, an automated geometry and process parameter optimization was carried out using the open-source tools OpenFOAM and DAKOTA. The Kolmogorov–Smirnov test statistic was used for optimization. A HEK293-F cell expansion (batch mode) from benchtop (Infors Minifors 2 with 4 L working volume) to pilot scale (D-DCU from Sartorius with 30 L working volume) was carried out. As a reference cultivation, the classical scale-up approach with constant specific power input (233 W m⁻³) was used, where a maximum viable cell density (VCD${}_{\max }$) of $5.02·{10}^6$ cells mL⁻¹ was achieved (VCD${}_{\max }$ at laboratory scale $5.77·{10}^6$ cells mL⁻¹). Through the automated optimization of the stirrer geometry (three parameters), position and speed, comparable cultivation results were achieved as in the small scale with a maximum VCD of $5.60·{10}^6$ cells mL⁻¹. In addition, even on the pilot scale, cell aggregate size distribution was seen to strictly follow a geometric distribution and can be predicted with the help of CFD with the previously published correlation.