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2025, Vol: 15, Issue: 8
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Research Article


Cost-effective suspension adaptation of BHK-21 cells for scalable FMD vaccine production in resource-limited settings

Soad Eid, Sonia A. Rizk, Dalia Ayman, Mahmoud Ali, Mohamed Saad, Ahmed A. El-sanousi, Ausama A. Yousif, Mohamed A. Shalaby.


Abstract
Background:
The foot and mouth disease virus (FMDV) remains a significant threat to livestock health and agricultural economies, particularly in endemic regions such as Egypt. Although suspension cultures of BHK-21 cells are widely used for FMD vaccine production. Suspension cells play a vital role in biomanufacturing, but their high cost often limits their accessibility. This straightforward method offers an efficient and economical solution for obtaining BHK-adapted suspension cells that are ideal for large-scale cultivation in bioreactors.

Aim:
We developed a simplified and cost-effective method for adapting BHK-21 cells to suspension culture using a progressive accelerated rolling system, eliminating the need for microcarriers or complex bioreactor systems. The resulting suspension-adapted cells (BHK-S) were assessed for growth kinetics, sterility, postthaw viability, and their ability to support FMDV replication and 146S antigen production.

Methods:
Conversion of adherent BHK-21 to BHK suspension was performed, followed by investigation of cell counts, cell viability, and cell morphology and growth curve analysis.

Results:
BHK-S cells demonstrated robust growth with >95% viability and a density of 2 × 10⁶ cells/ml. After FMDV infection, suspension cultures yielded significantly higher virus titers (>10⁸ TCID₅₀/mL) compared with adherent cultures (106.8 TCID₅₀/mL; p < 0.001). Furthermore, 146S antigen yield was substantially improved, with suspension cultures producing 4.4 µg/mL compared to 1.5 µg/mL in adherent cells. Scale-up to a 10L bioreactor confirmed the stability of growth parameters and viral productivity.

Conclusion:
This streamlined and scalable approach for adapting BHK-21 cells to suspension culture offers a practical and affordable alternative for FMD vaccine production in resource-limited settings, facilitating the transition from bench-to-bioprocessing scale.

Key words: Foot and mouth disease virus, Baby Hamster kidney cells, Suspension culture, 146S antigen, Bioreactor scalability


 
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How to Cite this Article
Pubmed Style

Eid S, Rizk SA, Ayman D, Ali M, Saad M, El-sanousi AA, Yousif AA, Shalaby MA. Cost-effective suspension adaptation of BHK-21 cells for scalable FMD vaccine production in resource-limited settings. Open Vet. J.. 2025; 15(7): 3193-3205. doi:10.5455/OVJ.2025.v15.i7.30

Web Style

Eid S, Rizk SA, Ayman D, Ali M, Saad M, El-sanousi AA, Yousif AA, Shalaby MA. Cost-effective suspension adaptation of BHK-21 cells for scalable FMD vaccine production in resource-limited settings. https://www.openveterinaryjournal.com/?mno=263811 [Access: September 01, 2025]. doi:10.5455/OVJ.2025.v15.i7.30

AMA (American Medical Association) Style

Eid S, Rizk SA, Ayman D, Ali M, Saad M, El-sanousi AA, Yousif AA, Shalaby MA. Cost-effective suspension adaptation of BHK-21 cells for scalable FMD vaccine production in resource-limited settings. Open Vet. J.. 2025; 15(7): 3193-3205. doi:10.5455/OVJ.2025.v15.i7.30


Vancouver/ICMJE Style

Eid S, Rizk SA, Ayman D, Ali M, Saad M, El-sanousi AA, Yousif AA, Shalaby MA. Cost-effective suspension adaptation of BHK-21 cells for scalable FMD vaccine production in resource-limited settings. Open Vet. J.. (2025), [cited September 01, 2025]; 15(7): 3193-3205. doi:10.5455/OVJ.2025.v15.i7.30


Harvard Style

Eid, S., Rizk, . S. A., Ayman, . D., Ali, . M., Saad, . M., El-sanousi, . A. A., Yousif, . A. A. & Shalaby, . M. A. (2025) Cost-effective suspension adaptation of BHK-21 cells for scalable FMD vaccine production in resource-limited settings. Open Vet. J., 15 (7), 3193-3205. doi:10.5455/OVJ.2025.v15.i7.30


Turabian Style

Eid, Soad, Sonia A. Rizk, Dalia Ayman, Mahmoud Ali, Mohamed Saad, Ahmed A. El-sanousi, Ausama A. Yousif, and Mohamed A. Shalaby. 2025. Cost-effective suspension adaptation of BHK-21 cells for scalable FMD vaccine production in resource-limited settings. Open Veterinary Journal, 15 (7), 3193-3205. doi:10.5455/OVJ.2025.v15.i7.30


Chicago Style

Eid, Soad, Sonia A. Rizk, Dalia Ayman, Mahmoud Ali, Mohamed Saad, Ahmed A. El-sanousi, Ausama A. Yousif, and Mohamed A. Shalaby. "Cost-effective suspension adaptation of BHK-21 cells for scalable FMD vaccine production in resource-limited settings." Open Veterinary Journal 15 (2025), 3193-3205. doi:10.5455/OVJ.2025.v15.i7.30


MLA (The Modern Language Association) Style

Eid, Soad, Sonia A. Rizk, Dalia Ayman, Mahmoud Ali, Mohamed Saad, Ahmed A. El-sanousi, Ausama A. Yousif, and Mohamed A. Shalaby. "Cost-effective suspension adaptation of BHK-21 cells for scalable FMD vaccine production in resource-limited settings." Open Veterinary Journal 15.7 (2025), 3193-3205. Print. doi:10.5455/OVJ.2025.v15.i7.30


APA (American Psychological Association) Style

Eid, S., Rizk, . S. A., Ayman, . D., Ali, . M., Saad, . M., El-sanousi, . A. A., Yousif, . A. A. & Shalaby, . M. A. (2025) Cost-effective suspension adaptation of BHK-21 cells for scalable FMD vaccine production in resource-limited settings. Open Veterinary Journal, 15 (7), 3193-3205. doi:10.5455/OVJ.2025.v15.i7.30


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