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Metzger KFJ, Voloshin A, Schillinger H, Kühnel H, Maurer M. Adsorptive filtration: A case study for early impurity reduction in an Escherichia coli production process. Biotechnol Prog 2019; 36:e2948. [PMID: 31837191 DOI: 10.1002/btpr.2948] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/28/2019] [Revised: 11/22/2019] [Accepted: 12/08/2019] [Indexed: 11/10/2022]
Abstract
Primary recovery of intracellular products from Escherichia coli requires cell disruption which leads to a massive release of process-related impurities burdening subsequent downstream process (DSP) unit operations. Especially, DNA and endotoxins challenge purification operations due to their size and concentrations. Consequently, an early reduction in impurities will not only simplify the production process but also increase robustness while alleviating the workload afterward. In the present work, we studied the proof of concept whether a nonwoven anion exchange filter material decreases soluble impurities immediately at the clarification step of E. coli DSP. In a first attempt, endotoxin burden was reduced by 4.6-fold and the DNA concentration by 3.6-fold compared to conventional depth filtration. A design of experiment for the adsorptive filtration approach was carried out to analyze the influence of different critical process parameters (CPPs) on impurity reduction. We showed that depending on the CPPs chosen, a DNA lowering of more than 3 log values, an endotoxin decrease of approximately 7 logs, and a minor HCP clearance of at least 0.3 logs could be achieved. Thus, we further revealed a chromatography column protecting effect when using adsorptive filtration beforehand.
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Affiliation(s)
- Karl F J Metzger
- Life Sciences, University of Applied Sciences Campus Vienna, Wien, AT, Austria.,Bioprocess Engineering, Austrian Centre of Industrial Biotechnology, Wien, AT, Austria.,Department of Biotechnology, University of Natural Resources and Life Sciences Vienna, Wien, AT, Austria
| | - Alexei Voloshin
- 3M Company, Separation and Purification Sciences Division, 3M Center, Saint Paul, Minnesota
| | - Harald Schillinger
- Life Sciences, University of Applied Sciences Campus Vienna, Wien, AT, Austria.,3M Österreich, 3M Separation and Purification Sciences Division, Wien, AT, Austria
| | - Harald Kühnel
- Life Sciences, University of Applied Sciences Campus Vienna, Wien, AT, Austria
| | - Michael Maurer
- Life Sciences, University of Applied Sciences Campus Vienna, Wien, AT, Austria.,Bioprocess Engineering, Austrian Centre of Industrial Biotechnology, Wien, AT, Austria
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Quality Control and Downstream Processing of Therapeutic Enzymes. ADVANCES IN EXPERIMENTAL MEDICINE AND BIOLOGY 2019; 1148:55-80. [PMID: 31482494 DOI: 10.1007/978-981-13-7709-9_3] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.2] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 05/15/2023]
Abstract
Therapeutic enzymes are a commercially minor but clinically important area of biopharmaceuticals. An array of therapeutic enzymes has been developed for a variety of human diseases, including leukaemia and enzyme-deficiency diseases such as Gaucher's disease. Production and testing of therapeutic enzymes is strictly governed by regulatory bodies in each country around the world, and batch-to-batch consistency is crucially important. Manufacture of a batch starts with the fermentation or cell culture stage. After expression of the therapeutic enzyme in a cell culture bioreactor, robust and reproducible protein purification, or downstream processing (DSP) of the target product, is critical to ensuring safe delivery of these medicines. Modern processing technology, including the use of disposable processing equipment, has greatly improved the DSP development pathway in terms of robustness and speed to clinic. Once purified, the drug substance undergoes rigorous quality control (QC) testing according to current regulatory guidance, to enable release to the clinic and patient. QC testing is conducted to ensure the safety, purity, identity, potency and strength of the medicinal product, requiring multiple analytical methods that are rigorously validated and monitored for robust performance. Several case studies, including L-asparaginase and asfotase alfa, are discussed to illustrate the methods described herein.
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Singh N, Herzer S. Downstream Processing Technologies/Capturing and Final Purification : Opportunities for Innovation, Change, and Improvement. A Review of Downstream Processing Developments in Protein Purification. ADVANCES IN BIOCHEMICAL ENGINEERING/BIOTECHNOLOGY 2019; 165:115-178. [PMID: 28795201 DOI: 10.1007/10_2017_12] [Citation(s) in RCA: 8] [Impact Index Per Article: 1.6] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 12/12/2022]
Abstract
Increased pressure on upstream processes to maximize productivity has been crowned with great success, although at the cost of shifting the bottleneck to purification. As drivers were economical, focus is on now on debottlenecking downstream processes as the main drivers of high manufacturing cost. Devising a holistically efficient and economical process remains a key challenge. Traditional and emerging protein purification strategies with particular emphasis on methodologies implemented for the production of recombinant proteins of biopharmaceutical importance are reviewed. The breadth of innovation is addressed, as well as the challenges the industry faces today, with an eye to remaining impartial, fair, and balanced. In addition, the scope encompasses both chromatographic and non-chromatographic separations directed at the purification of proteins, with a strong emphasis on antibodies. Complete solutions such as integrated USP/DSP strategies (i.e., continuous processing) are discussed as well as gains in data quantity and quality arising from automation and high-throughput screening (HTS). Best practices and advantages through design of experiments (DOE) to access a complex design space such as multi-modal chromatography are reviewed with an outlook on potential future trends. A discussion of single-use technology, its impact and opportunities for further growth, and the exciting developments in modeling and simulation of DSP rounds out the overview. Lastly, emerging trends such as 3D printing and nanotechnology are covered. Graphical Abstract Workflow of high-throughput screening, design of experiments, and high-throughput analytics to understand design space and design space boundaries quickly. (Reproduced with permission from Gregory Barker, Process Development, Bristol-Myers Squibb).
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Affiliation(s)
- Nripen Singh
- Bristol-Myers Squibb, Global Manufacturing and Supply, Devens, MA, 01434, USA.
| | - Sibylle Herzer
- Bristol-Myers Squibb, Global Manufacturing and Supply, Hopewell, NJ, 01434, USA
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4
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Large scale microbial cell disruption using hydrodynamic cavitation: Energy saving options. Biochem Eng J 2019. [DOI: 10.1016/j.bej.2018.12.010] [Citation(s) in RCA: 27] [Impact Index Per Article: 5.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/24/2023]
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Ultra scale-down approaches to enhance the creation of bioprocesses at scale: impacts of process shear stress and early recovery stages. Curr Opin Chem Eng 2016. [DOI: 10.1016/j.coche.2016.09.012] [Citation(s) in RCA: 17] [Impact Index Per Article: 2.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/19/2022]
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6
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Liu D, Ding L, Sun J, Boussetta N, Vorobiev E. Yeast cell disruption strategies for recovery of intracellular bio-active compounds — A review. INNOV FOOD SCI EMERG 2016. [DOI: 10.1016/j.ifset.2016.06.017] [Citation(s) in RCA: 69] [Impact Index Per Article: 8.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/24/2022]
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7
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Boulet-Audet M, Kazarian SG, Byrne B. In-column ATR-FTIR spectroscopy to monitor affinity chromatography purification of monoclonal antibodies. Sci Rep 2016; 6:30526. [PMID: 27470880 PMCID: PMC4965771 DOI: 10.1038/srep30526] [Citation(s) in RCA: 29] [Impact Index Per Article: 3.6] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/31/2016] [Accepted: 07/04/2016] [Indexed: 11/18/2022] Open
Abstract
In recent years many monoclonal antibodies (mAb) have entered the biotherapeutics market, offering new treatments for chronic and life-threatening diseases. Protein A resin captures monoclonal antibody (mAb) effectively, but the binding capacity decays over repeated purification cycles. On an industrial scale, replacing fouled Protein A affinity chromatography resin accounts for a large proportion of the raw material cost. Cleaning-in-place (CIP) procedures were developed to extend Protein A resin lifespan, but chromatograms cannot reliably quantify any remaining contaminants over repeated cycles. To study resin fouling in situ, we coupled affinity chromatography and Fourier transform infrared (FTIR) spectroscopy for the first time, by embedding an attenuated total reflection (ATR) sensor inside a micro-scale column while measuring the UV 280 nm and conductivity. Our approach quantified the in-column protein concentration in the resin bed and determined protein conformation. Our results show that Protein A ligand leached during CIP. We also found that host cell proteins bound to the Protein A resin even more strongly than mAbs and that typical CIP conditions do not remove all fouling contaminants. The insights derived from in-column ATR-FTIR spectroscopic monitoring could contribute to mAb purification quality assurance as well as guide the development of more effective CIP conditions to optimise resin lifespan.
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Affiliation(s)
- Maxime Boulet-Audet
- Department of Chemical Engineering, Imperial College London, South Kensington Campus, London, SW7 2AZ, UK.,Department of Life Sciences, Imperial College London, South Kensington Campus, London, SW7 2AZ, UK
| | - Sergei G Kazarian
- Department of Chemical Engineering, Imperial College London, South Kensington Campus, London, SW7 2AZ, UK
| | - Bernadette Byrne
- Department of Life Sciences, Imperial College London, South Kensington Campus, London, SW7 2AZ, UK
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Felo M, Christensen B, Higgins J. Process cost and facility considerations in the selection of primary cell culture clarification technology. Biotechnol Prog 2013; 29:1239-45. [DOI: 10.1002/btpr.1776] [Citation(s) in RCA: 17] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/07/2013] [Revised: 04/21/2013] [Indexed: 11/10/2022]
Affiliation(s)
- Michael Felo
- Biomanufacturing Sciences Network, EMD Millipore Corp.900 Middlesex TurnpikeBillerica MA01821
| | | | - John Higgins
- Process Development, Novavax9920 Belward Campus DriveRockville MD20850
- Previously employed with MedImmune
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Close EJ, Salm JR, Iskra T, Sørensen E, Bracewell DG. Fouling of an anion exchange chromatography operation in a monoclonal antibody process: Visualization and kinetic studies. Biotechnol Bioeng 2013; 110:2425-35. [PMID: 23483524 PMCID: PMC3840701 DOI: 10.1002/bit.24898] [Citation(s) in RCA: 18] [Impact Index Per Article: 1.6] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/21/2012] [Revised: 02/19/2013] [Accepted: 02/25/2013] [Indexed: 11/10/2022]
Abstract
Fouling of chromatographic resins over their operational lifetimes can be a significant problem for commercial bioseparations. In this article, scanning electron microscopy (SEM), batch uptake experiments, confocal laser scanning microscopy (CLSM) and small-scale column studies were applied to characterize a case study where fouling had been observed during process development. The fouling was found to occur on an anion exchange (AEX) polishing step following a protein A affinity capture step in a process for the purification of a monoclonal antibody. Fouled resin samples analyzed by SEM and batch uptake experiments indicated that after successive batch cycles, significant blockage of the pores at the resin surface occurred, thereby decreasing the protein uptake rate. Further studies were performed using CLSM to allow temporal and spatial measurements of protein adsorption within the resin, for clean, partially fouled and extensively fouled resin samples. These samples were packed within a miniaturized flowcell and challenged with fluorescently labeled albumin that enabled in situ measurements. The results indicated that the foulant has a significant impact on the kinetics of adsorption, severely decreasing the protein uptake rate, but only results in a minimal decrease in saturation capacity. The impact of the foulant on the kinetics of adsorption was further investigated by loading BSA onto fouled resin over an extended range of flow rates. By decreasing the flow rate during BSA loading, the capacity of the resin was recovered. These data support the hypothesis that the foulant is located on the particle surface, only penetrating the particle to a limited degree. The increased understanding into the nature of the fouling can help in the continued process development of this industrial example. Scanning electron microscopy (SEM), batch uptake experiments, confocal laser scanning microscopy (CLSM) and small-scale column experiments were applied to characterize a case study where fouling had been observed on an anion exchange chromatography in a monoclonal antibody process. The results suggest the foulant is located on the particle surface, resulting in a minimal decrease in saturation capacity, but having a significant impact on the kinetics of adsorption, severely decreasing protein uptake rate.
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Affiliation(s)
- Edward J Close
- The Advanced Centre for Biochemical Engineering, Department of Biochemical Engineering, University College London, Torrington Place, London, UK
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Burden CS, Jin J, Podgornik A, Bracewell DG. A monolith purification process for virus-like particles from yeast homogenate. J Chromatogr B Analyt Technol Biomed Life Sci 2011; 880:82-9. [PMID: 22134039 DOI: 10.1016/j.jchromb.2011.10.044] [Citation(s) in RCA: 44] [Impact Index Per Article: 3.4] [Reference Citation Analysis] [Abstract] [MESH Headings] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/03/2011] [Revised: 10/20/2011] [Accepted: 10/22/2011] [Indexed: 11/19/2022]
Abstract
Monoliths are an alternative stationary phase format to conventional particle based media for large biomolecules. Conventional resins suffer from limited capacities and flow rates when used for viruses, virus-like particles (VLP) and other nanoplex materials. The monolith structure provides a more open pore structure to improve accessibility for these materials and better mass transport from convective flow and reduced pressure drops. To examine the performance of this format for bioprocessing we selected the challenging capture of a VLP from clarified yeast homogenate. Using a recombinant Saccharomyces cerevisiae host it was found hydrophobic interaction based separation using a hydroxyl derivatised monolith had the best performance. The monolith was then compared to a known beaded resin method, where the dynamic binding capacity was shown to be three-fold superior for the monolith with equivalent 90% recovery of the VLP. To understand the impact of the crude feed material confocal microscopy was used to visualise lipid contaminants, deriving from the homogenised yeast. It was seen that the lipid formed a layer on top of the column, even after regeneration of the column with isopropanol, resulting in increasing pressure drops with the number of operational cycles. Removal of the lipid pre-column significantly reduces the amount and rate of this fouling process. Using Amberlite/XAD-4 beads around 70% of the lipid was removed, with a loss of VLP around 20%. Applying a reduced lipid feed versus an untreated feed further increased the dynamic binding capacity of the monolith from 0.11 mg/mL column to 0.25 mg/mL column.
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Affiliation(s)
- Claire S Burden
- The Advanced Centre for Biochemical Engineering, Department of Biochemical Engineering, University College London, London, UK
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Boushaba R, Baldascini H, Gerontas S, Titchener-Hooker NJ, Bracewell DG. Demonstration of the use of windows of operation to visualize the effects of fouling on the performance of a chromatographic step. Biotechnol Prog 2011; 27:1009-17. [DOI: 10.1002/btpr.617] [Citation(s) in RCA: 8] [Impact Index Per Article: 0.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/28/2010] [Revised: 03/22/2011] [Indexed: 11/06/2022]
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Balasundaram B, Nesbeth D, Ward JM, Keshavarz-Moore E, Bracewell DG. Step change in the efficiency of centrifugation through cell engineering: co-expression of Staphylococcal nuclease to reduce the viscosity of the bioprocess feedstock. Biotechnol Bioeng 2009; 104:134-42. [PMID: 19415775 DOI: 10.1002/bit.22369] [Citation(s) in RCA: 27] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/06/2022]
Abstract
Cell engineering to enable step change improvements in bioprocessing can be directed at targets other than increasing product titer. The physical properties of the process suspension such as viscosity, for example, have a major impact on various downstream processing unit operations. The release of chromosomal DNA during homogenization of Escherichia coli and its influence on viscosity is well-recognized. In this current article we demonstrate co-expression of Staphylococcus aureus nuclease in E. coli to reduce viscosity through auto-hydrolysis of nucleic acids. Viscosity reduction of up to 75% was achieved while the particle size distribution of cell debris was maintained approximately constant (d(50) = 0.5-0.6 microm). Critically, resultant step change improvements to the clarification performance under disc-stack centrifugation conditions are shown. The cell-engineered nuclease matched or exceeded the viscosity reduction performance seen with the addition of exogenous nuclease removing the expense and validation issues associated with such additions to a bioprocess. The resultant material dramatically altered performance in scale-down mimics of continuous disc-stack centrifugation. Laboratory scale data indicated that a fourfold reduction in the settling area of a disc-stack centrifuge can be expected due to a less viscous process stream achieved through nuclease co-expression with a recombinant protein.
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Affiliation(s)
- B Balasundaram
- Department of Biochemical Engineering, The Advanced Centre for Biochemical Engineering, University College London, London, UK
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Advances in product release strategies and impact on bioprocess design. Trends Biotechnol 2009; 27:477-85. [DOI: 10.1016/j.tibtech.2009.04.004] [Citation(s) in RCA: 115] [Impact Index Per Article: 7.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/05/2009] [Revised: 04/20/2009] [Accepted: 04/22/2009] [Indexed: 11/21/2022]
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Wohlgemuth R. The locks and keys to industrial biotechnology. N Biotechnol 2009; 25:204-13. [PMID: 19429540 DOI: 10.1016/j.nbt.2009.01.002] [Citation(s) in RCA: 46] [Impact Index Per Article: 3.1] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/04/2008] [Revised: 01/07/2009] [Accepted: 01/08/2009] [Indexed: 11/27/2022]
Abstract
The sustainable use of resources by Nature to synthesize the required products at the right place, when they are needed, continues to be the role model for total synthesis and production in general. The combination of molecular and engineering science and technology in the biotechnological approach needs no protecting groups at all and has therefore been established for numerous large-scale routes to both natural and synthetic products in industry. The use of biobased raw materials for chemical synthesis, and the economy of molecular transformations like atom economy and step economy are of growing importance. As safety, health and environmental issues are key drivers for process improvements in the chemical industry, the development of biocatalytic reactions or pathways replacing hazardous reagents is a major focus. The integration of the biocatalytic reaction and downstream processing with product isolation has led to a variety of in situ product recovery techniques and has found numerous successful applications. With the growing collection of biocatalytic reactions, the retrosynthetic thinking can be applied to biocatalysis as well. The introduction of biocatalytic reactions is uniquely suited to cost reductions and higher quality products, as well as to more sustainable processes. The transfer of Nature's simple and robust sensing and control principles as well as its reaction and separation organization into useful technical systems can be applied to different fermentations, biotransformations and downstream processes. Biocatalyst and pathway discovery and development is the key towards new synthetic transformations in industrial biotechnology.
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Affiliation(s)
- Roland Wohlgemuth
- Sigma-Aldrich, Research Specialities, Industriestrasse 25, 9470 Buchs, Switzerland.
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