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Xiang S, Zhang J, Yu L, Tian J, Tang W, Tang H, Xu K, Wang X, Cui Y, Ren K, Cao W, Su Y, Zhou W. Developing an ultra-intensified fed-batch cell culture process with greatly improved performance and productivity. Biotechnol Bioeng 2024; 121:696-709. [PMID: 37994547 DOI: 10.1002/bit.28605] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/22/2023] [Revised: 10/31/2023] [Accepted: 11/06/2023] [Indexed: 11/24/2023]
Abstract
Intensified fed-batch (IFB), a popular cell culture intensification strategy, has been widely used for productivity improvement through high density inoculation followed by fed-batch cultivation. However, such an intensification strategy may counterproductively induce rapidly progressing cell apoptosis and difficult-to-sustain productivity. To improve culture performance, we developed a novel cell culture process intermittent-perfusion fed-batch (IPFB) which incorporates one single or multiple cycles of intermittent perfusion during an IFB process for better sustained cellular and metabolic behaviors and notably improved productivity. Unlike continuous perfusion or other semi-continuous processes such as hybrid perfusion fed-batch with only early-stage perfusion, IPFB applies limited times of intermittent perfusion in the mid-to-late stage of production and still inherits bolus feedings on nonperfusion days as in a fed-batch culture. Compared to IFB, an average titer increase of ~45% was obtained in eight recombinant CHO cell lines studied. Beyond IPFB, ultra-intensified IPFB (UI-IPFB) was designed with a markedly elevated seeding density of 20-80 × 106 cell/mL, achieved through the conventional alternating tangential flow filtration (ATF) perfusion expansion followed with a cell culture concentration step using the same ATF system. With UI-IPFB, up to ~6 folds of traditional fed-batch and ~3 folds of IFB productivity were achieved. Furthermore, the application grounded in these two novel processes showed broad-based feasibility in multiple cell lines and products of interest, and was proven to be effective in cost of goods reduction and readily scalable to a larger scale in existing facilities.
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Affiliation(s)
| | | | - Le Yu
- Process Development, WuXi Biologics, Wuxi, China
| | - Jun Tian
- Process Development, WuXi Biologics, Wuxi, China
| | - Wenxiu Tang
- Process Development, WuXi Biologics, Wuxi, China
| | - Hao Tang
- Process Development, WuXi Biologics, Wuxi, China
| | - Kecui Xu
- Process Development, WuXi Biologics, Wuxi, China
| | - Xin Wang
- Process Development, WuXi Biologics, Wuxi, China
| | - Yanyan Cui
- Process Development, WuXi Biologics, Wuxi, China
| | - Kaidi Ren
- Process Development, WuXi Biologics, Wuxi, China
| | - Weijia Cao
- Process Development, WuXi Biologics, Wuxi, China
| | - Yuning Su
- Process Development, WuXi Biologics, Wuxi, China
| | - Weichang Zhou
- Waigaoqiao Free Trade Zone, WuXi Biologics, Shanghai, China
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