1
|
Ninga KA, Desobgo SCZ, Nso EJ, Kayem J. White-flesh guava juice clarification by a fixed-angle conical rotor centrifuge laboratory and characterization of continuous disk stack centrifuges. Heliyon 2022; 8:e11606. [DOI: 10.1016/j.heliyon.2022.e11606] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/12/2022] [Revised: 10/01/2022] [Accepted: 11/09/2022] [Indexed: 11/17/2022] Open
|
2
|
Malik S, Hagopian J, Mohite S, Lintong C, Stoffels L, Giannakopoulos S, Beckett R, Leung C, Ruiz J, Cruz M, Parker B. Robotic Extrusion of Algae-Laden Hydrogels for Large-Scale Applications. GLOBAL CHALLENGES (HOBOKEN, NJ) 2020; 4:1900064. [PMID: 31956429 PMCID: PMC6957016 DOI: 10.1002/gch2.201900064] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 07/23/2019] [Revised: 10/07/2019] [Indexed: 05/14/2023]
Abstract
A bioprinting technique for large-scale, custom-printed immobilization of microalgae is developed for potential applications within architecture and the built environment. Alginate-based hydrogels with various rheology modifying polymers and varying water percentages are characterized to establish a window of operation suitable for layer-by-layer deposition on a large scale. Hydrogels formulated with methylcellulose and carrageenan, with water percentages ranging from 80% to 92.5%, demonstrate a dominant viscoelastic solid-like property with G' > G″ and a low phase angle, making them the most suitable for extrusion-based printing. A custom multimaterial pneumatic extrusion system is developed to be attached on the end effector of an industrial multiaxis robot arm, allowing precision-based numerically controlled layered deposition of the viscous hydrogel. The relationship between the various printing parameters, namely air pressure, material viscosity, viscoelasticity, feed rate, printing distance, nozzle diameter, and the speed of printing, are characterized to achieve the desired resolution of the component. Printed prototypes are postcured in CaCl2 via crosslinking. Biocompatibility tests show that cells can survive for 21 days after printing the constructs. To demonstrate the methodology for scale-up, a 1000 × 500 mm fibrous hydrogel panel is additively deposited with 3 different hydrogels with varying water percentages.
Collapse
Affiliation(s)
- Shneel Malik
- Bartlett School of ArchitectureUniversity College LondonLondonWC1E 6BTUK
| | - Julie Hagopian
- Bartlett School of ArchitectureUniversity College LondonLondonWC1E 6BTUK
| | - Sanika Mohite
- Bartlett School of ArchitectureUniversity College LondonLondonWC1E 6BTUK
| | - Cao Lintong
- Department of Biochemical EngineeringBernard Katz BuildingUniversity College LondonLondonWC1H 0AHUK
| | - Laura Stoffels
- Institute of Structural and Molecular BiologyUniversity College LondonLondonWC1E 6BTUK
| | | | - Richard Beckett
- Bartlett School of ArchitectureUniversity College LondonLondonWC1E 6BTUK
| | - Christopher Leung
- Bartlett School of ArchitectureUniversity College LondonLondonWC1E 6BTUK
| | - Javier Ruiz
- Bartlett School of ArchitectureUniversity College LondonLondonWC1E 6BTUK
| | - Marcos Cruz
- Bartlett School of ArchitectureUniversity College LondonLondonWC1E 6BTUK
| | - Brenda Parker
- Department of Biochemical EngineeringBernard Katz BuildingUniversity College LondonLondonWC1H 0AHUK
| |
Collapse
|
3
|
Stoffels L, Finlan A, Mannall G, Purton S, Parker B. Downstream Processing of Chlamydomonas reinhardtii TN72 for Recombinant Protein Recovery. Front Bioeng Biotechnol 2019; 7:383. [PMID: 31867315 PMCID: PMC6908742 DOI: 10.3389/fbioe.2019.00383] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.2] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/20/2019] [Accepted: 11/18/2019] [Indexed: 12/14/2022] Open
Abstract
The green microalga Chlamydomonas reinhardtii is under development as a production host for recombinant proteins and whole-cell therapeutics. In particular, the cell wall-reduced strain TN72 is used as a model organism for protein expression and algal synthetic biology. However, the bioprocessing characteristics of TN72 and other C. reinhardtii strains have yet to be examined. Here we use a TN72 strain expressing a protein-based antibiotic (Pal) to study the scale-up of cell harvest and product recovery. Cell harvest was examined with 100L cultures in two intermittent-discharge continuous-flow disc-stack centrifuges at flow rates of 150–250 L.h−1, as well as with an ultra scale-down (USD) mimic of the centrifuges. Solids recovery exceeded 99.5% and the loss of product to the supernatant was below 2–3%. TN72 is intact following the high shear conditions of the feed zone, however discharge from both disc-stack centrifuges resulted in full cell breakage and in the case of Pal, partial degradation in the subsequent hours. We demonstrated that shake flask cultivation and the USD centrifuge technique can be used to predict the pilot-scale clarification efficiency and product release at the centrifuge inlet for TN72, but not the cell breakage on discharge. This study outlines a number of challenges for scale-up of recombinant protein production in the microalgal host in particular for whole cell therapeutics, but also opportunities for the bioprocessing of intracellular products from TN72.
Collapse
Affiliation(s)
- Laura Stoffels
- Department of Biochemical Engineering, Bernard Katz Building, University College London, London, United Kingdom.,Algal Research Group, Institute of Structural and Molecular Biology, University College London, London, United Kingdom
| | - Arran Finlan
- Department of Biochemical Engineering, Bernard Katz Building, University College London, London, United Kingdom
| | - Gareth Mannall
- Department of Biochemical Engineering, Bernard Katz Building, University College London, London, United Kingdom
| | - Saul Purton
- Algal Research Group, Institute of Structural and Molecular Biology, University College London, London, United Kingdom
| | - Brenda Parker
- Department of Biochemical Engineering, Bernard Katz Building, University College London, London, United Kingdom
| |
Collapse
|
4
|
Wang B, Nesbeth D, Keshavarz-Moore E. Sorbitol/methanol mixed induction reduces process impurities and improves centrifugal dewatering in Pichia pastoris culture. Enzyme Microb Technol 2019; 130:109366. [PMID: 31421726 DOI: 10.1016/j.enzmictec.2019.109366] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.2] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/03/2019] [Revised: 06/18/2019] [Accepted: 06/19/2019] [Indexed: 11/25/2022]
Abstract
This study investigates how sorbitol/methanol mixed induction affects fermentation performance, dewatering characteristics of cells during harvesting and the profile of host cell proteins (HCP) in the process fluid when producing the target recombinant protein aprotinin. Compared to standard methanol induction, sorbitol/methanol (1:1, C-mol/C-mol) mixed induction improved cellular viability from 92.8 ± 0.3% to 97.7 ± 0.1% although resulted in a reduced product yield from 1.65 ± 0.03 g L-1 to 1.12 ± 0.07 g L-1. On the other hand, average oxygen consumption rate (OUR) dropped from 241.4 ± 21.3 mmol L-1 h-1 to 145.5 ± 6.7 mmol L-1 h-1. Cell diameter decreased over time in the mixed induction, resulting in a D50 value of 3.14 μm at harvest compared to 3.85 μm with methanol. The reduction in cell size enhanced the maximum dewatering efficiency from 78.1 ± 3.9% to 84.5 ± 3.3% as evaluated by using an established ultra scale-down methodology that models pilot and industrial scale disc stack centrifugation. Seventy host cell proteins (HCPs) were identified in clarified supernatant when using sorbitol/methanol mixed induction regimen. The total number of HCPs identified with standard methanol induction was nearly one hundred. The downstream process advantage of the mixed induction lies in improved product purity by reducing both cell mortality and level of released whole cell proteins. This needs to be balanced and optimised against the observed reduction in product yield during fermentation.
Collapse
Affiliation(s)
- Baolong Wang
- The Advanced Centre for Biochemical Engineering, Department of Biochemical Engineering, University College London, Gower Street, Bernard Katz Building, London, WC1E 6BT, UK
| | - Darren Nesbeth
- The Advanced Centre for Biochemical Engineering, Department of Biochemical Engineering, University College London, Gower Street, Bernard Katz Building, London, WC1E 6BT, UK
| | - Eli Keshavarz-Moore
- The Advanced Centre for Biochemical Engineering, Department of Biochemical Engineering, University College London, Gower Street, Bernard Katz Building, London, WC1E 6BT, UK.
| |
Collapse
|
5
|
Turner R, Joseph A, Titchener-Hooker N, Bender J. Manufacturing of Proteins and Antibodies: Chapter Downstream Processing Technologies. ADVANCES IN BIOCHEMICAL ENGINEERING/BIOTECHNOLOGY 2019; 165:95-114. [PMID: 28776064 DOI: 10.1007/10_2016_54] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/18/2023]
Abstract
Cell harvesting is the separation or retention of cells and cellular debris from the supernatant containing the target molecule Selection of harvest method strongly depends on the type of cells, mode of bioreactor operation, process scale, and characteristics of the product and cell culture fluid. Most traditional harvesting methods use some form of filtration, centrifugation, or a combination of both for cell separation and/or retention. Filtration methods include normal flow depth filtration and tangential flow microfiltration. The ability to scale down predictably the selected harvest method helps to ensure successful production and is critical for conducting small-scale characterization studies for confirming parameter targets and ranges. In this chapter we describe centrifugation and depth filtration harvesting methods, share strategies for harvest optimization, present recent developments in centrifugation scale-down models, and review alternative harvesting technologies.
Collapse
Affiliation(s)
- Richard Turner
- MedImmune LLC Gaithersburg Headquarters, One MedImmune Way, Gaithersburg, MD, 20878, USA
| | - Adrian Joseph
- The Advanced Centre of Biochemical Engineering, Department of Biochemical Engineering, University College London, Bernard Katz Building, London, WC1E 6BT, UK
| | - Nigel Titchener-Hooker
- The Advanced Centre of Biochemical Engineering, Department of Biochemical Engineering, University College London, Bernard Katz Building, London, WC1E 6BT, UK
| | - Jean Bender
- MedImmune LLC Gaithersburg Headquarters, One MedImmune Way, Gaithersburg, MD, 20878, USA.
| |
Collapse
|
6
|
Törnblom O. Turbulent Shear and Breakup of Flocculated Biomaterial in Centrifuge Inlets. Chem Eng Technol 2018; 41:2366-2374. [PMID: 31007403 PMCID: PMC6472584 DOI: 10.1002/ceat.201800297] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/08/2018] [Revised: 08/30/2018] [Accepted: 09/07/2018] [Indexed: 11/24/2022]
Abstract
Analyses and simulations of a lab-scale device for determining floc strength are presented together with simulations of two different hermetic disc-stack centrifuge inlets. Two methods for determining the turbulent shear stresses on flocs in hermetic centrifuge inlets are described. A model for the average shear rate in a hermetic centrifuge inlet is proposed. A correlation for estimating the floc size of the centrifuge feed after passing the high-shear zone of the inlet is derived.
Collapse
Affiliation(s)
- Olle Törnblom
- Alfa Laval Tumba ABHans Stahles väg 7147 80TumbaSweden
| |
Collapse
|
7
|
Melinek BJ, Dessoy S, Wright B, Bracewell DG, Mukhopadhyay TK. Ultra scale-down approaches to study the centrifugal harvest for viral vaccine production. Biotechnol Bioeng 2018; 115:1226-1238. [PMID: 29315484 DOI: 10.1002/bit.26546] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.2] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/15/2017] [Accepted: 01/03/2018] [Indexed: 02/06/2023]
Abstract
Large scale continuous cell-line cultures promise greater reproducibility and efficacy for the production of influenza vaccines, and adenovirus for gene therapy. This paper seeks to use an existing validated ultra scale-down tool, which is designed to mimic the commercial scale process environment using only milliliters of material, to provide some initial insight into the performance of the harvest step for these processes. The performance of industrial scale centrifugation and subsequent downstream process units is significantly affected by shear. The properties of these cells, in particular their shear sensitivity, may be changed considerably by production of a viral product, but literature on this is limited to date. In addition, the scale-down tool used here has not previously been applied to the clarification of virus production processes. The results indicate that virus infected cells do not actually show any increase in sensitivity to shear, and may indeed become less shear sensitive, in a similar manner to that previously observed in old or dead cell cultures. Clarification may be most significantly dependent on the virus release mechanism, with the budding influenza virus producing a much greater decrease in clarification than the lytic, non-enveloped adenovirus. A good match was also demonstrated to the industrial scale performance in terms of clarification, protein release, and impurity profile.
Collapse
Affiliation(s)
- Beatrice J Melinek
- Department of Biochemical Engineering, Bernard Katz building, University College London, London, UK
| | | | - Bernice Wright
- Department of Biochemical Engineering, Bernard Katz building, University College London, London, UK
| | - Dan G Bracewell
- Department of Biochemical Engineering, Bernard Katz building, University College London, London, UK
| | - Tarit K Mukhopadhyay
- Department of Biochemical Engineering, Bernard Katz building, University College London, London, UK
| |
Collapse
|
8
|
Molina-Miras A, Sánchez-Mirón A, García-Camacho F, Molina-Grima E. CFD-aided optimization of a laboratory-scale centrifugation for a shear-sensitive insect cell line. FOOD AND BIOPRODUCTS PROCESSING 2018. [DOI: 10.1016/j.fbp.2017.11.005] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 02/05/2023]
|
9
|
Husson G, Delangle A, O’Hara J, Cianferani S, Gervais A, Van Dorsselaer A, Bracewell D, Carapito C. Dual Data-Independent Acquisition Approach Combining Global HCP Profiling and Absolute Quantification of Key Impurities during Bioprocess Development. Anal Chem 2017; 90:1241-1247. [DOI: 10.1021/acs.analchem.7b03965] [Citation(s) in RCA: 15] [Impact Index Per Article: 2.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
Affiliation(s)
- Gauthier Husson
- Laboratoire
de Spectrométrie de Masse BioOrganique, Université de Strasbourg, CNRS,
IPHC, UMR 7178, F-67000 Strasbourg, France
| | - Aurélie Delangle
- Department
of Analytical Sciences Biologicals, UCB Pharma s.a., Chemin du
Foriest, B-1420 Braine L’alleud, Belgium
| | - John O’Hara
- Department
of Analytical Sciences Biologicals, UCB Pharma s.a., 216 Bath
Road, Slough SL1 4EN, U.K
| | - Sarah Cianferani
- Laboratoire
de Spectrométrie de Masse BioOrganique, Université de Strasbourg, CNRS,
IPHC, UMR 7178, F-67000 Strasbourg, France
| | - Annick Gervais
- Department
of Analytical Sciences Biologicals, UCB Pharma s.a., Chemin du
Foriest, B-1420 Braine L’alleud, Belgium
| | - Alain Van Dorsselaer
- Laboratoire
de Spectrométrie de Masse BioOrganique, Université de Strasbourg, CNRS,
IPHC, UMR 7178, F-67000 Strasbourg, France
| | - Dan Bracewell
- Dept.
Biochemical Engineering, University College London, Gower Street, London WC1E 6BT, U.K
| | - Christine Carapito
- Laboratoire
de Spectrométrie de Masse BioOrganique, Université de Strasbourg, CNRS,
IPHC, UMR 7178, F-67000 Strasbourg, France
| |
Collapse
|
10
|
Velez-Suberbie ML, Betts JPJ, Walker KL, Robinson C, Zoro B, Keshavarz-Moore E. High throughput automated microbial bioreactor system used for clone selection and rapid scale-down process optimization. Biotechnol Prog 2017; 34:58-68. [PMID: 28748655 PMCID: PMC5836883 DOI: 10.1002/btpr.2534] [Citation(s) in RCA: 27] [Impact Index Per Article: 3.9] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/11/2017] [Revised: 06/29/2017] [Indexed: 11/16/2022]
Abstract
High throughput automated fermentation systems have become a useful tool in early bioprocess development. In this study, we investigated a 24 x 15 mL single use microbioreactor system, ambr 15f, designed for microbial culture. We compared the fed‐batch growth and production capabilities of this system for two Escherichia coli strains, BL21 (DE3) and MC4100, and two industrially relevant molecules, hGH and scFv. In addition, different carbon sources were tested using bolus, linear or exponential feeding strategies, showing the capacity of the ambr 15f system to handle automated feeding. We used power per unit volume (P/V) as a scale criterion to compare the ambr 15f with 1 L stirred bioreactors which were previously scaled‐up to 20 L with a different biological system, thus showing a potential 1,300 fold scale comparability in terms of both growth and product yield. By exposing the cells grown in the ambr 15f system to a level of shear expected in an industrial centrifuge, we determined that the cells are as robust as those from a bench scale bioreactor. These results provide evidence that the ambr 15f system is an efficient high throughput microbial system that can be used for strain and molecule selection as well as rapid scale‐up. © 2017 The Authors Biotechnology Progress published by Wiley Periodicals, Inc. on behalf of American Institute of Chemical Engineers Biotechnol. Prog., 34:58–68, 2018
Collapse
Affiliation(s)
- M Lourdes Velez-Suberbie
- The Advanced Centre for Biochemical Engineering, Department of Biochemical Engineering, University College London, Gower Street, Bernard Katz Building, London, WC1E 6BT, U.K
| | - John P J Betts
- Sartorius Stedim Biotech, York Way, Royston, Herts, SG8 5WY, U.K
| | - Kelly L Walker
- Centre for Molecular Processing, School of Biosciences, University of Kent, Canterbury, CT2 7NJ, U.K
| | - Colin Robinson
- Centre for Molecular Processing, School of Biosciences, University of Kent, Canterbury, CT2 7NJ, U.K
| | - Barney Zoro
- Sartorius Stedim Biotech, York Way, Royston, Herts, SG8 5WY, U.K
| | - Eli Keshavarz-Moore
- The Advanced Centre for Biochemical Engineering, Department of Biochemical Engineering, University College London, Gower Street, Bernard Katz Building, London, WC1E 6BT, U.K
| |
Collapse
|
11
|
Gąciarz A, Khatri NK, Velez-Suberbie ML, Saaranen MJ, Uchida Y, Keshavarz-Moore E, Ruddock LW. Efficient soluble expression of disulfide bonded proteins in the cytoplasm of Escherichia coli in fed-batch fermentations on chemically defined minimal media. Microb Cell Fact 2017; 16:108. [PMID: 28619018 PMCID: PMC5471842 DOI: 10.1186/s12934-017-0721-x] [Citation(s) in RCA: 46] [Impact Index Per Article: 6.6] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/12/2017] [Accepted: 06/06/2017] [Indexed: 02/07/2023] Open
Abstract
BACKGROUND The production of recombinant proteins containing disulfide bonds in Escherichia coli is challenging. In most cases the protein of interest needs to be either targeted to the oxidizing periplasm or expressed in the cytoplasm in the form of inclusion bodies, then solubilized and re-folded in vitro. Both of these approaches have limitations. Previously we showed that soluble expression of disulfide bonded proteins in the cytoplasm of E. coli is possible at shake flask scale with a system, known as CyDisCo, which is based on co-expression of a protein of interest along with a sulfhydryl oxidase and a disulfide bond isomerase. With CyDisCo it is possible to produce disulfide bonded proteins in the presence of intact reducing pathways in the cytoplasm. RESULTS Here we scaled up production of four disulfide bonded proteins to stirred tank bioreactors and achieved high cell densities and protein yields in glucose fed-batch fermentations, using an E. coli strain (BW25113) with the cytoplasmic reducing pathways intact. Even without process optimization production of purified human single chain IgA1 antibody fragment reached 139 mg/L and hen avidin 71 mg/L, while purified yields of human growth hormone 1 and interleukin 6 were around 1 g/L. Preliminary results show that human growth hormone 1 was also efficiently produced in fermentations of W3110 strain and when glucose was replaced with glycerol as the carbon source. CONCLUSIONS Our results show for the first time that efficient production of high yields of soluble disulfide bonded proteins in the cytoplasm of E. coli with the reducing pathways intact is feasible to scale-up to bioreactor cultivations on chemically defined minimal media.
Collapse
Affiliation(s)
- Anna Gąciarz
- Faculty of Biochemistry and Molecular Medicine, University of Oulu, P.O. Box 5400, 90014 Oulu, Finland
| | - Narendar Kumar Khatri
- The Department of Process and Environment Engineering, University of Oulu, P.O. Box 8000, 90014 Oulu, Finland
| | - M. Lourdes Velez-Suberbie
- The Advanced Center for Biochemical Engineering, Department of Biochemical Engineering, University College London, Bernard Katz Building, Gower Street, London, WC1E 6BT UK
| | - Mirva J. Saaranen
- Faculty of Biochemistry and Molecular Medicine, University of Oulu, P.O. Box 5400, 90014 Oulu, Finland
| | - Yuko Uchida
- Faculty of Biochemistry and Molecular Medicine, University of Oulu, P.O. Box 5400, 90014 Oulu, Finland
| | - Eli Keshavarz-Moore
- The Advanced Center for Biochemical Engineering, Department of Biochemical Engineering, University College London, Bernard Katz Building, Gower Street, London, WC1E 6BT UK
| | - Lloyd W. Ruddock
- Faculty of Biochemistry and Molecular Medicine, University of Oulu, P.O. Box 5400, 90014 Oulu, Finland
| |
Collapse
|
12
|
Joseph A, Goldrick S, Mollet M, Turner R, Bender J, Gruber D, Farid SS, Titchener-Hooker N. An automated laboratory-scale methodology for the generation of sheared mammalian cell culture samples. Biotechnol J 2017; 12. [DOI: 10.1002/biot.201600730] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/17/2016] [Revised: 02/12/2017] [Accepted: 02/12/2017] [Indexed: 11/09/2022]
Affiliation(s)
- Adrian Joseph
- The Advanced Centre of Biochemical Engineering; Department of Biochemical Engineering; University College London; London UK
| | - Stephen Goldrick
- The Advanced Centre of Biochemical Engineering; Department of Biochemical Engineering; University College London; London UK
| | - Michael Mollet
- MedImmune; Gaithersburg Headquarters; Gaithersburg MD USA
| | | | - Jean Bender
- MedImmune; Gaithersburg Headquarters; Gaithersburg MD USA
| | - David Gruber
- MedImmune; Milstein Building, Granta Park; Cambridge UK
| | - Suzanne S. Farid
- The Advanced Centre of Biochemical Engineering; Department of Biochemical Engineering; University College London; London UK
| | - Nigel Titchener-Hooker
- The Advanced Centre of Biochemical Engineering; Department of Biochemical Engineering; University College London; London UK
| |
Collapse
|
13
|
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]
|
14
|
Konrath M, Gorenflo J, Hübner N, Nirschl H. Application of magnetic bearing technology in high-speed centrifugation. Chem Eng Sci 2016. [DOI: 10.1016/j.ces.2016.03.025] [Citation(s) in RCA: 16] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/22/2022]
|
15
|
Popova D, Stonier A, Pain D, Titchener-Hooker NJ, Farid SS. Integrated economic and experimental framework for screening of primary recovery technologies for high cell density CHO cultures. Biotechnol J 2016; 11:899-909. [PMID: 27067803 PMCID: PMC4999028 DOI: 10.1002/biot.201500336] [Citation(s) in RCA: 8] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/01/2015] [Revised: 11/30/2015] [Accepted: 04/06/2016] [Indexed: 12/20/2022]
Abstract
Increases in mammalian cell culture titres and densities have placed significant demands on primary recovery operation performance. This article presents a methodology which aims to screen rapidly and evaluate primary recovery technologies for their scope for technically feasible and cost‐effective operation in the context of high cell density mammalian cell cultures. It was applied to assess the performance of current (centrifugation and depth filtration options) and alternative (tangential flow filtration (TFF)) primary recovery strategies. Cell culture test materials (CCTM) were generated to simulate the most demanding cell culture conditions selected as a screening challenge for the technologies. The performance of these technology options was assessed using lab scale and ultra scale‐down (USD) mimics requiring 25–110mL volumes for centrifugation and depth filtration and TFF screening experiments respectively. A centrifugation and depth filtration combination as well as both of the alternative technologies met the performance selection criteria. A detailed process economics evaluation was carried out at three scales of manufacturing (2,000L, 10,000L, 20,000L), where alternative primary recovery options were shown to potentially provide a more cost‐effective primary recovery process in the future. This assessment process and the study results can aid technology selection to identify the most effective option for a specific scenario.
Collapse
Affiliation(s)
- Daria Popova
- Department of Biochemical Engineering, University College London, London, UK
| | | | - David Pain
- Lonza Biologics plc, Slough, Berkshire, UK
| | | | - Suzanne S Farid
- Department of Biochemical Engineering, University College London, London, UK.
| |
Collapse
|
16
|
Joseph A, Kenty B, Mollet M, Hwang K, Rose S, Goldrick S, Bender J, Farid SS, Titchener-Hooker N. A scale-down mimic for mapping the process performance of centrifugation, depth and sterile filtration. Biotechnol Bioeng 2016; 113:1934-41. [PMID: 26927621 PMCID: PMC4999036 DOI: 10.1002/bit.25967] [Citation(s) in RCA: 13] [Impact Index Per Article: 1.6] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/20/2015] [Revised: 02/19/2016] [Accepted: 02/24/2016] [Indexed: 11/28/2022]
Abstract
In the production of biopharmaceuticals disk‐stack centrifugation is widely used as a harvest step for the removal of cells and cellular debris. Depth filters followed by sterile filters are often then employed to remove residual solids remaining in the centrate. Process development of centrifugation is usually conducted at pilot‐scale so as to mimic the commercial scale equipment but this method requires large quantities of cell culture and significant levels of effort for successful characterization. A scale‐down approach based upon the use of a shear device and a bench‐top centrifuge has been extended in this work towards a preparative methodology that successfully predicts the performance of the continuous centrifuge and polishing filters. The use of this methodology allows the effects of cell culture conditions and large‐scale centrifugal process parameters on subsequent filtration performance to be assessed at an early stage of process development where material availability is limited. Biotechnol. Bioeng. 2016;113: 1934–1941. © 2016 The Authors. Biotechnology and Bioengineering Published by Wiley Periodicals, Inc.
Collapse
Affiliation(s)
- Adrian Joseph
- The Advanced Centre of Biochemical Engineering, Department of Biochemical Engineering, University College London, Bernard Katz Building, London, WC1E 6BT, United Kingdom
| | - Brian Kenty
- MedImmune LLC Gaithersburg Headquarters, One MedImmune Way, Gaithersburg, Maryland
| | - Michael Mollet
- MedImmune LLC Gaithersburg Headquarters, One MedImmune Way, Gaithersburg, Maryland
| | - Kenneth Hwang
- MedImmune LLC Gaithersburg Headquarters, One MedImmune Way, Gaithersburg, Maryland
| | - Steven Rose
- MedImmune LLC Gaithersburg Headquarters, One MedImmune Way, Gaithersburg, Maryland
| | - Stephen Goldrick
- The Advanced Centre of Biochemical Engineering, Department of Biochemical Engineering, University College London, Bernard Katz Building, London, WC1E 6BT, United Kingdom
| | - Jean Bender
- MedImmune LLC Gaithersburg Headquarters, One MedImmune Way, Gaithersburg, Maryland
| | - Suzanne S Farid
- The Advanced Centre of Biochemical Engineering, Department of Biochemical Engineering, University College London, Bernard Katz Building, London, WC1E 6BT, United Kingdom
| | - Nigel Titchener-Hooker
- The Advanced Centre of Biochemical Engineering, Department of Biochemical Engineering, University College London, Bernard Katz Building, London, WC1E 6BT, United Kingdom.
| |
Collapse
|
17
|
Voulgaris I, Chatel A, Hoare M, Finka G, Uden M. Evaluation of options for harvest of a recombinant E. Coli fermentation producing a domain antibody using ultra scale-down techniques and pilot-scale verification. Biotechnol Prog 2016; 32:382-92. [PMID: 26698375 PMCID: PMC4991298 DOI: 10.1002/btpr.2220] [Citation(s) in RCA: 8] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/30/2015] [Revised: 11/06/2015] [Indexed: 01/21/2023]
Abstract
Ultra scale‐down (USD) methods operating at the millilitre scale were used to characterise full‐scale processing of E. coli fermentation broths autolysed to different extents for release of a domain antibody. The focus was on the primary clarification stages involving continuous centrifugation followed by depth filtration. The performance of this sequence was predicted by USD studies to decrease significantly with increased extents of cell lysis. The use of polyethyleneimine reagent was studied to treat the lysed cell broth by precipitation of soluble contaminants such as DNA and flocculation of cell debris material. The USD studies were used to predict the impact of this treatment on the performance and here it was found that the fermentation could be run to maximum productivity using an acceptable clarification process (e.g., a centrifugation stage operating at 0.11 L/m2 equivalent gravity settling area per hour followed by a resultant required depth filter area of 0.07 m2/L supernatant). A range of USD predictions was verified at the pilot scale for centrifugation followed by depth filtration. © 2016 The Authors Biotechnology Progress published by Wiley Periodicals, Inc. on behalf of American Institute of Chemical Engineers Biotechnol. Prog., 32:382–392, 2016
Collapse
Affiliation(s)
- Ioannis Voulgaris
- Dept. of Biochemical Engineering, The Advanced Centre for Biochemical Engineering, UCL, Gower St, London, WC1E 6BT.,Biopharm Process Research, BioPharm R&D, GlaxoSmithKline, R&D, Stevenage, SG1 2NY
| | - Alex Chatel
- Dept. of Biochemical Engineering, The Advanced Centre for Biochemical Engineering, UCL, Gower St, London, WC1E 6BT
| | - Mike Hoare
- Dept. of Biochemical Engineering, The Advanced Centre for Biochemical Engineering, UCL, Gower St, London, WC1E 6BT
| | - Gary Finka
- Biopharm Process Research, BioPharm R&D, GlaxoSmithKline, R&D, Stevenage, SG1 2NY
| | - Mark Uden
- Biopharm Process Research, BioPharm R&D, GlaxoSmithKline, R&D, Stevenage, SG1 2NY
| |
Collapse
|
18
|
Popova D, Stonier A, Pain D, Titchener-Hooker NJ, Farid SS. Representative mammalian cell culture test materials for assessment of primary recovery technologies: a rapid method with industrial applicability. Biotechnol J 2015; 10:162-70. [PMID: 25377169 PMCID: PMC4674960 DOI: 10.1002/biot.201400294] [Citation(s) in RCA: 5] [Impact Index Per Article: 0.6] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/01/2014] [Revised: 09/22/2014] [Accepted: 11/05/2014] [Indexed: 12/20/2022]
Abstract
Mammalian cell culture material is often difficult to produce accurately and reproducibly for downstream studies. This article presents a methodology for the creation of a set of cell culture test materials where key variables including cell density, cell viability, product, and the host cell protein (HCP) load can be manipulated individually. The methodology was developed using a glutamine synthetase Chinese hamster ovary cell line cultured at 5-L and 70-L scales. Cell concentration post-cell growth was manipulated using tangential flow filtration to generate a range of target cell densities of up to 100 × 106 cells/mL. A method to prepare an apoptotic cell stock to achieve target viabilities of 40–90% is also described. In addition, a range of IgG1 and HCP concentrations was achieved. The results illustrate that the proposed methodology is able to mimic different cell culture profiles by decoupling the control of the key variables. The cell culture test materials were shown to be representative of typical cell culture feed material in terms of particle size distribution and HCP population. This provides a rapid method to create the required feeds for assessing the feasibility of primary recovery technologies designed to cope with higher cell density cultures.
Collapse
Affiliation(s)
- Daria Popova
- Department of Biochemical Engineering, University College London, London, UK
| | | | | | | | | |
Collapse
|
19
|
Noyes A, Huffman B, Berrill A, Merchant N, Godavarti R, Titchener-Hooker N, Coffman J, Sunasara K, Mukhopadhyay T. High throughput screening of particle conditioning operations: II. Evaluation of scale-up heuristics with prokaryotically expressed polysaccharide vaccines. Biotechnol Bioeng 2015; 112:1568-82. [PMID: 25727194 DOI: 10.1002/bit.25580] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.2] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/04/2014] [Revised: 02/15/2015] [Accepted: 02/17/2015] [Indexed: 11/08/2022]
Abstract
Multivalent polysaccharide conjugate vaccines are typically comprised of several different polysaccharides produced with distinct and complex production processes. Particle conditioning steps, such as precipitation and flocculation, may be used to aid the recovery and purification of such microbial vaccine products. An ultra scale-down approach to purify vaccine polysaccharides at the micro-scale would greatly enhance productivity, robustness, and speed the development of novel conjugate vaccines. In part one of this series, we described a modular and high throughput approach to develop particle conditioning processes (HTPC) for biologicals that combines flocculation, solids removal, and streamlined analytics. In this second part of the series, we applied HTPC to industrially relevant feedstreams comprised of capsular polysaccharides (CPS) from several bacterial species. The scalability of HTPC was evaluated between 0.8 mL and 13 L scales, with several different scaling methodologies examined. Clarification, polysaccharide yield, impurity clearance, and product quality achieved with HTPC were reproducible and comparable with larger scales. Particle sizing was the response with greatest sensitivity to differences in processing scale and enabled the identification of useful scaling rules. Scaling with constant impeller tip speed or power per volume in the impeller swept zone offered the most accurate scale up, with evidence that time integration of these values provided the optimal basis for scaling. The capability to develop a process at the micro-scale combined with evidence-based scaling metrics provide a significant advance for purification process development of vaccine processes. The USD system offers similar opportunities for HTPC of proteins and other complex biological molecules.
Collapse
Affiliation(s)
- Aaron Noyes
- The Advanced Centre for Biochemical Engineering, Department of Biochemical Engineering, University College London, Bernard Katz Building, Gordon Street, London, WC1E 7JE, UK.,Pfizer Bioprocess R&D, Andover, Massachusetts
| | - Ben Huffman
- Pfizer Bioprocess R&D, Chesterfield, Missouri
| | | | | | | | - Nigel Titchener-Hooker
- The Advanced Centre for Biochemical Engineering, Department of Biochemical Engineering, University College London, Bernard Katz Building, Gordon Street, London, WC1E 7JE, UK
| | | | | | - Tarit Mukhopadhyay
- The Advanced Centre for Biochemical Engineering, Department of Biochemical Engineering, University College London, Bernard Katz Building, Gordon Street, London, WC1E 7JE, UK.
| |
Collapse
|
20
|
Noyes A, Huffman B, Godavarti R, Titchener-Hooker N, Coffman J, Sunasara K, Mukhopadhyay T. High throughput screening of particle conditioning operations: I. System design and method development. Biotechnol Bioeng 2015; 112:1554-67. [PMID: 25728932 DOI: 10.1002/bit.25575] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.4] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/04/2014] [Revised: 02/15/2015] [Accepted: 02/17/2015] [Indexed: 11/06/2022]
Abstract
The biotech industry is under increasing pressure to decrease both time to market and development costs. Simultaneously, regulators are expecting increased process understanding. High throughput process development (HTPD) employs small volumes, parallel processing, and high throughput analytics to reduce development costs and speed the development of novel therapeutics. As such, HTPD is increasingly viewed as integral to improving developmental productivity and deepening process understanding. Particle conditioning steps such as precipitation and flocculation may be used to aid the recovery and purification of biological products. In this first part of two articles, we describe an ultra scale-down system (USD) for high throughput particle conditioning (HTPC) composed of off-the-shelf components. The apparatus is comprised of a temperature-controlled microplate with magnetically driven stirrers and integrated with a Tecan liquid handling robot. With this system, 96 individual reaction conditions can be evaluated in parallel, including downstream centrifugal clarification. A comprehensive suite of high throughput analytics enables measurement of product titer, product quality, impurity clearance, clarification efficiency, and particle characterization. HTPC at the 1 mL scale was evaluated with fermentation broth containing a vaccine polysaccharide. The response profile was compared with the Pilot-scale performance of a non-geometrically similar, 3 L reactor. An engineering characterization of the reactors and scale-up context examines theoretical considerations for comparing this USD system with larger scale stirred reactors. In the second paper, we will explore application of this system to industrially relevant vaccines and test different scale-up heuristics.
Collapse
Affiliation(s)
- Aaron Noyes
- The Advanced Centre for Biochemical Engineering, Department of Biochemical Engineering, University College London, Bernard Katz Building, Gordon Street, London, WC1E 7JE, UK.,Pfizer Bioprocess R&D, Andover, Massachusetts
| | - Ben Huffman
- Pfizer Bioprocess R&D, Chesterfield, Missouri
| | | | - Nigel Titchener-Hooker
- The Advanced Centre for Biochemical Engineering, Department of Biochemical Engineering, University College London, Bernard Katz Building, Gordon Street, London, WC1E 7JE, UK
| | | | | | - Tarit Mukhopadhyay
- The Advanced Centre for Biochemical Engineering, Department of Biochemical Engineering, University College London, Bernard Katz Building, Gordon Street, London, WC1E 7JE, UK.
| |
Collapse
|
21
|
Development of an ELP-Z based mAb affinity precipitation process using scaled-down filtration techniques. J Biotechnol 2014; 192 Pt A:11-9. [DOI: 10.1016/j.jbiotec.2014.09.020] [Citation(s) in RCA: 13] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/03/2014] [Revised: 09/20/2014] [Accepted: 09/24/2014] [Indexed: 11/21/2022]
|
22
|
Coons JE, Kalb DM, Dale T, Marrone BL. Getting to low-cost algal biofuels: A monograph on conventional and cutting-edge harvesting and extraction technologies. ALGAL RES 2014. [DOI: 10.1016/j.algal.2014.08.005] [Citation(s) in RCA: 70] [Impact Index Per Article: 7.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/09/2023]
|
23
|
Kolade OO, Jin W, Tengroth C, Green KD, Bracewell DG. Shear effects on aluminum phosphate adjuvant particle properties in vaccine drug products. J Pharm Sci 2014; 104:378-87. [PMID: 25175154 DOI: 10.1002/jps.24127] [Citation(s) in RCA: 16] [Impact Index Per Article: 1.6] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/24/2014] [Revised: 07/27/2014] [Accepted: 07/29/2014] [Indexed: 01/23/2023]
Abstract
Adjuvant-containing drug products can be exposed to high levels of interfacial shear during manufacture. This may affect the integrity of the adjuvant, alter its interaction with the drug substance or change the physical characteristics of the drug product. In this study, a solid-liquid interfacial shear device was used to investigate the shear response of aluminum phosphate adjuvant alone and two adjuvant containing vaccine drug products (DP1 and DP2). The relationship between the shear sensitivity of each and its resuspension properties was determined. Changes in the particle dimensions of the bulk adjuvant were minimal at shear strain rates of 10,900 s(-1) . However, at 25,500 s(-1) , the median particle diameter was reduced from 6.2 to 3.5 μm and was marked by the presence of sub-micron fines. A formulation without drug substance and DP2 produced similar shear responses but with less impact on particle diameter. The behavior of DP1 was less predictable. Sheared DP1 was characterized by prolonged sedimentation because of the presence of fine particulates and required in excess of 300 rotations to resuspend after extended storage. The study confirms that the solid-liquid interfacial shear device may be applied to understand product shear sensitivity associated with vaccine manufacturing.
Collapse
Affiliation(s)
- Olatomirin O Kolade
- The Advanced Centre for Biochemical Engineering, Department of Biochemical Engineering, University College London, Gordon Street, London, WC1H 0AH, UK
| | | | | | | | | |
Collapse
|
24
|
Aucamp JP, Davies R, Hallet D, Weiss A, Titchener-Hooker NJ. Integration of host strain bioengineering and bioprocess development using ultra-scale down studies to select the optimum combination: an antibody fragment primary recovery case study. Biotechnol Bioeng 2014; 111:1971-81. [PMID: 24838387 PMCID: PMC4282095 DOI: 10.1002/bit.25259] [Citation(s) in RCA: 9] [Impact Index Per Article: 0.9] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/06/2013] [Revised: 02/23/2014] [Accepted: 03/31/2014] [Indexed: 11/10/2022]
Abstract
An ultra scale-down primary recovery sequence was established for a platform E. coli Fab production process. It was used to evaluate the process robustness of various bioengineered strains. Centrifugal discharge in the initial dewatering stage was determined to be the major cause of cell breakage. The ability of cells to resist breakage was dependant on a combination of factors including host strain, vector, and fermentation strategy. Periplasmic extraction studies were conducted in shake flasks and it was demonstrated that key performance parameters such as Fab titre and nucleic acid concentrations were mimicked. The shake flask system also captured particle aggregation effects seen in a large scale stirred vessel, reproducing the fine particle size distribution that impacts the final centrifugal clarification stage. The use of scale-down primary recovery process sequences can be used to screen a larger number of engineered strains. This can lead to closer integration with and better feedback between strain development, fermentation development, and primary recovery studies. Biotechnol. Bioeng. 2014;111: 1971–1981. © 2014 Wiley Periodicals, Inc.
Collapse
Affiliation(s)
- Jean P Aucamp
- Bioprocess Research and Development, Novartis Phama AG, Basel, Switzerland.
| | | | | | | | | |
Collapse
|
25
|
Chatel A, Kumpalume P, Hoare M. Ultra scale-down characterization of the impact of conditioning methods for harvested cell broths on clarification by continuous centrifugation-Recovery of domain antibodies from rec E. coli. Biotechnol Bioeng 2013; 111:913-24. [PMID: 24284936 PMCID: PMC4153950 DOI: 10.1002/bit.25164] [Citation(s) in RCA: 16] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/12/2013] [Revised: 11/19/2013] [Accepted: 11/19/2013] [Indexed: 11/30/2022]
Abstract
The processing of harvested E. coli cell broths is examined where the expressed protein product has been released into the extracellular space. Pre-treatment methods such as freeze–thaw, flocculation, and homogenization are studied. The resultant suspensions are characterized in terms of the particle size distribution, sensitivity to shear stress, rheology and solids volume fraction, and, using ultra scale-down methods, the predicted ability to clarify the material using industrial scale continuous flow centrifugation. A key finding was the potential of flocculation methods both to aid the recovery of the particles and to cause the selective precipitation of soluble contaminants. While the flocculated material is severely affected by process shear stress, the impact on the very fine end of the size distribution is relatively minor and hence the predicted performance was only diminished to a small extent, for example, from 99.9% to 99.7% clarification compared with 95% for autolysate and 65% for homogenate at equivalent centrifugation conditions. The lumped properties as represented by ultra scale-down centrifugation results were correlated with the basic properties affecting sedimentation including particle size distribution, suspension viscosity, and solids volume fraction. Grade efficiency relationships were used to allow for the particle and flow dynamics affecting capture in the centrifuge. The size distribution below a critical diameter dependant on the broth pre-treatment type was shown to be the main determining factor affecting the clarification achieved. Biotechnol. Bioeng. 2014;111: 913–924. © 2013 The Authors. Biotechnology and Bioengineering Published by Wiley Periodicals, Inc.
Collapse
Affiliation(s)
- Alex Chatel
- Department of Biochemical Engineering, UCL, Torrington Place, London, WC1E 7JE, UK
| | | | | |
Collapse
|
26
|
Potty ASR, Xenopoulos A, Patel S, Prentice H, DiLeo A. The effect of antiapoptosis genes on clarification performance. Biotechnol Prog 2013; 30:100-7. [DOI: 10.1002/btpr.1827] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/20/2013] [Revised: 08/06/2013] [Indexed: 01/28/2023]
Affiliation(s)
- Ajish S. R. Potty
- Downstream Technologies; EMD Millipore; 80 Ashby Road Bedford MA 01730
| | - Alex Xenopoulos
- Downstream Technologies; EMD Millipore; 80 Ashby Road Bedford MA 01730
| | - Sonal Patel
- Upstream Technologies; EMD Millipore, 80 Ashby Road Bedford MA 01730
| | - Holly Prentice
- Upstream Technologies; EMD Millipore, 80 Ashby Road Bedford MA 01730
| | - Anthony DiLeo
- Divisional Business Development; EMD Millipore; 290 Concord Road Billerica MA 01821
| |
Collapse
|
27
|
Lopes AG, Keshavarz-Moore E. Ultra scale-down device to predict dewatering levels of solids recovered in a continuous scroll decanter centrifuge. Biotechnol Prog 2013; 29:1494-502. [PMID: 24124159 DOI: 10.1002/btpr.1814] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.1] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/15/2013] [Revised: 08/18/2013] [Indexed: 11/08/2022]
Abstract
During centrifugation operation, the major challenge in the recovery of extracellular proteins is the removal of the maximum liquid entrapped within the spaces between the settled solids-dewatering level. The ability of the scroll decanter centrifuge (SDC) to process continuously large amounts of feed material with high concentration of solids without the need for resuspension of feeds, and also to achieve relatively high dewatering, could be of great benefit for future use in the biopharmaceutical industry. However, for reliable prediction of dewatering in such a centrifuge, tests using the same kind of equipment at pilot-scale are required, which are time consuming and costly. To alleviate the need of pilot-scale trials, a novel USD device, with reduced amounts of feed (2 mL) and to be used in the laboratory, was developed to predict the dewatering levels of a SDC. To verify USD device, dewatering levels achieved were plotted against equivalent compression (Gtcomp ) and decanting (Gtdec ) times, obtained from scroll rates and feed flow rates operated at pilot-scale, respectively. The USD device was able to successfully match dewatering trends of the pilot-scale as a function of both Gtcomp and Gtdec , particularly for high cell density feeds, hence accounting for all key variables that influenced dewatering in a SDC. In addition, it accurately mimicked the maximum dewatering performance of the pilot-scale equipment. Therefore the USD device has the potential to be a useful tool at early stages of process development to gather performance data in the laboratory thus minimizing lengthy and costly runs with pilot-scale SDC.
Collapse
Affiliation(s)
- A G Lopes
- The Advanced Centre of Biochemical Engineering, Department of Biochemical Engineering, University College London, Torrington Place, London, WC1E 7JE, U.K
| | | |
Collapse
|
28
|
Li Q, Mannall GJ, Ali S, Hoare M. An ultra scale-down approach to study the interaction of fermentation, homogenization, and centrifugation for antibody fragment recovery from recE. coli. Biotechnol Bioeng 2013; 110:2150-60. [DOI: 10.1002/bit.24891] [Citation(s) in RCA: 16] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/11/2012] [Revised: 02/06/2013] [Accepted: 02/07/2013] [Indexed: 11/06/2022]
|
29
|
Tait AS, Tarrant RDR, Velez-Suberbie ML, Spencer DIR, Bracewell DG. Differential response in downstream processing of CHO cells grown under mild hypothermic conditions. Biotechnol Prog 2013; 29:688-96. [PMID: 23636936 PMCID: PMC3738919 DOI: 10.1002/btpr.1726] [Citation(s) in RCA: 25] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/21/2013] [Revised: 03/12/2013] [Indexed: 11/16/2022]
Abstract
The manufacture of complex therapeutic proteins using mammalian cells is well established, with several strategies developed to improve productivity. The application of sustained mild hypothermic conditions during culture has been associated with increases in product titer and improved product quality. However, despite associated cell physiological effects, very few studies have investigated the impact on downstream processing (DSP). Characterization of cells grown under mild hypothermic conditions demonstrated that the stationary phase was prolonged by delaying the onset of apoptosis. This enabled cells to maintain viability for extended periods and increase volumetric productivity from 0.74 to 1.02 g L−1. However, host cell proteins, measured by ELISA, increased by ∼50%, attributed to the extended time course and higher peak and harvest cell densities. The individual components making up this impurity, as determined by SELDI-TOF MS and 2D-PAGE, were shown to be largely comparable. Under mild hypothermic conditions, cells were less shear sensitive than those maintained at 37°C, enhancing the preliminary primary recovery step. Adaptive changes in membrane fluidity were further investigated by adopting a pronounced temperature shift immediately prior to primary recovery and the improvement observed suggests that such a strategy may be implementable when shear sensitivity is of concern. Early and late apoptotic cells were particularly susceptible to shear, at either temperature, even under the lowest shear rate investigated. These findings demonstrate the importance of considering the impact of cell culture strategies and cell physiology on DSP, by implementing a range of experimental methods for process characterization. © 2013 American Institute of Chemical Engineers Biotechnol. Prog., 29:688–696, 2013
Collapse
Affiliation(s)
- Andrew S Tait
- Dept. of Biochemical Engineering, Advanced Centre for Biochemical Engineering, University College London, Torrington Place, London, WC1E 7JE, UK
| | | | | | | | | |
Collapse
|
30
|
Zhang J, Hunter A, Zhou Y. A logic-reasoning based system to harness bioprocess experimental data and knowledge for design. Biochem Eng J 2013. [DOI: 10.1016/j.bej.2013.02.016] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/27/2022]
|
31
|
Lau EC, Kong S, McNulty S, Entwisle C, Mcilgorm A, Dalton KA, Hoare M. An ultra scale-down characterization of low shear stress primary recovery stages to enhance selectivity of fusion protein recovery from its molecular variants. Biotechnol Bioeng 2013; 110:1973-83. [DOI: 10.1002/bit.24865] [Citation(s) in RCA: 12] [Impact Index Per Article: 1.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/26/2012] [Revised: 01/23/2013] [Accepted: 02/05/2013] [Indexed: 11/12/2022]
|
32
|
Chhatre S. Modelling approaches for bio-manufacturing operations. ADVANCES IN BIOCHEMICAL ENGINEERING/BIOTECHNOLOGY 2012. [PMID: 23183689 DOI: 10.1007/10_2012_170] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 02/20/2023]
Abstract
Fast and cost-effective methods are needed to reduce the time and money needed for drug commercialisation and to determine the risks involved in adopting specific manufacturing strategies. Simulations offer one such approach for exploring design spaces before significant process development is carried out and can be used from the very earliest development stages through to scale-up and optimisation of operating conditions and resource deployment patterns both before and after plant start-up. The advantages this brings in terms of financial savings can be considerable, but to achieve these requires a full appreciation of the complexities of processes and how best to represent them mathematically within the context of in silico software. This chapter provides a summary of some of the work that has been carried out in the areas of mathematical modelling and discrete event simulations for production, recovery and purification operations when designing bio-pharmaceutical processes, looking at both financial and technical modelling.
Collapse
Affiliation(s)
- Sunil Chhatre
- The Advanced Centre for Biochemical Engineering, University College London, Gower Street, London, WC1E 7JE, UK,
| |
Collapse
|
33
|
Velez-Suberbie ML, Tarrant RDR, Tait AS, Spencer DIR, Bracewell DG. Impact of aeration strategy on CHO cell performance during antibody production. Biotechnol Prog 2012; 29:116-26. [PMID: 23074084 DOI: 10.1002/btpr.1647] [Citation(s) in RCA: 19] [Impact Index Per Article: 1.6] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/29/2012] [Revised: 10/12/2012] [Indexed: 12/20/2022]
Abstract
Stirred tank bioreactors using suspension adapted mammalian cells are typically used for the production of complex therapeutic proteins. The hydrodynamic conditions experienced by cells within this environment have been shown to directly impact growth, productivity, and product quality and therefore an improved understanding of the cellular response is critical. Here we investigate the sub-lethal effects of different aeration strategies on Chinese hamster ovary cells during monoclonal antibody production. Two gas delivery systems were employed to study the presence and absence of the air-liquid interface: bubbled direct gas sparging and a non-bubbled diffusive silicone membrane system. Additionally, the effect of higher gas flow rate in the sparged bioreactor was examined. Both aeration systems were run using chemically defined media with and without the shear protectant Pluronic F-68 (PF-68). Cells were unable to grow with direct gas sparging without PF-68; however, when a silicone membrane aeration system was implemented growth was comparable to the sparged bioreactor with PF-68, indicating the necessity of shear protectants in the presence of bubbles. The cultures exposed to increased hydrodynamic stress were shown by flow cytometry to have decreased F-actin intensity within the cytoskeleton and enter apoptosis earlier. This indicates that these conditions elicit a sub-lethal physiological change in cells that would not be detected by the at-line assays which are normally implemented during cell culture. These physiological changes only result in a difference in continuous centrifugation performance under high flow rate conditions. Product quality was more strongly affected by culture age than the hydrodynamic conditions tested.
Collapse
Affiliation(s)
- M Lourdes Velez-Suberbie
- The Advanced Centre of Biochemical Engineering, Dept. of Biochemical Engineering, University College London, Torrington Place, London, WC1E 7JE, U.K
| | | | | | | | | |
Collapse
|
34
|
Hogwood CE, Tait AS, Koloteva-Levine N, Bracewell DG, Smales CM. The dynamics of the CHO host cell protein profile during clarification and protein A capture in a platform antibody purification process. Biotechnol Bioeng 2012; 110:240-51. [DOI: 10.1002/bit.24607] [Citation(s) in RCA: 83] [Impact Index Per Article: 6.9] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/21/2012] [Revised: 05/29/2012] [Accepted: 07/05/2012] [Indexed: 11/12/2022]
|
35
|
Li Q, Aucamp JP, Tang A, Chatel A, Hoare M. Use of focused acoustics for cell disruption to provide ultra scale-down insights of microbial homogenization and its bioprocess impact-recovery of antibody fragments from rec E. coli. Biotechnol Bioeng 2012; 109:2059-69. [DOI: 10.1002/bit.24484] [Citation(s) in RCA: 19] [Impact Index Per Article: 1.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/03/2011] [Revised: 01/27/2012] [Accepted: 02/16/2012] [Indexed: 11/11/2022]
|
36
|
Lopes A, Keshavarz-Moore E. Prediction and verification of centrifugal dewatering of P. pastoris fermentation cultures using an ultra scale-down approach. Biotechnol Bioeng 2012; 109:2039-47. [DOI: 10.1002/bit.24478] [Citation(s) in RCA: 9] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/29/2011] [Revised: 02/14/2012] [Accepted: 02/16/2012] [Indexed: 11/09/2022]
|
37
|
Garcia T, McCurdy V, Watson TNJ, am Ende M, Butterell P, Vukovinsky K, Chueh A, Coffman J, Cooper S, Schuemmelfeder B. Verification of Design Spaces Developed at Subscale. J Pharm Innov 2012. [DOI: 10.1007/s12247-012-9123-0] [Citation(s) in RCA: 8] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/28/2022]
|
38
|
Branston SD, Matos CFRO, Freedman RB, Robinson C, Keshavarz-Moore E. Investigation of the impact of Tat export pathway enhancement on E. coli culture, protein production and early stage recovery. Biotechnol Bioeng 2011; 109:983-91. [PMID: 22125050 DOI: 10.1002/bit.24384] [Citation(s) in RCA: 18] [Impact Index Per Article: 1.4] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/16/2011] [Revised: 11/15/2011] [Accepted: 11/17/2011] [Indexed: 11/06/2022]
Abstract
The twin arginine translocation (Tat) pathway occurs naturally in E. coli and has the distinct ability to translocate folded proteins across the inner membrane of the cell. It has the potential to export commercially useful proteins that cannot be exported by the ubiquitous Sec pathway. To better understand the bioprocess potential of the Tat pathway, this article addresses the fermentation and downstream processing performances of E. coli strains with a wild-type Tat system exporting the over-expressed substrate protein FhuD. These were compared to strains cell-engineered to over-express the Tat pathway, since the native export capacity of the Tat pathway is low. This low capacity makes the pathway susceptible to saturation by over-expressed substrate proteins, and can result in compromised cell integrity. However, there is concern in the literature that over-expression of membrane proteins, like those of the Tat pathway, can impact negatively upon membrane integrity itself. Under controlled fermentation conditions E. coli cells with a wild-type Tat pathway showed poor protein accumulation, reaching a periplasmic maximum of only 0.5 mg L⁻¹ of growth medium. Cells over-expressing the Tat pathway showed a 25% improvement in growth rate, avoided pathway saturation, and showed 40-fold higher periplasmic accumulation of FhuD. Moreover, this was achieved whilst conserving the integrity of cells for downstream processing: experimentation comparing the robustness of cells to increasing levels of shear showed no detrimental effect from pathway over-expression. Further experimentation on spheroplasts generated by the lysozyme/osmotic shock method--a scaleable way to release periplasmic protein--showed similar robustness between strains. A scale-down mimic of continuous disk-stack centrifugation predicted clarifications in excess of 90% for both intact cells and spheroplasts. Cells over-expressing the Tat pathway performed comparably to cells with the wild-type system. Overall, engineering E. coli cells to over-express the Tat pathway allowed for greater periplasmic yields of FhuD at the fermentation scale without compromising downstream processing performance.
Collapse
Affiliation(s)
- Steven D Branston
- The Advanced Centre for Biochemical Engineering, Department of Biochemical Engineering, University College London, Torrington Place, London WC1E 7JE, UK
| | | | | | | | | |
Collapse
|
39
|
Hu W, Berdugo C, Chalmers JJ. The potential of hydrodynamic damage to animal cells of industrial relevance: current understanding. Cytotechnology 2011; 63:445-60. [PMID: 21785843 PMCID: PMC3176934 DOI: 10.1007/s10616-011-9368-3] [Citation(s) in RCA: 102] [Impact Index Per Article: 7.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/20/2008] [Accepted: 06/11/2011] [Indexed: 11/25/2022] Open
Abstract
Suspension animal cell culture is now routinely scaled up to bioreactors on the order of 10,000 L, and greater, to meet commercial demand. However, the concern of the 'shear sensitivity' of animal cells still remains, not only within the bioreactor, but also in the downstream processing. As the productivities continue to increase, titer of ~10 g/L are now reported with cell densities greater than 2 × 10(7) cells/mL. Such high, and potentially higher cell densities will inevitably translate to increased demand in mass transfer and mixing. In addition, achieving productivity gains in both the upstream stage and downstream processes can subject the cells to aggressive environments such as those involving hydrodynamic stresses. The perception of 'shear sensitivity' has historically put an arbitrary upper limit on agitation and aeration in bioreactor operation; however, as cell densities and productivities continue to increase, mass transfer requirements can exceed those imposed by these arbitrary low limits. Therefore, a better understanding of how animal cells, used to produce therapeutic products, respond to hydrodynamic forces in both qualitative and quantitative ways will allow an experimentally based, higher, "upper limit" to be created to guide the design and operation of future commercial, large scale bioreactors. With respect to downstream hydrodynamic conditions, situations have already been achieved in which practical limits with respect to hydrodynamic forces have been experienced. This review mainly focuses on publications from both the academy and industry regarding the effect of hydrodynamic forces on industrially relevant animal cells, and not on the actual scale-up of bioreactors. A summary of implications and remaining challenges will also be presented.
Collapse
Affiliation(s)
- Weiwei Hu
- Cell Culture Development, Biogen Idec Inc., 5000 Davis Drive, RTP, NC 27709 USA
| | - Claudia Berdugo
- Scientist / Research & Development, BD Biosciences, 54 Loveton Circle, Sparks, MD 21152 USA
| | - Jeffrey J. Chalmers
- William G. Lowrie Department of Chemical and Biomolecular Engineering, The Ohio State University, 140 West 19th Ave., Columbus, OH 43210 USA
| |
Collapse
|
40
|
Sharma C, Malhotra D, Rathore AS. Review of Computational fluid dynamics applications in biotechnology processes. Biotechnol Prog 2011; 27:1497-1510. [DOI: 10.1002/btpr.689] [Citation(s) in RCA: 58] [Impact Index Per Article: 4.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/07/2022]
|
41
|
Balasundaram B, Sachdeva S, Bracewell DG. Dual salt precipitation for the recovery of a recombinant protein from Escherichia coli. Biotechnol Prog 2011; 27:1306-14. [PMID: 21626723 DOI: 10.1002/btpr.645] [Citation(s) in RCA: 9] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/15/2010] [Revised: 03/30/2011] [Indexed: 11/10/2022]
Abstract
When considering worldwide demand for biopharmaceuticals, it becomes necessary to consider alternative process strategies to improve the economics of manufacturing such molecules. To address this issue, the current study investigates precipitation to selectively isolate the product or remove contaminants and thus assist the initial purification of a intracellular protein. The hypothesis tested was that the combination of two or more precipitating agents will alter the solubility profile of the product through synergistic or antagonistic effects. This principle was investigated through several combinations of ammonium sulfate and sodium citrate at different ratios. A synergistic effect mediated by a known electrostatic interaction of citrate ions with Fab' in addition to the typical salting-out effects was observed. On the basis of the results of the solubility studies, a two step primary recovery route was investigated. In the first step termed conditioning, post-homogenization and before clarification, addition of 0.8 M ammonium sulfate extracted 30% additional product. Clarification performance measured using a scale-down disc stack centrifugation mimic determined a four-fold reduction in centrifuge size requirements. Dual salt precipitation in the second step resulted in >98% recovery of Fab' while removing 36% of the contaminant proteins simultaneously.
Collapse
Affiliation(s)
- Bangaru Balasundaram
- Dept. of Biochemical Engineering, The Advanced Centre for Biochemical Engineering, University College London, London WC1E 7JE, UK
| | | | | |
Collapse
|
42
|
Branston S, Stanley E, Ward J, Keshavarz-Moore E. Study of robustness of filamentous bacteriophages for industrial applications. Biotechnol Bioeng 2011; 108:1468-72. [DOI: 10.1002/bit.23066] [Citation(s) in RCA: 19] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/09/2010] [Revised: 01/06/2011] [Accepted: 01/10/2011] [Indexed: 11/08/2022]
|
43
|
Westoby M, Rogers JK, Haverstock R, Romero J, Pieracci J. Modeling industrial centrifugation of mammalian cell culture using a capillary based scale-down system. Biotechnol Bioeng 2011; 108:989-98. [DOI: 10.1002/bit.23051] [Citation(s) in RCA: 25] [Impact Index Per Article: 1.9] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/05/2010] [Revised: 12/20/2010] [Accepted: 12/23/2010] [Indexed: 11/08/2022]
|
44
|
Reid CQ, Tait A, Baldascini H, Mohindra A, Racher A, Bilsborough S, Smales CM, Hoare M. Rapid whole monoclonal antibody analysis by mass spectrometry: An ultra scale-down study of the effect of harvesting by centrifugation on the post-translational modification profile. Biotechnol Bioeng 2010; 107:85-95. [PMID: 20506289 DOI: 10.1002/bit.22790] [Citation(s) in RCA: 34] [Impact Index Per Article: 2.4] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/23/2023]
Abstract
With the trend towards the generation and production of increasing numbers of complex biopharmaceutical (protein based) products, there is an increased need and requirement to characterize both the product and production process in terms of robustness and reproducibility. This is of particular importance for products from mammalian cell culture which have large molecular structures and more often than not complex post-translational modifications (PTMs) that can impact the efficacy, stability and ultimately the safety of the final product. It is therefore vital to understand how the operating conditions of a bioprocess affect the distribution and make up of these PTMs to ensure a consistent quality and activity in the final product. Here we have characterized a typical bioprocess and determined (a) how the time of harvest from a mammalian cell culture and, (b) through the use of an ultra scale-down mimic how the nature of the primary recovery stages, affect the distribution and make up of the PTMs observed on a recombinant IgG(4) monoclonal antibody. In particular we describe the use of rapid whole antibody analysis by mass spectrometry to analyze simultaneously the changes that occur to the cleavage of heavy chain C-terminal lysine residues and the glycosylation pattern, as well as the presence of HL dimers. The time of harvest was found to have a large impact upon the range of glycosylation patterns observed, but not upon C-terminal lysine cleavage. The culture age had a profound impact on the ratio of different glycan moieties found on antibody molecules. The proportion of short glycans increased (e.g., (G0F)(2) 20-35%), with an associated decrease in the proportion of long glycans with culture age (e.g., (G2F)(2) 7-4%, and G1F/G2F from 15.2% to 7.8%). Ultra scale-down mimics showed that subsequent processing of these cultures did not change the post-translational modifications investigated, but did increase the proportion of half antibodies present in the process stream. The combination of ultra scale-down methodology and whole antibody analysis by mass spectrometry has demonstrated that the effects of processing on the detailed molecular structure of a monoclonal antibody can be rapidly determined early in the development process. In this study we have demonstrated this analysis to be applicable to critical process design decisions (e.g., time of harvest) in terms of achieving a desired molecular structure, but this approach could also be applied as a selection criterion as to the suitability of a platform process for the preparation of a new drug candidate. Also the methodology provides means for bioprocess engineers to predict at the discovery phase how a bioprocess will impact upon the quality of the final product.
Collapse
Affiliation(s)
- C Q Reid
- Department of Biochemical Engineering, University College London, UK
| | | | | | | | | | | | | | | |
Collapse
|
45
|
Ma G, Aucamp J, Gerontas S, Eardley-Patel R, Craig A, Hoare M, Zhou Y. Mimic of a large-scale diafiltration process by using ultra scale-down rotating disc filter. Biotechnol Prog 2010; 26:466-76. [PMID: 19938066 DOI: 10.1002/btpr.327] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/07/2022]
Abstract
Ultra scale-down (USD) approach is a powerful tool to predict large-scale process performance by using very small amounts of material. In this article, we present a method to mimic flux and transmission performance in a labscale crossflow operation by an USD rotating disc filter (RDF). The Pellicon 2 labscale system used for evaluation of the mimic can readily be related to small pilot and industrial scale. Adopted from the pulsed sample injection technique by Ghosh and Cui (J Membr Sci. 2000;175:5-84), the RDF has been modified by building in inserts to allow the flexibility of the chamber volume, so that only 1.5 mL of processing material is required for each diafiltration experiment. The reported method enjoys the simplicity of dead-end mode operation with accurate control of operation conditions that can mimic well the crossflow operation in large scale. Wall shear rate correlations have been established for both the labscale cassette and the USD device, and a mimic has been developed by operating both scales under conditions with equivalent averaged shear rates. The studies using E. coli lysate show that the flux vs. transmembrane pressure profile follows a first-order model, and the transmission of antibody fragment (Fab') is independent of transmembrane pressure. Predicted flux and transmission data agreed well with the experimental results of a labscale diafiltration where the cassette resistance was considered.
Collapse
Affiliation(s)
- Guijun Ma
- Dept. of Biochemical Engineering, The Advanced Centre for Biochemical Engineering, University College London, Torrington Place, London, WC1E 7JE, UK
| | | | | | | | | | | | | |
Collapse
|
46
|
Spelter LE, Steiwand A, Nirschl H. Processing of dispersions containing fine particles or biological products in tubular bowl centrifuges. Chem Eng Sci 2010. [DOI: 10.1016/j.ces.2010.04.028] [Citation(s) in RCA: 24] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/15/2022]
|
47
|
Zumaeta N, Byrne EP, Fitzpatrick JJ. Application of CFD and breakage modelling for predicting the size reduction of protein precipitates during transport. Chem Eng Res Des 2010. [DOI: 10.1016/j.cherd.2009.12.007] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
|
48
|
Zaman F, Allan CM, Ho SV. Ultra scale-down approaches for clarification of mammalian cell culture broths in disc-stack centrifuges. Biotechnol Prog 2010; 25:1709-16. [PMID: 19768799 DOI: 10.1002/btpr.275] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.1] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/08/2022]
Abstract
Ultra-scale down (USD) methodology developed by University College London for cell broth clarification with industrial centrifuges was applied to two common cell lines (NS0 and GS-CHO) expressing various therapeutic monoclonal antibodies. A number of centrifuges at various scales were used with shear devices operating either by high speed rotation or flow-through narrow channels. The USD methodology was found effective in accounting for both gravitational and shear effects on clarification performance with three continuous centrifuges at pilot and manufacturing scales. Different shear responses were observed with the two different cell lines and even with the same cell line expressing different products. Separate particle size analysis of the treated broths seems consistent with the shear results. Filterability of the centrifuged solutions was also evaluated to assess the utility of the USD approach for this part of the clarification operation.
Collapse
Affiliation(s)
- Ferhana Zaman
- Pfizer Global Biologics, Worldwide Pharmaceutical Sciences, PGRD, Pfizer Inc. Chesterfield, MO 63017, USA.
| | | | | |
Collapse
|
49
|
Gao Y, Kipling K, Glassey J, Willis M, Montague G, Zhou Y, Titchener-Hooker NJ. Application of agent-based system for bioprocess description and process improvement. Biotechnol Prog 2009; 26:706-16. [PMID: 20014420 DOI: 10.1002/btpr.361] [Citation(s) in RCA: 7] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/07/2022]
Abstract
Modeling plays an important role in bioprocess development for design and scale-up. Predictive models can also be used in biopharmaceutical manufacturing to assist decision-making either to maintain process consistency or to identify optimal operating conditions. To predict the whole bioprocess performance, the strong interactions present in a processing sequence must be adequately modeled. Traditionally, bioprocess modeling considers process units separately, which makes it difficult to capture the interactions between units. In this work, a systematic framework is developed to analyze the bioprocesses based on a whole process understanding and considering the interactions between process operations. An agent-based approach is adopted to provide a flexible infrastructure for the necessary integration of process models. This enables the prediction of overall process behavior, which can then be applied during process development or once manufacturing has commenced, in both cases leading to the capacity for fast evaluation of process improvement options. The multi-agent system comprises a process knowledge base, process models, and a group of functional agents. In this system, agent components co-operate with each other in performing their tasks. These include the description of the whole process behavior, evaluating process operating conditions, monitoring of the operating processes, predicting critical process performance, and providing guidance to decision-making when coping with process deviations. During process development, the system can be used to evaluate the design space for process operation. During manufacture, the system can be applied to identify abnormal process operation events and then to provide suggestions as to how best to cope with the deviations. In all cases, the function of the system is to ensure an efficient manufacturing process. The implementation of the agent-based approach is illustrated via selected application scenarios, which demonstrate how such a framework may enable the better integration of process operations by providing a plant-wide process description to facilitate process improvement.
Collapse
Affiliation(s)
- Ying Gao
- Dept. of Biochemical Engineering, University College London, Torrington Place, London, WC1E 7JE, UK
| | | | | | | | | | | | | |
Collapse
|
50
|
Grant Y, Matejtschuk P, Dalby PA. Rapid optimization of protein freeze-drying formulations using ultra scale-down and factorial design of experiment in microplates. Biotechnol Bioeng 2009; 104:957-64. [PMID: 19530082 DOI: 10.1002/bit.22448] [Citation(s) in RCA: 26] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/08/2022]
Abstract
Retaining biopharmaceutical proteins in a stable form is critical to their safety and efficacy, and is a major factor for optimizing the final product. Freeze-dried formulations offer one route for improved stability. Currently the optimization of formulations for freeze-drying is an empirical process that requires many time-consuming experiments and also uses large quantities of product material. Here we describe a generic framework for the rapid identification and optimization of formulation excipients to prevent loss of protein activity during a lyophilization process. Using factorial design of experiment (DOE) methods combined with lyophilization in microplates a range of optimum formulations were rapidly identified that stabilized lactose dehydrogenase (derived from Lactobacillus leichmanii) during freeze-drying. The procedure outlined herein involves two rounds of factorially designed experiments-an initial screen to identify key excipients and potential interactions followed by a central composite face designed optimization experiment. Polyethylene glycol (PEG) and lactose were shown to have significant effects on maintaining protein stability at the screening stage and optimization resulted in an accurate model that was used to plot a window of operation. The variation of freezing temperatures and rates of sublimation that occur across a microplate during freeze-drying have been characterized also. The optimum formulation was then freeze-dried in stoppered vials to verify that the microscale data was relevant to the effects observed at larger pilot scales. This work provides a generic approach to biopharmaceutical formulation screening where possible excipients can be screened for single and interactive effects thereby increasing throughput while reducing costs in terms of time and materials.
Collapse
Affiliation(s)
- Yitzchak Grant
- Department of Biochemical Engineering, The Advanced Centre for Biochemical Engineering, University College London, Torrington Place, London WC1E 7JE, UK
| | | | | |
Collapse
|