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Matos T, Hoying D, Kristopeit A, Wenger M, Joyce J. Continuous multi-membrane chromatography of large viral particles. J Chromatogr A 2023; 1705:464194. [PMID: 37419021 DOI: 10.1016/j.chroma.2023.464194] [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: 04/09/2023] [Revised: 06/30/2023] [Accepted: 07/02/2023] [Indexed: 07/09/2023]
Abstract
Continuous multi-column chromatography (CMCC) has been successfully implemented to address biopharmaceutical biomolecule instability, to improve process efficiency, and to reduce facility footprint and capital cost. This paper explores the implementation of a continuous multi-membrane chromatography (CMMC) process, using four membrane units, for a large viral particle in just few weeks. CMMC improves the efficiency of the chromatography step by enabling higher loads with smaller membranes for multiple cycles of column use and enables steady-state continuous bioprocessing. The separation performance of CMMC was compared to a conventional batch chromatographic capture step used at full manufacturing scale. The product step yield was 80% using CMMC versus 65% in batch mode while increasing slightly the relative purity. Furthermore, the total amount of membrane area required for the CMMC approach was approximately 10% of the area needed for batch operation, while realizing similar processing times. Since CMMC uses smaller membrane sizes, it can take advantage of the high flow rates achievable for membrane chromatography that are not typically possible at larger membrane scales due to skid flow rate limitations. As such, CMMC offers the potential for more efficient and cost-effective purification trains.
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Affiliation(s)
- Tiago Matos
- Vaccine Bioprocess Research and Development, Merck & Co., Inc., West Point, PA 19486, United States.
| | - David Hoying
- Vaccine Bioprocess Research and Development, Merck & Co., Inc., West Point, PA 19486, United States
| | - Adam Kristopeit
- Vaccine Bioprocess Research and Development, Merck & Co., Inc., West Point, PA 19486, United States
| | - Marc Wenger
- Vaccine Bioprocess Research and Development, Merck & Co., Inc., West Point, PA 19486, United States
| | - Joseph Joyce
- Vaccine Bioprocess Research and Development, Merck & Co., Inc., West Point, PA 19486, United States
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2
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Becker L, Sturm J, Eiden F, Holtmann D. Analyzing and understanding the robustness of bioprocesses. Trends Biotechnol 2023; 41:1013-1026. [PMID: 36959084 DOI: 10.1016/j.tibtech.2023.03.002] [Citation(s) in RCA: 4] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/29/2022] [Revised: 02/27/2023] [Accepted: 03/01/2023] [Indexed: 03/25/2023]
Abstract
The robustness of bioprocesses is becoming increasingly important. The main driving forces of this development are, in particular, increasing demands on product purities as well as economic aspects. In general, bioprocesses exhibit extremely high complexity and variability. Biological systems often have a much higher intrinsic variability compared with chemical processes, which makes the development and characterization of robust processes tedious task. To predict and control robustness, a clear understanding of interactions between input and output variables is necessary. Robust bioprocesses can be realized, for example, by using advanced control strategies for the different unit operations. In this review, we discuss the different biological, technical, and mathematical tools for the analysis and control of bioprocess robustness.
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Affiliation(s)
- Lucas Becker
- Institute of Bioprocess Engineering and Pharmaceutical Technology, University of Applied Sciences Mittelhessen, Wiesenstrasse 14, 35390 Giessen, Germany
| | - Jonathan Sturm
- Bioprozesstechnik Group, Westfälische Hochschule, August-Schmidt-Ring 10, 45665 Recklinghausen, Germany; iAMB - Institute of Applied Microbiology, ABBt - Aachen Biology and Biotechnology, RWTH Aachen University, Worringerweg 1, 52074 Aachen, Germany
| | - Frank Eiden
- Bioprozesstechnik Group, Westfälische Hochschule, August-Schmidt-Ring 10, 45665 Recklinghausen, Germany
| | - Dirk Holtmann
- Institute of Bioprocess Engineering and Pharmaceutical Technology, University of Applied Sciences Mittelhessen, Wiesenstrasse 14, 35390 Giessen, Germany.
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Benedini LJ, Furlan FF, Figueiredo D, Cabrera-Crespo J, Ribeiro MPA, Campani G, Gonçalves VM, Zangirolami TC. A comprehensive method for modeling and simulating ion exchange chromatography of complex mixtures. Protein Expr Purif 2023; 205:106228. [PMID: 36587709 DOI: 10.1016/j.pep.2022.106228] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/27/2022] [Revised: 12/09/2022] [Accepted: 12/22/2022] [Indexed: 12/31/2022]
Abstract
In recent years, many biological-based products have been developed, representing a significant fraction of income in the pharmaceutical market. Ion exchange chromatography is an important downstream step for the purification of target recombinant proteins present in clarified cell extracts, together with many other unknown impurities. This work develops a robust approach to model and simulate the purification of untagged heterologous proteins, so that the improved conditions to carry out an ion exchange chromatography are identified in a rational basis prior to the real purification run itself. Purification of the pneumococcal surface protein A (PspA4Pro) was used as a case study. This protein is produced by recombinant Escherichia coli and is a candidate for the manufacture of improved pneumococcal vaccines. The developed method combined experimental and computational procedures. Different anion exchange operating conditions were mapped in order to gather a broad range of representative experimental data. The equilibrium dispersive and the steric mass action equations were used to model and simulate the process. A training strategy to fit the model and separately describe the elution profiles of PspA4Pro and other proteins of the cell extract was applied. Based on the simulation results, a reduced ionic strength was applied for PspA4Pro elution, leading to increases of 14.9% and 11.5% for PspA4Pro recovery and purity, respectively, compared to the original elution profile. These results showed the potential of this method, which could be further applied to improve the performance of ion exchange chromatography in the purification of other target proteins under real process conditions.
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Affiliation(s)
- Leandro J Benedini
- Graduate Program in Chemical Engineering (PPGEQ), Federal University of São Carlos (UFSCar), São Carlos, Brazil; Federal Institute of São Paulo (IFSP), Catanduva, Brazil.
| | - Felipe F Furlan
- Graduate Program in Chemical Engineering (PPGEQ), Federal University of São Carlos (UFSCar), São Carlos, Brazil; Chemical Engineering Department, Federal University of São Carlos (UFSCar), São Carlos, Brazil
| | - Douglas Figueiredo
- Butantan Institute, Laboratory of Vaccine Development, São Paulo, Brazil
| | | | - Marcelo P A Ribeiro
- Graduate Program in Chemical Engineering (PPGEQ), Federal University of São Carlos (UFSCar), São Carlos, Brazil; Chemical Engineering Department, Federal University of São Carlos (UFSCar), São Carlos, Brazil
| | - Gilson Campani
- Department of Engineering, Federal University of Lavras, Lavras, Brazil
| | | | - Teresa C Zangirolami
- Graduate Program in Chemical Engineering (PPGEQ), Federal University of São Carlos (UFSCar), São Carlos, Brazil; Chemical Engineering Department, Federal University of São Carlos (UFSCar), São Carlos, Brazil
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Rathore AS, Thakur G, Kateja N. Continuous integrated manufacturing for biopharmaceuticals: A new paradigm or an empty promise? Biotechnol Bioeng 2023; 120:333-351. [PMID: 36111450 DOI: 10.1002/bit.28235] [Citation(s) in RCA: 5] [Impact Index Per Article: 5.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/05/2022] [Revised: 09/09/2022] [Accepted: 09/11/2022] [Indexed: 01/13/2023]
Abstract
Continuous integrated bioprocessing has elicited considerable interest from the biopharma industry for the many purported benefits it promises. Today many major biopharma manufacturers around the world are engaged in the development of continuous process platforms for their products. In spite of great potential, the path toward continuous integrated bioprocessing remains unclear for the biologics industry due to legacy infrastructure, process integration challenges, vague regulatory guidelines, and a diverging focus toward novel therapies. In this article, we present a review and perspective on this topic. We explore the status of the implementation of continuous integrated bioprocessing among biopharmaceutical manufacturers. We also present some of the key hurdles that manufacturers are likely to face during this implementation. Finally, we hypothesize that the real impact of continuous manufacturing is likely to come when the cost of manufacturing is a substantial portion of the cost of product development, such as in the case of biosimilar manufacturing and emerging economies.
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Affiliation(s)
- Anurag S Rathore
- Department of Chemical Engineering, Indian Institute of Technology, New Delhi, India
| | - Garima Thakur
- Department of Chemical Engineering, Indian Institute of Technology, New Delhi, India
| | - Nikhil Kateja
- Department of Chemical Engineering, Indian Institute of Technology, New Delhi, India
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Madabhushi SR, Pinto NDS, Lin H. Comparison of process mass intensity (PMI) of continuous and batch manufacturing processes for biologics. N Biotechnol 2022; 72:122-127. [PMID: 36368463 DOI: 10.1016/j.nbt.2022.11.002] [Citation(s) in RCA: 4] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/11/2022] [Revised: 11/04/2022] [Accepted: 11/06/2022] [Indexed: 11/09/2022]
Abstract
Biologics encompasses a wide variety of therapeutics including monoclonal antibodies, fusion proteins, and enzymes, among others. The biologics market is growing at a rapid pace and different manufacturing processes, including continuous manufacturing processes, are being increasingly adopted. There is a strong drive to assess the sustainability of such processes. Here, we calculated the process mass intensity (PMI) of a continuous manufacturing process and compared it to the PMI of batch processes for monoclonal antibodies (mAbs). Results show that the PMI of continuous manufacturing process is comparable to that of batch processes. Sensitivity analysis was performed to assess the impact of different process strategies on the material usage efficiency of continuous processes. Although PMI is a useful benchmarking metric of sustainability, it does not account for factors such as energy consumption which is a key driver of sustainability for biologics manufacturing. Comparison of a higher PMI continuous process with a lower PMI batch process operating at the same bioreactor scale shows that since the productivity (in g of drug substance, DS) per unit time is multifold higher for the continuous process, the overall energy consumption per unit of DS produced might be lower leading to a more environmentally sustainable process. This study highlights some of these key aspects that would require additional metrics and models to be developed to assess the overall sustainability of biologics processes.
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Affiliation(s)
- Sri R Madabhushi
- Biologics Process Research and Development, Merck & Co., Inc., 2000 Galloping Hill Road, Kenilworth, NJ 07033, USA.
| | - Nuno D S Pinto
- Biologics Process Research and Development, Merck & Co., Inc., 2000 Galloping Hill Road, Kenilworth, NJ 07033, USA
| | - Henry Lin
- Biologics Process Research and Development, Merck & Co., Inc., 2000 Galloping Hill Road, Kenilworth, NJ 07033, USA
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Gerstweiler L, Bi J, Middelberg AP. Continuous downstream bioprocessing for intensified manufacture of biopharmaceuticals and antibodies. Chem Eng Sci 2021. [DOI: 10.1016/j.ces.2020.116272] [Citation(s) in RCA: 12] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/08/2023]
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Tripathi NK, Shrivastava A. Recent Developments in Bioprocessing of Recombinant Proteins: Expression Hosts and Process Development. Front Bioeng Biotechnol 2019; 7:420. [PMID: 31921823 PMCID: PMC6932962 DOI: 10.3389/fbioe.2019.00420] [Citation(s) in RCA: 237] [Impact Index Per Article: 47.4] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/07/2019] [Accepted: 11/29/2019] [Indexed: 12/22/2022] Open
Abstract
Infectious diseases, along with cancers, are among the main causes of death among humans worldwide. The production of therapeutic proteins for treating diseases at large scale for millions of individuals is one of the essential needs of mankind. Recent progress in the area of recombinant DNA technologies has paved the way to producing recombinant proteins that can be used as therapeutics, vaccines, and diagnostic reagents. Recombinant proteins for these applications are mainly produced using prokaryotic and eukaryotic expression host systems such as mammalian cells, bacteria, yeast, insect cells, and transgenic plants at laboratory scale as well as in large-scale settings. The development of efficient bioprocessing strategies is crucial for industrial production of recombinant proteins of therapeutic and prophylactic importance. Recently, advances have been made in the various areas of bioprocessing and are being utilized to develop effective processes for producing recombinant proteins. These include the use of high-throughput devices for effective bioprocess optimization and of disposable systems, continuous upstream processing, continuous chromatography, integrated continuous bioprocessing, Quality by Design, and process analytical technologies to achieve quality product with higher yield. This review summarizes recent developments in the bioprocessing of recombinant proteins, including in various expression systems, bioprocess development, and the upstream and downstream processing of recombinant proteins.
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Affiliation(s)
- Nagesh K. Tripathi
- Bioprocess Scale Up Facility, Defence Research and Development Establishment, Gwalior, India
| | - Ambuj Shrivastava
- Division of Virology, Defence Research and Development Establishment, Gwalior, India
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Fedorenko D, Dutta AK, Tan J, Walko J, Brower M, Pinto NDS, Zydney AL, Shinkazh O. Improved protein A resin for antibody capture in a continuous countercurrent tangential chromatography system. Biotechnol Bioeng 2019; 117:646-653. [DOI: 10.1002/bit.27232] [Citation(s) in RCA: 9] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/07/2019] [Revised: 10/28/2019] [Accepted: 11/22/2019] [Indexed: 11/07/2022]
Affiliation(s)
| | | | - Jasmine Tan
- Chromatan CorporationState College Pennsylvania
| | | | - Mark Brower
- Biologics Process R&DMerck & Co., Inc.Kenilworth New Jersey
| | | | - Andrew L. Zydney
- Department of Chemical EngineeringThe Pennsylvania State University, University Park Pennsylvania
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Taraban MB, Briggs KT, Merkel P, Yu YB. Flow Water Proton NMR: In-Line Process Analytical Technology for Continuous Biomanufacturing. Anal Chem 2019; 91:13538-13546. [DOI: 10.1021/acs.analchem.9b02622] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/01/2023]
Affiliation(s)
- Marc B. Taraban
- Department of Pharmaceutical Sciences, School of Pharmacy, University of Maryland, Baltimore, Maryland 21201, United States
| | - Katharine T. Briggs
- Department of Pharmaceutical Sciences, School of Pharmacy, University of Maryland, Baltimore, Maryland 21201, United States
| | - Peter Merkel
- Department of Pharmaceutical Sciences, School of Pharmacy, University of Maryland, Baltimore, Maryland 21201, United States
| | - Y. Bruce Yu
- Department of Pharmaceutical Sciences, School of Pharmacy, University of Maryland, Baltimore, Maryland 21201, United States
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Experimental designs for optimizing the purification of immunoglobulin G by mixed-mode chromatography. J Chromatogr B Analyt Technol Biomed Life Sci 2019; 1125:121719. [DOI: 10.1016/j.jchromb.2019.121719] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/23/2019] [Revised: 07/03/2019] [Accepted: 07/13/2019] [Indexed: 11/22/2022]
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Yang O, Qadan M, Ierapetritou M. Economic Analysis of Batch and Continuous Biopharmaceutical Antibody Production: A Review. J Pharm Innov 2019; 14:1-19. [PMID: 30923586 PMCID: PMC6432653 DOI: 10.1007/s12247-018-09370-4] [Citation(s) in RCA: 30] [Impact Index Per Article: 6.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/30/2023]
Abstract
PURPOSE There is a growing interest in continuous biopharmaceutical processing due to the advantages of small footprint, increased productivity, consistent product quality, high process flexibility and robustness, facility cost-effectiveness, and reduced capital and operating cost. To support the decision making of biopharmaceutical manufacturing, comparisons between conventional batch and continuous processing are provided. METHODS Various process unit operations in different operating modes are summarized. Software implementation, as well as computational methods used, are analyzed pointing to the advantages and disadvantages that have been highlighted in the literature. Economic analysis methods and their applications in different parts of the processes are also discussed with examples from publications in the last decade. RESULTS The results of the comparison between batch and continuous process operation alternatives are discussed. Possible improvements in process design and analysis are recommended. The methods used here do not reflect Lilly's cost structures or economic evaluation methods. CONCLUSION This paper provides a review of the work that has been published in the literature on computational process design and economic analysis methods on continuous biopharmaceutical antibody production and its comparison with a conventional batch process.
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Affiliation(s)
- Ou Yang
- Department of Chemical and Biochemical Engineering, Rutgers—The State University of New Jersey, 98 Brett Road, Piscataway, New Jersey 08854-8058, United States
| | - Maen Qadan
- Eli Lilly and Company, Lilly Corporate Center, Indianapolis, IN 46285, United States
| | - Marianthi Ierapetritou
- Department of Chemical and Biochemical Engineering, Rutgers—The State University of New Jersey, 98 Brett Road, Piscataway, New Jersey 08854-8058, United States
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12
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Recent developments in chromatographic purification of biopharmaceuticals. Biotechnol Lett 2018; 40:895-905. [DOI: 10.1007/s10529-018-2552-1] [Citation(s) in RCA: 46] [Impact Index Per Article: 7.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/21/2018] [Accepted: 04/03/2018] [Indexed: 02/07/2023]
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