Detailed, real-time characterization of particle deposition during crossflow filtration as influenced by solution properties

Intramodule pressure profiles and protein accumulation during tangential flow filtration

Tangential flow filtration (TFF) through a 30 kDa nominal molecular weight cut-off (MWCO) ultrafiltration membrane is widely employed to concentrate purified monoclonal antibodies (mAbs) to levels required for their formulation into injectable biologics. While TFF has been used to remove casein from milk for cheese production for over 35 years, and in pharmaceutical manufacture of biotherapeutic proteins for 20 years, the rapid decline in filtration rate (i.e., flux) at high protein concentrations is a limitation that still needs to be addressed. This is particularly important for mAbs, many of which are 140-160 kDa immunoglobulin G (IgG) type proteins recovered at concentrations of 200 mg/mL or higher. This work reports the direct measurement of local transmembrane pressure drops and off-line confocal imaging of protein accumulation in stagnant regions on the surface of a 30 kDa regenerated cellulose membrane in a flat-sheet configuration widely used in manufacture of biotherapeutic proteins. These first-of-a-kind measurements using 150 kDa bovine IgG show that while axial pressure decreases by 58 psi across a process membrane cassette, the decrease in transmembrane pressure drop is constant at about 1.2 psi/cm along the 20.7 cm length of the membrane. Confocal laser scanning microscopy of the membrane surface at the completion of runs where retentate protein concentration exceeds 200 mg/mL, shows a 50 μm thick protein layer is uniformly deposited. The localized measurements made possible by the modified membrane system confirm the role of protein deposition on limiting ultrafiltration rate and indicate possible targets for improving membrane performance.

Monitoring Membrane Fouling Using Fluid Dynamic Gauging: Influence of Feed Characteristics and Operating Conditions

Recent studies on membrane fouling have made considerable progress in reducing its adverse effects. However, a lack of comprehensive studies focusing on the underlying fouling mechanisms remains. This work aims to address a part of this gap by investigating the influence of feed suspension chemistry and operating conditions on the fouling characteristics of microcrystalline cellulose. Fluid dynamic gauging (FDG) was employed to monitor the properties of fouling layers under varied conditions. FDG results revealed that the cohesive strength of fouling layers increased in the direction towards the membrane, which can be associated with the higher compressive pressures exerted on foulants deposited near the surface. At lower pHs and higher ionic strengths, reduced electrostatic repulsions between particles likely resulted in particle agglomeration, leading to the formation of thicker cakes. In addition, thicker cake layers were also observed at higher feed concentrations, higher operating transmembrane pressures, and longer filtration times. The cross-flow velocity influenced the resilience of fouling layers significantly, resulting in thinner yet stronger cake layers in the transition and turbulent flow regimes. These findings regarding the influence of feed characteristics and operating conditions on the fouling behavior can be beneficial in developing effective antifouling strategies in membrane separation processes.

Microfluidics Used as a Tool to Understand and Optimize Membrane Filtration Processes

Membrane filtration processes are best known for their application in the water, oil, and gas sectors, but also in food production they play an eminent role. Filtration processes are known to suffer from a decrease in efficiency in time due to e.g., particle deposition, also known as fouling and pore blocking. Although these processes are not very well understood at a small scale, smart engineering approaches have been used to keep membrane processes running. Microfluidic devices have been increasingly applied to study membrane filtration processes and accommodate observation and understanding of the filtration process at different scales, from nanometer to millimeter and more. In combination with microscopes and high-speed imaging, microfluidic devices allow real time observation of filtration processes. In this review we will give a general introduction on microfluidic devices used to study membrane filtration behavior, followed by a discussion of how microfluidic devices can be used to understand current challenges. We will then discuss how increased knowledge on fundamental aspects of membrane filtration can help optimize existing processes, before wrapping up with an outlook on future prospects on the use of microfluidics within the field of membrane separation.