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Ito T, Lutz H, Tan L, Wang B, Tan J, Patel M, Chen L, Tsunakawa Y, Park B, Banerjee S. Host cell proteins in monoclonal antibody processing: Control, detection, and removal. Biotechnol Prog 2024:e3448. [PMID: 38477405 DOI: 10.1002/btpr.3448] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/30/2023] [Revised: 02/13/2024] [Accepted: 02/14/2024] [Indexed: 03/14/2024]
Abstract
Host cell proteins (HCPs) are process-related impurities in a therapeutic protein expressed using cell culture technology. This review presents biopharmaceutical industry trends in terms of both HCPs in the bioprocessing of monoclonal antibodies (mAbs) and the capabilities for HCP clearance by downstream unit operations. A comprehensive assessment of currently implemented and emerging technologies in the manufacturing processes with extensive references was performed. Meta-analyses of published downstream data were conducted to identify trends. Improved analytical methods and understanding of "high-risk" HCPs lead to more robust manufacturing processes and higher-quality therapeutics. The trend of higher cell density cultures leads to both higher mAb expression and higher HCP levels. However, HCP levels can be significantly reduced with improvements in operations, resulting in similar concentrations of approx. 10 ppm HCPs. There are no differences in the performance of HCP clearance between recent enhanced downstream operations and traditional batch processing. This review includes best practices for developing improved processes.
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Affiliation(s)
- Takao Ito
- Life Science, Process Solutions, Merck Ltd. (An Affiliate of Merck KGaA, Darmstadt, Germany), Tokyo, Japan
| | - Herb Lutz
- Independent Consultant, Sudbury, Massachusetts, USA
| | - Lihan Tan
- Life Science Services, Sigma-Aldrich Pte Ltd, Singapore, Singapore
| | - Bin Wang
- Life Science, Process Solutions, Merck Chemicals (Shanghai) Co. Ltd. (An Affiliate of Merck KGaA Darmstadt, Germany), Shanghai, China
| | - Janice Tan
- Life Science, Process Solutions, Merck Pte Ltd. (An Affiliate of Merck KGaA, Darmstadt, Germany), Singapore
| | - Masum Patel
- Life Science, Process Solutions, Merck Life Sciences Pvt. Ltd. (An Affiliate of Merck KGaA, Darmstadt, Germany), Bangalore, India
| | - Lance Chen
- Life Science, Process Solutions, Merck Pte Ltd. (An Affiliate of Merck KGaA, Darmstadt, Germany), Singapore
| | - Yuki Tsunakawa
- Life Science, Process Solutions, Merck Ltd. (An Affiliate of Merck KGaA, Darmstadt, Germany), Tokyo, Japan
| | - Byunghyun Park
- Life Science, Process Solutions, Merck Ltd. (An Affiliate of Merck KGaA, Darmstadt, Germany), Seoul, South Korea
| | - Subhasis Banerjee
- Life Science, Process Solutions, Merck Life Sciences Pvt. Ltd. (An Affiliate of Merck KGaA, Darmstadt, Germany), Bangalore, India
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Li Z, Chen J, Martinez-Fonts K, Rauscher M, Rivera S, Welsh J, Kandula S. Cationic polymer precipitation for enhanced impurity removal in downstream processing. Biotechnol Bioeng 2023. [PMID: 37148495 DOI: 10.1002/bit.28416] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/30/2023] [Revised: 04/13/2023] [Accepted: 04/23/2023] [Indexed: 05/08/2023]
Abstract
Precipitation can be used for the removal of impurities early in the downstream purification process of biologics, with the soluble product remaining in the filtrate through microfiltration. The objective of this study was to examine the use of polyallylamine (PAA) precipitation to increase the purity of product via higher host cell protein removal to enhance polysorbate excipient stability to enable a longer shelf life. Experiments were performed using three monoclonal antibodies (mAbs) with different properties of isoelectric point and IgG subclass. High throughput workflows were established to quickly screen precipitation conditions as a function of pH, conductivity and PAA concentrations. Process analytical tools (PATs) were used to evaluate the size distribution of particles and inform the optimal precipitation condition. Minimal pressure increase was observed during depth filtration of the precipitates. The precipitation was scaled up to 20L size and the extensive characterization of precipitated samples after protein A chromatography showed >75% reduction of host cell protein (HCP) concentrations (by ELISA), >90% reduction of number of HCP species (by mass spectrometry), and >99.8% reduction of DNA. The stability of polysorbate containing formulation buffers for all three mAbs in the protein A purified intermediates was improved at least 25% after PAA precipitation. Mass spectrometry was used to obtain additional understanding of the interaction between PAA and HCPs with different properties. Minimal impact on product quality and <5% yield loss after precipitation were observed while the residual PAA was <9 ppm. These results expand the toolbox in downstream purification to solve HCP clearance issues for programs with purification challenges, while also providing important insights into the integration of precipitation-depth filtration and the current platform process for the purification of biologics.
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Affiliation(s)
- Zhao Li
- Biologics Process Development, Biologics Process Research and Development, Merck & Co., Inc., Rahway, New Jersey, USA
| | - Justin Chen
- Biologics Process Development, Biologics Process Research and Development, Merck & Co., Inc., Rahway, New Jersey, USA
| | - Kirby Martinez-Fonts
- Biologics Analytical Research and Development, Merck & Co., Inc., Rahway, New Jersey, USA
| | - Michael Rauscher
- Biologics Process Development, Biologics Process Research and Development, Merck & Co., Inc., Rahway, New Jersey, USA
| | - Shannon Rivera
- Analytical Research and Development Mass Spectrometry, Merck & Co., Inc., Rahway, New Jersey, USA
| | - John Welsh
- Biologics Process Development, Biologics Process Research and Development, Merck & Co., Inc., Rahway, New Jersey, USA
| | - Sunitha Kandula
- Biologics Process Development, Biologics Process Research and Development, Merck & Co., Inc., Rahway, New Jersey, USA
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Kanti Mal D, Nilaya Jonnalgadda P, Kant Chittela R, Chakraborty G. Utilization of Host Assisted Aggregation-Induced Emission of ANS Dye for ATP Sensing. J Mol Liq 2023. [DOI: 10.1016/j.molliq.2023.121402] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/10/2023]
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Chen S, Cheng R, Xu X, Kong C, Wang L, Fu R, Li J, Wang S, Zhang J. The structure and flocculation characteristics of a novel exopolysaccharide from a Paenibacillus isolate. Carbohydr Polym 2022; 291:119561. [DOI: 10.1016/j.carbpol.2022.119561] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/20/2021] [Revised: 02/28/2022] [Accepted: 04/28/2022] [Indexed: 11/30/2022]
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5
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Fluidized bed centrifugation of precipitated and flocculated cell cultures: An intensified clarification approach for monoclonal antibodies. J Biotechnol 2022; 352:16-25. [DOI: 10.1016/j.jbiotec.2022.05.004] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/08/2021] [Revised: 04/11/2022] [Accepted: 05/13/2022] [Indexed: 11/16/2022]
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6
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Jaffar-Aghaei M, Khanipour F, Maghsoudi A, Sarvestani R, Mohammadian M, Maleki M, Havasi F, Rahmani H, Karagah AH, Kazemali MR. QbD-guided pharmaceutical development of Pembrolizumab biosimilar candidate PSG-024 propelled to industry meeting primary requirements of comparability to Keytruda®. Eur J Pharm Sci 2022; 173:106171. [DOI: 10.1016/j.ejps.2022.106171] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/19/2021] [Revised: 02/13/2022] [Accepted: 03/17/2022] [Indexed: 11/03/2022]
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7
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Dryden WA, Larsen LM, Britt DW, Smith MT. Technical and economic considerations of cell culture harvest and clarification technologies. Biochem Eng J 2021. [DOI: 10.1016/j.bej.2020.107892] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/16/2022]
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8
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Saballus M, Nisser L, Kampmann M, Greller G. A novel clarification approach for intensified monoclonal antibody processes with 100 million cells/mL using a single-use fluidized bed centrifuge. Biochem Eng J 2021. [DOI: 10.1016/j.bej.2020.107887] [Citation(s) in RCA: 7] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/22/2023]
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Hammerschmidt N, Engelmaier H, Dattenböck C, Sencar J, Jungbauer A. Structured bottom section in inclined settlers for efficient continuous solid-liquid separation and washing of the solid fraction. Sep Purif Technol 2021. [DOI: 10.1016/j.seppur.2020.118142] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/24/2022]
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10
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Liu X, Yin H, Zhao J, Guo Z, Liu Z, Sang Y. Investigation of molecular weight effect on lignin flocculation induced by poly(diallyldimethylammonium chloride) (PDADMAC) through population balance modeling. Sep Purif Technol 2021. [DOI: 10.1016/j.seppur.2020.117569] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
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11
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Nadar S, Shooter G, Somasundaram B, Shave E, Baker K, Lua LHL. Intensified Downstream Processing of Monoclonal Antibodies Using Membrane Technology. Biotechnol J 2020; 16:e2000309. [PMID: 33006254 DOI: 10.1002/biot.202000309] [Citation(s) in RCA: 13] [Impact Index Per Article: 3.3] [Reference Citation Analysis] [Abstract] [Key Words] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/07/2022]
Abstract
The need to intensify downstream processing of monoclonal antibodies to complement the advances in upstream productivity has led to increased attention toward implementing membrane technologies. With the industry moving toward continuous operations and single use processes, membrane technologies show promise in fulfilling the industry needs due to their operational flexibility and ease of implementation. Recently, the applicability of membrane-based unit operations in integrating the downstream process has been explored. In this article, the major developments in the application of membrane-based technologies in the bioprocessing of monoclonal antibodies are reviewed. The recent progress toward developing intensified end-to-end bioprocesses and the critical role membrane technology will play in achieving this goal are focused upon.
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Affiliation(s)
- Sathish Nadar
- Australian Research Council Training Centre for Biopharmaceutical Innovation, Australian Institute for Bioengineering and Nanotechnology, The University of Queensland, Corner College and Cooper Roads, Brisbane, Queensland, 4072, Australia
| | - Gary Shooter
- Australian Research Council Training Centre for Biopharmaceutical Innovation, Australian Institute for Bioengineering and Nanotechnology, The University of Queensland, Corner College and Cooper Roads, Brisbane, Queensland, 4072, Australia
| | - Balaji Somasundaram
- Protein Expression Facility, The University of Queensland, Corner College and Cooper Roads, Brisbane, Queensland, 4072, Australia
| | - Evan Shave
- Australian Research Council Training Centre for Biopharmaceutical Innovation, Australian Institute for Bioengineering and Nanotechnology, The University of Queensland, Corner College and Cooper Roads, Brisbane, Queensland, 4072, Australia.,Pharma services group, Thermo Fisher Scientific, 37 Kent St, Woolloongabba, Brisbane, Queensland, 4102, Australia
| | - Kym Baker
- Pharma services group, Thermo Fisher Scientific, 37 Kent St, Woolloongabba, Brisbane, Queensland, 4102, Australia
| | - Linda H L Lua
- Australian Research Council Training Centre for Biopharmaceutical Innovation, Australian Institute for Bioengineering and Nanotechnology, The University of Queensland, Corner College and Cooper Roads, Brisbane, Queensland, 4072, Australia.,Protein Expression Facility, The University of Queensland, Corner College and Cooper Roads, Brisbane, Queensland, 4072, Australia
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12
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Hadpe SR, Mohite V, Alva S, Rathore AS. Pretreatments for enhancing clarification efficiency of depth filtration during production of monoclonal antibody therapeutics. Biotechnol Prog 2020; 36:e2996. [DOI: 10.1002/btpr.2996] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/24/2019] [Revised: 02/17/2020] [Accepted: 03/19/2020] [Indexed: 11/06/2022]
Affiliation(s)
- Sandeep R. Hadpe
- Research and Development Biocon Research Limited, Biocon Special Economic Zone Bangalore India
| | - Vipin Mohite
- Research and Development Biocon Research Limited, Biocon Special Economic Zone Bangalore India
| | - Solomon Alva
- Research and Development Biocon Research Limited, Biocon Special Economic Zone Bangalore India
| | - Anurag S. Rathore
- Department of Chemical Engineering Indian Institute of Technology New Delhi India
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13
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Cataldo A, Burgstaller D, Hribar G, Jungbauer A, Satzer P. Economics and ecology: Modelling of continuous primary recovery and capture scenarios for recombinant antibody production. J Biotechnol 2020; 308:87-95. [DOI: 10.1016/j.jbiotec.2019.12.001] [Citation(s) in RCA: 24] [Impact Index Per Article: 6.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/24/2019] [Revised: 11/27/2019] [Accepted: 12/02/2019] [Indexed: 11/28/2022]
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14
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Comparison of Cationic Flocculants for the Clarification of CHO-derived Monoclonal Antibodies. BIOTECHNOL BIOPROC E 2019. [DOI: 10.1007/s12257-019-0158-7] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/13/2023]
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16
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Application of a genome-scale model in tandem with enzyme assays for identification of metabolic signatures of high and low CHO cell producers. Metab Eng Commun 2019; 9:e00097. [PMID: 31720213 PMCID: PMC6838488 DOI: 10.1016/j.mec.2019.e00097] [Citation(s) in RCA: 8] [Impact Index Per Article: 1.6] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/11/2019] [Revised: 07/30/2019] [Accepted: 07/31/2019] [Indexed: 12/17/2022] Open
Abstract
Biopharmaceutical industrial processes are based on high yielding stable recombinant Chinese Hamster Ovary (CHO) cells that express monoclonal antibodies. However, the process and feeding regimes need to be adapted for each new cell line, as they all have a slightly different metabolism and product performance. A main limitation for accelerating process development is that the metabolic pathways underlying this physiological variability are not yet fully understood. This study describes the evolution of intracellular fluxes during the process for 4 industrial cell lines, 2 high producers and 2 low producers (n = 3), all of them producing a different antibody. In order to understand from a metabolic point of view the phenotypic differences observed, and to find potential targets for improving specific productivity of low producers, the analysis was supported by a tailored genome-scale model and was validated with enzymatic assays performed at different days of the process. A total of 59 reactions were examined from different key pathways, namely glycolysis, pentose phosphate pathway, TCA cycle, lipid metabolism, and oxidative phosphorylation. The intracellular fluxes did not show a metabolic correlation between high producers, but the degree of similitude observed between cell lines could be confirmed with additional experimental observations. The whole analysis led to a better understanding of the metabolic requirements for all the cell lines, allowed to the identification of metabolic bottlenecks and suggested targets for further cell line engineering. This study is a successful application of a curated genome-scale model to multiple industrial cell lines, which makes the metabolic model suitable for process platform.
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Patil R, Walther J. Continuous Manufacturing of Recombinant Therapeutic Proteins: Upstream and Downstream Technologies. ADVANCES IN BIOCHEMICAL ENGINEERING/BIOTECHNOLOGY 2019; 165:277-322. [PMID: 28265699 DOI: 10.1007/10_2016_58] [Citation(s) in RCA: 14] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 12/16/2022]
Abstract
Continuous biomanufacturing of recombinant therapeutic proteins offers several potential advantages over conventional batch processing, including reduced cost of goods, more flexible and responsive manufacturing facilities, and improved and consistent product quality. Although continuous approaches to various upstream and downstream unit operations have been considered and studied for decades, in recent years interest and application have accelerated. Researchers have achieved increasingly higher levels of process intensification, and have also begun to integrate different continuous unit operations into larger, holistically continuous processes. This review first discusses approaches for continuous cell culture, with a focus on perfusion-enabling cell separation technologies including gravitational, centrifugal, and acoustic settling, as well as filtration-based techniques. We follow with a review of various continuous downstream unit operations, covering categories such as clarification, chromatography, formulation, and viral inactivation and filtration. The review ends by summarizing case studies of integrated and continuous processing as reported in the literature.
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Affiliation(s)
- Rohan Patil
- Bioprocess Development, Sanofi, Framingham, MA, 01701, USA
| | - Jason Walther
- Bioprocess Development, Sanofi, Framingham, MA, 01701, USA.
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Singh N, Herzer S. Downstream Processing Technologies/Capturing and Final Purification : Opportunities for Innovation, Change, and Improvement. A Review of Downstream Processing Developments in Protein Purification. ADVANCES IN BIOCHEMICAL ENGINEERING/BIOTECHNOLOGY 2019; 165:115-178. [PMID: 28795201 DOI: 10.1007/10_2017_12] [Citation(s) in RCA: 8] [Impact Index Per Article: 1.6] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 12/12/2022]
Abstract
Increased pressure on upstream processes to maximize productivity has been crowned with great success, although at the cost of shifting the bottleneck to purification. As drivers were economical, focus is on now on debottlenecking downstream processes as the main drivers of high manufacturing cost. Devising a holistically efficient and economical process remains a key challenge. Traditional and emerging protein purification strategies with particular emphasis on methodologies implemented for the production of recombinant proteins of biopharmaceutical importance are reviewed. The breadth of innovation is addressed, as well as the challenges the industry faces today, with an eye to remaining impartial, fair, and balanced. In addition, the scope encompasses both chromatographic and non-chromatographic separations directed at the purification of proteins, with a strong emphasis on antibodies. Complete solutions such as integrated USP/DSP strategies (i.e., continuous processing) are discussed as well as gains in data quantity and quality arising from automation and high-throughput screening (HTS). Best practices and advantages through design of experiments (DOE) to access a complex design space such as multi-modal chromatography are reviewed with an outlook on potential future trends. A discussion of single-use technology, its impact and opportunities for further growth, and the exciting developments in modeling and simulation of DSP rounds out the overview. Lastly, emerging trends such as 3D printing and nanotechnology are covered. Graphical Abstract Workflow of high-throughput screening, design of experiments, and high-throughput analytics to understand design space and design space boundaries quickly. (Reproduced with permission from Gregory Barker, Process Development, Bristol-Myers Squibb).
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Affiliation(s)
- Nripen Singh
- Bristol-Myers Squibb, Global Manufacturing and Supply, Devens, MA, 01434, USA.
| | - Sibylle Herzer
- Bristol-Myers Squibb, Global Manufacturing and Supply, Hopewell, NJ, 01434, USA
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Khodadadian M, Ghassemi M, Behrouz H, Maleknia S, Mahboudi F. Determination of residual poly diallyldimethylammonium chloride (pDADMAC) in monoclonal antibody formulations by size exclusion chromatography and evaporative light scattering detector. Biologicals 2018; 57:21-28. [PMID: 30447860 DOI: 10.1016/j.biologicals.2018.11.002] [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: 06/05/2018] [Revised: 09/21/2018] [Accepted: 11/09/2018] [Indexed: 10/27/2022] Open
Abstract
The cationic polyelectrolyte pDADMAC is widely used in biopharmaceutical industry as a flocculating agent to enhance clarification throughput and downstream filtration operations. Due to the possible toxicity, pDADMAC should be assessed for an acceptable residual level to ascertain the safety of the product to patients. The strong protein-polyelectrolyte interaction, however, can negatively affect sensitivity and accuracy of measurements. This paper reports on the application of size exclusion (SE) chromatography coupled to evaporative light scattering detector (ELSD) to the quantitative determination of pDADMAC in monoclonal antibody formulations and in process intermediates during downstream purification. The SE chromatography was performed under isocratic condition with a mobile phase consisting of 0.1% TFA in water (90%) and acetonitrile (10%) at a flow rate of 0.4 ml/min. A quantification limit (S/N = 10) of 0.85 ppm was achieved in sample matrix, which is sufficiently low for the trace analysis of this compound in protein-containing samples.
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Affiliation(s)
- Mehdi Khodadadian
- Biopharmaceutical Research Center, AryoGen Pharmed Inc., Alborz University of Medical Sciences, Karaj, Iran.
| | - Maryam Ghassemi
- Biopharmaceutical Research Center, AryoGen Pharmed Inc., Alborz University of Medical Sciences, Karaj, Iran
| | - Hossein Behrouz
- Biopharmaceutical Research Center, AryoGen Pharmed Inc., Alborz University of Medical Sciences, Karaj, Iran
| | - Shayan Maleknia
- Biopharmaceutical Research Center, AryoGen Pharmed Inc., Alborz University of Medical Sciences, Karaj, Iran
| | - Fereidoun Mahboudi
- Biopharmaceutical Research Center, AryoGen Pharmed Inc., Alborz University of Medical Sciences, Karaj, Iran
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Burgstaller D, Krepper W, Haas J, Maszelin M, Mohoric J, Pajnic K, Jungbauer A, Satzer P. Continuous cell flocculation for recombinant antibody harvesting. JOURNAL OF CHEMICAL TECHNOLOGY AND BIOTECHNOLOGY (OXFORD, OXFORDSHIRE : 1986) 2018; 93:1881-1890. [PMID: 30008503 PMCID: PMC6033189 DOI: 10.1002/jctb.5500] [Citation(s) in RCA: 18] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 09/20/2017] [Revised: 10/31/2017] [Accepted: 10/31/2017] [Indexed: 06/08/2023]
Abstract
BACKGROUND Integrated continuous production technology is of great interest in biopharmaceutical industry. Efficient, flexible and cost effective methods for continuous cell removal have to be developed, before a fully continuous and integrated product train can be realized. The paper describes the development and testing of such an integrated continuous and disposable set-up for cell separation by flocculation combined with depth filtration. RESULTS Screening of multiple flocculation agents, depth filters, and conditions demonstrated that the best performance was obtained with 0.0375% polydiallyldimethylammonium chloride (pDADMAC; a polycationic flocculation agent) in combination with Clarisolve® depth filters. Using this set-up, a 4-fold decrease of filtration area was achieved relative to standard filtration without flocculation, with yields of ≥97% and DNA depletion of up to 99%. Continuous operation was accomplished using a simple tubular reactor design with parallelization of the filtration. The reactor length was selected to allow a 13.2-min residence time, which was sufficient to complete flocculation in batch experiments. Continuous flocculation performance was monitored on-line using focused beam reflectance measurement. Filter switch cycles based on upstream pressure were controlled by in-line pressure sensors, and were stable from one filter to the next. CONCLUSION It was demonstrated that stable and efficient continuous flocculation associated with depth filtration can be easily accomplished using tubular reactors and parallelization. Continuous cell separation is essential for the development of fully continuous integrated process trains. This cost-efficient disposable design run in continuous mode significantly reduces facility foot print, process costs and enables great flexbility. © 2017 The Authors. Journal of Chemical Technology & Biotechnology published by John Wiley & Sons Ltd on behalf of Society of Chemical Industry.
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Affiliation(s)
- Daniel Burgstaller
- Department of BiotechnologyUniversity of Natural Resources and Life Sciences, Vienna (BOKU)ViennaAustria
| | - Walpurga Krepper
- Department of BiotechnologyUniversity of Natural Resources and Life Sciences, Vienna (BOKU)ViennaAustria
| | | | | | | | | | - Alois Jungbauer
- Department of BiotechnologyUniversity of Natural Resources and Life Sciences, Vienna (BOKU)ViennaAustria
- Austrian Centre of Industrial Biotechnology (ACIB)ViennaAustria
| | - Peter Satzer
- Department of BiotechnologyUniversity of Natural Resources and Life Sciences, Vienna (BOKU)ViennaAustria
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21
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Flocculation of CHO cells for primary separation of recombinant glycoproteins: Effect on glycosylation profiles. Biochem Eng J 2018. [DOI: 10.1016/j.bej.2018.01.027] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/16/2022]
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22
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Shukla AA, Wolfe LS, Mostafa SS, Norman C. Evolving trends in mAb production processes. Bioeng Transl Med 2017; 2:58-69. [PMID: 29313024 PMCID: PMC5689530 DOI: 10.1002/btm2.10061] [Citation(s) in RCA: 138] [Impact Index Per Article: 19.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/11/2016] [Revised: 02/24/2017] [Accepted: 03/06/2017] [Indexed: 12/30/2022] Open
Abstract
Monoclonal antibodies (mAbs) have established themselves as the leading biopharmaceutical therapeutic modality. The establishment of robust manufacturing platforms are key for antibody drug discovery efforts to seamlessly translate into clinical and commercial successes. Several drivers are influencing the design of mAb manufacturing processes. The advent of biosimilars is driving a desire to achieve lower cost of goods and globalize biologics manufacturing. High titers are now routinely achieved for mAbs in mammalian cell culture. These drivers have resulted in significant evolution in process platform approaches. Additionally, several new trends in bioprocessing have arisen in keeping with these needs. These include the consideration of alternative expression systems, continuous biomanufacturing and non‐chromatographic separation formats. This paper discusses these drivers in the context of the kinds of changes they are driving in mAb production processes.
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Affiliation(s)
- Abhinav A Shukla
- Process Development & Manufacturing KBI Biopharma Inc.Durham NC 27704
| | - Leslie S Wolfe
- Process Development & Manufacturing KBI Biopharma Inc.Durham NC 27704
| | - Sigma S Mostafa
- Process Development & Manufacturing KBI Biopharma Inc.Durham NC 27704
| | - Carnley Norman
- Process Development & Manufacturing KBI Biopharma Inc.Durham NC 27704
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23
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Continuous polyethylene glycol precipitation of recombinant antibodies: Sequential precipitation and resolubilization. Process Biochem 2016. [DOI: 10.1016/j.procbio.2015.11.032] [Citation(s) in RCA: 52] [Impact Index Per Article: 6.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Submit a Manuscript] [Subscribe] [Scholar Register] [Indexed: 01/03/2023]
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24
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Advance chromatin extraction improves capture performance of protein A affinity chromatography. J Chromatogr A 2016; 1431:1-7. [DOI: 10.1016/j.chroma.2015.12.044] [Citation(s) in RCA: 35] [Impact Index Per Article: 4.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/03/2015] [Revised: 12/15/2015] [Accepted: 12/16/2015] [Indexed: 11/21/2022]
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25
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Yang WC, Minkler DF, Kshirsagar R, Ryll T, Huang YM. Concentrated fed-batch cell culture increases manufacturing capacity without additional volumetric capacity. J Biotechnol 2015; 217:1-11. [PMID: 26521697 DOI: 10.1016/j.jbiotec.2015.10.009] [Citation(s) in RCA: 64] [Impact Index Per Article: 7.1] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/21/2015] [Revised: 10/06/2015] [Accepted: 10/12/2015] [Indexed: 11/19/2022]
Abstract
Biomanufacturing factories of the future are transitioning from large, single-product facilities toward smaller, multi-product, flexible facilities. Flexible capacity allows companies to adapt to ever-changing pipeline and market demands. Concentrated fed-batch (CFB) cell culture enables flexible manufacturing capacity with limited volumetric capacity; it intensifies cell culture titers such that the output of a smaller facility can rival that of a larger facility. We tested this hypothesis at bench scale by developing a feeding strategy for CFB and applying it to two cell lines. CFB improved cell line A output by 105% and cell line B output by 70% compared to traditional fed-batch (TFB) processes. CFB did not greatly change cell line A product quality, but it improved cell line B charge heterogeneity, suggesting that CFB has both process and product quality benefits. We projected CFB output gains in the context of a 2000-L small-scale facility, but the output was lower than that of a 15,000-L large-scale TFB facility. CFB's high cell mass also complicated operations, eroded volumetric productivity, and showed our current processes require significant improvements in specific productivity in order to realize their full potential and savings in manufacturing. Thus, improving specific productivity can resolve CFB's cost, scale-up, and operability challenges.
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Affiliation(s)
- William C Yang
- Biogen, Inc., Cell Culture Development, 5000 Davis Drive, Research Triangle Park, NC 27709, United States.
| | - Daniel F Minkler
- Biogen, Inc., Cell Culture Development, 5000 Davis Drive, Research Triangle Park, NC 27709, United States
| | - Rashmi Kshirsagar
- Biogen, Inc., Cell Culture Development, 14 Cambridge Center, Cambridge, MA 02142, United States
| | - Thomas Ryll
- Biogen, Inc., Cell Culture Development, 14 Cambridge Center, Cambridge, MA 02142, United States
| | - Yao-Ming Huang
- Biogen, Inc., Cell Culture Development, 5000 Davis Drive, Research Triangle Park, NC 27709, United States
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Singh N, Arunkumar A, Chollangi S, Tan ZG, Borys M, Li ZJ. Clarification technologies for monoclonal antibody manufacturing processes: Current state and future perspectives. Biotechnol Bioeng 2015; 113:698-716. [DOI: 10.1002/bit.25810] [Citation(s) in RCA: 66] [Impact Index Per Article: 7.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/11/2015] [Revised: 08/20/2015] [Accepted: 08/20/2015] [Indexed: 01/15/2023]
Affiliation(s)
- Nripen Singh
- Biologics Development; Global Manufacturing and Supply, Bristol-Myers Squibb; 35 South Street Hopkinton Massachusetts 01748
| | - Abhiram Arunkumar
- Biologics Development; Global Manufacturing and Supply, Bristol-Myers Squibb; 35 South Street Hopkinton Massachusetts 01748
| | - Srinivas Chollangi
- Biologics Development; Global Manufacturing and Supply, Bristol-Myers Squibb; 35 South Street Hopkinton Massachusetts 01748
| | - Zhijun George Tan
- Biologics Development; Global Manufacturing and Supply, Bristol-Myers Squibb; 35 South Street Hopkinton Massachusetts 01748
| | - Michael Borys
- Biologics Development; Global Manufacturing and Supply, Bristol-Myers Squibb; 35 South Street Hopkinton Massachusetts 01748
| | - Zheng Jian Li
- Biologics Development; Global Manufacturing and Supply, Bristol-Myers Squibb; 35 South Street Hopkinton Massachusetts 01748
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Senczuk A, Petty K, Thomas A, McNerney T, Moscariello J, Yigzaw Y. Evaluation of predictive tools for cell culture clarification performance. Biotechnol Bioeng 2015; 113:568-75. [PMID: 26332572 DOI: 10.1002/bit.25819] [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: 04/19/2015] [Revised: 07/24/2015] [Accepted: 08/28/2015] [Indexed: 11/11/2022]
Abstract
Recent advances in the productivity of industrial mammalian cell culture processes have resulted in part in increased cell density. This increase and the associated increase in cellular debris are known to challenge harvest operations, however this understanding is limited and largely qualitative. Part of the issue arises from the heterogeneous size and composition of cellular debris, which makes harvest feed stream extremely difficult to characterize. Improved characterization methods would facilitate the development of clarification approaches that are consistent and scalable. This work describes how both particle size and cholesterol analysis can be used to characterize the feed stream. Particle size analysis by focused beam reflectance and dynamic light scattering are shown to be predictive of centrate filterability under certain harvest conditions. Because of the particle size range limitations of each detector, their applicability is limited to a particular stage or method of clarification. The measurement of cholesterol present in the cell culture supernatant or centrate was successfully used in providing relative amount of lysed cellular debris and enabled us to predict clarification performance of acid precipitated harvest regardless of particle size distribution profile.
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Affiliation(s)
- Anna Senczuk
- Process Development, Takeda Vaccines Inc., Bozeman.
| | - Krista Petty
- Drug Substance Development, Amgen Inc., Thousand Oaks, California
| | - Anne Thomas
- Drug Substance Development, Amgen Inc., Seattle, Washington
| | | | | | - Yinges Yigzaw
- Purification Development, Genentech Inc., South San Francisco, California
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28
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Olsvik PA, Berntssen MHG, Waagbø R, Hevrøy E, Søfteland L. The mining chemical Polydadmac is cytotoxic but does not interfere with Cu-induced toxicity in Atlantic salmon hepatocytes. Toxicol In Vitro 2015; 30:492-505. [PMID: 26368670 DOI: 10.1016/j.tiv.2015.09.012] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/04/2015] [Revised: 08/27/2015] [Accepted: 09/01/2015] [Indexed: 11/19/2022]
Abstract
To speed up sedimentation of suspended solids the mining industry often uses flocculent chemicals. In this work we evaluated the cytotoxic and mechanistic effects of Polydadmac, and its basic component Dadmac, on fish cells. Dose-response effects, temperature-dependent effects and impact of Dadmac and Polydadmac on Cu toxicity were studied in Atlantic salmon hepatocytes. We used the xCELLigence system and the MTT test for cytotoxicity assessments, and real-time RT-qPCR to evaluate molecular effects. The results showed a cytotoxic response for Polydadmac but not for Dadmac. Elevated levels of Cu were cytotoxic. Moderately cytotoxic concentrations of Cu (100-1000 μM) induced significant responses on the transcription of a number of genes in the cells, i.e. cuznsod (sod1), cat, mnsod (sod2), nfe2l2, hmox1, mta, casp3b, casp6, bclx, cyp1a, ccs, atp7a, app, mmp13, esr1, ppara, fads2 and ptgs2. A factorial PLS regression model for mnsod transcription showed a synergistic effect between Dadmac and Cu exposure in the cells, indicating an interaction effect between Dadmac and Cu on mitochondrial ROS scavenging. No interaction effects were seen for Polydadmac on Cu toxicity. In conclusion, Polydadmac is cytotoxic at elevated concentrations but appears to have low ability to interfere with Cu toxicity in Atlantic salmon liver cells.
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Affiliation(s)
- Pål A Olsvik
- National Institute of Nutrition and Seafood Research, N-5817 Bergen, Norway.
| | - Marc H G Berntssen
- National Institute of Nutrition and Seafood Research, N-5817 Bergen, Norway
| | - Rune Waagbø
- National Institute of Nutrition and Seafood Research, N-5817 Bergen, Norway
| | - Ernst Hevrøy
- National Institute of Nutrition and Seafood Research, N-5817 Bergen, Norway; EWOS AS, N-5803 Bergen, Norway
| | - Liv Søfteland
- National Institute of Nutrition and Seafood Research, N-5817 Bergen, Norway
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29
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The present state of the art in expression, production and characterization of monoclonal antibodies. Mol Divers 2015; 20:255-70. [DOI: 10.1007/s11030-015-9625-z] [Citation(s) in RCA: 36] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/14/2015] [Accepted: 07/21/2015] [Indexed: 02/01/2023]
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