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Crowell LE, Rodriguez SA, Love KR, Cramer SM, Love JC. Rapid optimization of processes for the integrated purification of biopharmaceuticals. Biotechnol Bioeng 2021; 118:3435-3446. [PMID: 33782945 PMCID: PMC8453909 DOI: 10.1002/bit.27767] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/18/2020] [Revised: 03/11/2021] [Accepted: 03/18/2021] [Indexed: 11/07/2022]
Abstract
Straight‐through chromatography, wherein the eluate from one column passes directly onto another column without adjustment, is one strategy to integrate and intensify manufacturing processes for biologics. Development and optimization of such straight‐through chromatographic processes is a challenge, however. Conventional high‐throughput screening methods optimize each chromatographic step independently, with limited consideration for the connectivity of steps. Here, we demonstrate a method for the development and optimization of fully integrated, multi‐column processes for straight‐through purification. Selection of resins was performed using an in silico tool for the prediction of processes for straight‐through purification based on a one‐time characterization of host‐cell proteins combined with the chromatographic behavior of the product. A two‐step optimization was then conducted to determine the buffer conditions that maximized yield while minimizing process‐ and product‐related impurities. This optimization of buffer conditions included a series of range‐finding experiments on each individual column, similar to conventional screening, followed by the development of a statistical model for the fully integrated, multi‐column process using design of experiments. We used this methodology to develop and optimize integrated purification processes for a single‐domain antibody and a cytokine, obtaining yields of 88% and 86%, respectively, with process‐ and product‐related variants reduced to phase‐appropriate levels for nonclinical material.
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Affiliation(s)
- Laura E. Crowell
- Koch Institute for Integrative Cancer ResearchMassachusetts Institute of TechnologyCambridgeMassachusettsUSA
- Department of Chemical EngineeringMassachusetts Institute of TechnologyCambridgeMassachusettsUSA
| | - Sergio A. Rodriguez
- Koch Institute for Integrative Cancer ResearchMassachusetts Institute of TechnologyCambridgeMassachusettsUSA
- Department of Biological EngineeringMassachusetts Institute of TechnologyCambridgeMassachusettsUSA
| | - Kerry R. Love
- Koch Institute for Integrative Cancer ResearchMassachusetts Institute of TechnologyCambridgeMassachusettsUSA
| | - Steven M. Cramer
- Department of Chemical and Biological EngineeringRensselaer Polytechnic InstituteTroyNew YorkUSA
- Center for Biotechnology and Interdisciplinary StudiesRensselaer Polytechnic InstituteTroyNew YorkUSA
| | - J. Christopher Love
- Koch Institute for Integrative Cancer ResearchMassachusetts Institute of TechnologyCambridgeMassachusettsUSA
- Department of Chemical EngineeringMassachusetts Institute of TechnologyCambridgeMassachusettsUSA
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Kateja N, Tiwari A, Thakur G, Rathore AS. Complete or periodic continuity in continuous manufacturing platforms for production of monoclonal antibodies? Biotechnol J 2021; 16:e2000524. [PMID: 33773062 DOI: 10.1002/biot.202000524] [Citation(s) in RCA: 12] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/14/2020] [Revised: 03/21/2021] [Accepted: 03/22/2021] [Indexed: 11/09/2022]
Abstract
BACKGROUND Monoclonal antibodies (mAbs) currently dominate the biotherapeutic market. This has resulted in significant efforts towards the development of a continuous integrated platform for the manufacturing of mAbs. MAIN METHODS AND MAJOR RESULTS In this study, a continuous mAb platform has been developed consisting of an Acoustic Wave Separator, a Cadence BioSMB PD system, a customized coiled flow reactor, a modular single-pass TFF kit, an in-line diafiltration module, and a continuous dead-end filtration skid. A three-step chromatographic purification was performed in the platform consisting of Protein A capture chromatography followed by an anion exchange membrane directly coupled to a cation exchange chromatography. Two operational case studies have been executed on the platform, namely complete continuous ("CC") and periodic continuous ("PC") modes of operation. The CC mode was designed to ensure that each unit operation had completely continuous inflow and outflow by increasing the number of columns, filtration modules and tanks, while the PC mode operated in periodic pulses with scheduled flow and hold steps. Both modes were designed to handle the same flow rate and titers from the upstream bioreactor or fed-batch harvest tank, and were compared in terms of productivity and operational complexity. Both modes offer viable options for continuous processing of mAbs and result in achievement of target critical quality attribute profiles of the final drug product over 24 h of operation. CONCLUSIONS AND IMPLICATIONS It was found that the CC mode was superior in terms of specific productivity (20-50% higher) and consumable utilization (20% lower resin utilization), while the PC mode was operationally simpler and had lower facility costs due to significant reductions in the number of auxiliary equipment (pumps, columns, tanks, and valves). The work successfully highlighted the pros and cons of both approaches, and demonstrates that while several groups have amply shown the superiority of continuous processing over batch mode, there are intermediate variants which may be optimal in a given situation.
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Affiliation(s)
- Nikhil Kateja
- Department of Chemical Engineering, Indian Institute of Technology Delhi, Hauz Khas, India
| | - Anamika Tiwari
- Department of Chemical Engineering, Indian Institute of Technology Delhi, Hauz Khas, India
| | - Garima Thakur
- Department of Chemical Engineering, Indian Institute of Technology Delhi, Hauz Khas, India
| | - Anurag S Rathore
- Department of Chemical Engineering, Indian Institute of Technology Delhi, Hauz Khas, India
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Crowell LE, Goodwine C, Holt CS, Rocha L, Vega C, Rodriguez SA, Dalvie NC, Tracey MK, Puntel M, Wigdorovitz A, Parreño V, Love KR, Cramer SM, Love JC. Development of a platform process for the production and purification of single-domain antibodies. Biotechnol Bioeng 2021; 118:3348-3358. [PMID: 33624832 PMCID: PMC8451865 DOI: 10.1002/bit.27724] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/18/2020] [Revised: 01/15/2021] [Accepted: 02/19/2021] [Indexed: 01/14/2023]
Abstract
Single‐domain antibodies (sdAbs) offer the affinity and therapeutic value of conventional antibodies, with increased stability and solubility. Unlike conventional antibodies, however, sdAbs do not benefit from a platform manufacturing process. While successful production of a variety of sdAbs has been shown in numerous hosts, purification methods are often molecule specific or require affinity tags, which generally cannot be used in clinical manufacturing due to regulatory concerns. Here, we have developed a broadly applicable production and purification process for sdAbs in Komagataella phaffii (Pichia pastoris) and demonstrated the production of eight different sdAbs at a quality appropriate for nonclinical studies. We developed a two‐step, integrated purification process without the use of affinity resins and showed that modification of a single process parameter, pH of the bridging buffer, was required for the successful purification of a variety of sdAbs. Further, we determined that this parameter can be predicted based only on the biophysical characteristics of the target molecule. Using these methods, we produced nonclinical quality sdAbs as few as 5 weeks after identifying the product sequence. Nonclinical studies of three different sdAbs showed that molecules produced using our platform process conferred protection against viral shedding of rotavirus or H1N1 influenza and were equivalent to similar molecules produced in Escherichia coli and purified using affinity tags.
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Affiliation(s)
- Laura E Crowell
- Koch Institute for Integrative Cancer Research, Massachusetts Institute of Technology, Cambridge, Massachusetts, USA.,Department of Chemical Engineering, Massachusetts Institute of Technology, Cambridge, Massachusetts, USA
| | - Chaz Goodwine
- Department of Chemical and Biological Engineering, Rensselaer Polytechnic Institute, Troy, New York, USA.,Center for Biotechnology and Interdisciplinary Studies, Rensselaer Polytechnic Institute, Troy, New York, USA
| | - Carla S Holt
- Instituto de Virología, Investigación en Ciencias Veterinarias y Agronómicas, Instituto Nacional de Tecnología Agropecuaria, Buenos Aires, Argentina
| | - Lucia Rocha
- Instituto de Virología, Investigación en Ciencias Veterinarias y Agronómicas, Instituto Nacional de Tecnología Agropecuaria, Buenos Aires, Argentina
| | - Celina Vega
- Instituto de Virología, Investigación en Ciencias Veterinarias y Agronómicas, Instituto Nacional de Tecnología Agropecuaria, Buenos Aires, Argentina
| | - Sergio A Rodriguez
- Koch Institute for Integrative Cancer Research, Massachusetts Institute of Technology, Cambridge, Massachusetts, USA.,Department of Biological Engineering, Massachusetts Institute of Technology, Cambridge, Massachusetts, USA
| | - Neil C Dalvie
- Koch Institute for Integrative Cancer Research, Massachusetts Institute of Technology, Cambridge, Massachusetts, USA.,Department of Chemical Engineering, Massachusetts Institute of Technology, Cambridge, Massachusetts, USA
| | - Mary K Tracey
- Koch Institute for Integrative Cancer Research, Massachusetts Institute of Technology, Cambridge, Massachusetts, USA
| | - Mariana Puntel
- Instituto de Virología, Investigación en Ciencias Veterinarias y Agronómicas, Instituto Nacional de Tecnología Agropecuaria, Buenos Aires, Argentina
| | - Andrés Wigdorovitz
- Instituto de Virología, Investigación en Ciencias Veterinarias y Agronómicas, Instituto Nacional de Tecnología Agropecuaria, Buenos Aires, Argentina
| | - Viviana Parreño
- Instituto de Virología, Investigación en Ciencias Veterinarias y Agronómicas, Instituto Nacional de Tecnología Agropecuaria, Buenos Aires, Argentina
| | - Kerry R Love
- Koch Institute for Integrative Cancer Research, Massachusetts Institute of Technology, Cambridge, Massachusetts, USA
| | - Steven M Cramer
- Department of Chemical and Biological Engineering, Rensselaer Polytechnic Institute, Troy, New York, USA.,Center for Biotechnology and Interdisciplinary Studies, Rensselaer Polytechnic Institute, Troy, New York, USA
| | - J Christopher Love
- Koch Institute for Integrative Cancer Research, Massachusetts Institute of Technology, Cambridge, Massachusetts, USA.,Department of Chemical Engineering, Massachusetts Institute of Technology, Cambridge, Massachusetts, USA
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