Optimized single-step affinity purification with a self-cleaving intein applied to human acidic fibroblast growth factor

To reduce the number of recovery steps during downstream processing and to overcome the limitations of present fusion-based affinity separations, a controllable self-splicing protein element in the form of a mini-intein was used to optimize the recovery of proteins for both batch and flow purification strategies. The ability to recover purified proteins was demonstrated using a tripartite fusion consisting of a maltose binding domain, a truncated intein as a controllable linker molecule, and a protein of interest. To characterize expression level, solubility, cleavage rates, pH and temperature controllability, and protein activity, recombinant human acidic fibroblast growth factor (aFGF) was used as a model protein. A simple mass transport model, based on cleavage reaction-limited mass transfer and constant dispersion, was successfully used to predict product concentration and peak shape in relation to critical process parameters (with no fitting parameters). Insight into the nature of the cleavage reaction and its regulation was obtained via temperature- and pH-dependent kinetic data.

Protein transmission during Dean vortex microfiltration of yeast suspensions

Substantially higher rates of protein and fluid volume transport for microfiltration of yeast suspensions were possible with improved hydrodynamics using centrifugal fluid instabilities called Dean vortices. Under constant permeate flux operation with suspended yeast cells, a helical module exhibited 19 times the filtration capacity of a linear module. For feed containing both BSA and beer yeast under constant transmembrane pressure with diafiltration, about twice as much protein (BSA and other proteins from cell lysis) was transported out of the feed by the helical module as compared with the linear module. The volumetric permeation flux improvements for the helical over the linear module ranged from 18 to 43% for yeast concentrations up to 4.5 dry wt %.

A new coiled hollow-fiber module design for enhanced microfiltration performance in biotechnology

The microfiltration performance of a novel membrane module design with helically wound hollow fibers is compared with that obtained with a standard commercial-type crossflow module containing linear hollow fibers. Cell suspensions (yeast, E. coli, and mammalian cell cultures) commonly clarified in the biotechnology industry are used for this comparison. The effect of variables such as transmembrane pressure, particle suspension concentration, and feed flow rate on membrane performance is evaluated. Normalized permeation fluxes versus flow rate or Dean number behave according to a heat transfer correlation obtained with centrifugal instabilities of the Taylor type. The microfiltration performance of this new module design, which uses secondary flows in helical tubes, is significantly better than an equivalent current commercial crossflow module when filtering suspensions relevant to the biotechnology industry. Flux and capacity improvements of up to 3.2-fold (constant transmembrane pressure operation) and 3.9-fold (constant flux operation), respectively, were obtained with the helical module over those for the linear module.

A genetic system yields self-cleaving inteins for bioseparations

A self-cleaving element for use in bioseparations has been derived from a naturally occurring, 43 kDa protein splicing element (intein) through a combination of protein engineering and random mutagenesis. A mini-intein (18 kDa) previously engineered for reduced size had compromised activity and was therefore subjected to random mutagenesis and genetic selection. In one selection a mini-intein was isolated with restored splicing activity, while in another, a mutant was isolated with enhanced, pH-sensitive C-terminal cleavage activity. The enhanced-cleavage mutant has utility in affinity fusion-based protein purification. These mutants also provide new insights into the structural and functional roles of some conserved residues in protein splicing.

Comparison of ultra- and microfiltration in the presence and absence of secondary flow with polysaccharides, proteins, and yeast suspensions

The purpose of this research was to show that controlled centrifugal instabilities-Dean vortices-produced by solutions and suspensions from typical biotechnology applications flowing through curved tubes can be used to reduce concentration polarization and/or fouling in pressure-driven ultrafiltration (UF) and microfiltration (MF) processes. Experiments were conducted to (i) evaluate the ultrafiltration performance of hollow fiber membranes in linear and helical configurations with dextran (low fouling) and bovine serum albumin (high fouling) solutions and (ii) compare the performance of linear and helical coiled UF hollow fiber modules with that of similar MF modules using baker's and beer yeast (Saccharomyces cerevisiae) suspensions as feed. Both constant transmembrane pressure (TMP) and constant permeation flux (J) experiments were utilized here. The membrane material was polyether sulfone. For the ultrafiltration experiments, the helical module performed consistently better than the linear module with dextran T500 and BSA solutions, resulting in performance improvements (helical versus linear) from 20 to 200% and up to 85%, respectively. For the comparative experiments between UF and MF, the helical module again performed better than the linear module for low concentration baker's yeast suspensions (0.5-1% dry wt). At constant TMP, the flux improvements for UF were 30-120%, while at constant J, the capacity or loading was 4.5 times higher for the UF as compared to the MF membrane. At high beer yeast concentrations (5.1-6.8% dry wt), although flux improvements were not observed between the linear and helical modules for UF, the UF fluxes were 72% higher than that obtained with MF. Also, for MF, with the same high beer yeast concentrations, the helical module exhibited 30-90% higher fluxes than that obtained with the linear module. At constant flux (117-137 L m-2 h-1) and intermediate baker's yeast concentrations (0.65-2.7% dry wt), 10-20 times the capacity was obtained for the helical over the linear module. Yeast cells were the dominant foulant. For constant UF flux (70 L m-2 h-1) experiments at high beer yeast concentrations ((4.3-7.7) x 10(7) cells/mL or 5.1-6.8% dry wt), the capacity (loading) for the helical module was 10 times that of the linear module. Again, the yeast cells were the dominant foulant. A new mass-transfer correlation for ultrafiltration of dextran T500 solutions for laminar flow in a helical hollow fiber module was obtained, viz. Sh = 0.173Re0.55Sc0.33(a/Rc)0.07.

Optimizing antibody production in batch hybridoma cell culture

Optimizing productivity by hybridoma cells relies partly on developing suitable methods for screening and selection of high producing cultures and on understanding regulation of antibody production. In this study, the behavior of hybridoma cells in batch culture was investigated using flow cytometry, and a simple model for antibody production was used to explain production data obtained from these cultures. Surface antibody fluorescence values were found to closely follow the decreasing trend of specific antibody secretion rate over the course of several batch cultures. Therefore, for the hybridoma cell lines studied here (ATCC HB124 and TIB138), surface immunofluorescence levels can be used to select high producing cells as well as to monitor culture productivity. Surface and intracellular antibody fluorescence values were also found to be correlated for cells exhibiting a bimodal distribution with respect to intracellular antibody content. The population of cells containing a bimodal distribution with respect to intracellular antibody content. The population of cells containing lower levels of intracellular antibody was determined to secrete significantly less antibody than the population possessing high intracellular antibody concentrations. Factors which influence antibody production rates and possible strategies for optimizing monoclonal antibody yield are discussed.

High-rate membrane supported aqueous-phase enzymatic conversion in organic solvent

Microporous membranes were used as a support material for enzyme immobilization by a supported aqueous-phase. To test the concept, a model reaction was chosen involving the oxidation of p-cresol by tyrosinase. Tyrosinase was first immobilized in a thin film of water formed on the inner surface of the membrane and then allowed to catalyze p-cresol oxidation in chloroform. By choosing optimal operating conditions, tyrosinase functioned catalytically for more than 6 hours with a stable reaction rate. The reaction rate was highly dependent on water content (water wt./enzyme wt. ratio) and permeation flux. Also, enzyme loading was an important factor for maintaining stable activity. This type of high-rate reactor utilized convective flow through an enzyme immobilized microporous membrane and provided high productivity by reducing mass transport limitations.

Attractive and repulsive interactions between and within adsorbed ribonuclease A layers

Adsorbed layers of pancreatic RNase A on molecularly smooth mica in aqueous solution attract inorganic mica surfaces whereas they repel similarly adsorbed RNase A layers. As the clean mica surface is covered with RNase A, the attractive interaction slowly diminishes with time and eventually converts to a purely repulsive interaction. Solvent is squeezed out of the solution in the gap during compression of the two surfaces so that the adsorbed protein concentration, as measured directly by the refractive index, increases significantly. The kinetics of this process is analyzed using surface force-distance measurements. All these results are predicted for constrained equilibrium by a discrete lattice model [Scheutjens, J. M. H. M. & Fleer, G. J. (1985) Macromolecules 18, 1882-1900]. Reasonable values are obtained for the constants of the model. We also report on the equilibrium behavior and interaction of densely adsorbed RNase A layers in aqueous solutions of varying ionic strength and pH. With increasing ionic strength, intramolecular forces dominate with diminished electrostatic repulsion. Thus, the adsorbed protein layer becomes more compact while unattached protein molecules coil and fold, making them less likely to form strong intermolecular bridges. Only at very low ionic strength (0.1 mM KCl), when electrostatic forces dominate, does the membrane potential model come close to predicting the long-distance repulsive behavior. Thus, at higher ionic strengths, other non-electrostatic interactions (such as hydrophobic interactions) possibly dominate. An increase in the pH of the solution from 5 to 9.2, the pI of RNase A, significantly reduces the electrostatic repulsion between protein molecules in favor of hydrophobic attractive interactions. This results in lower short-range steric repulsion. However, in contrast to the ionic-strength effect, an increased long-range repulsive force with a much longer decay length is observed. This may be due to contaminants such as DNase that have their pI at a pH other than 9.2. Thus, as with the changing-ionic-strength study, thinner and denser adsorbed layers are formed. Finally, for the kinetic studies, two characteristic length scales--the thickness of the adsorbed layer and the "jump-in" distance--vary linearly with the square root of time. This is consistent with our earlier results and once again implies a diffusion-driven process.

Manipulation of heterogeneous hybridoma cultures for overproduction of monoclonal antibodies

In searching for ways to manipulate heterogeneous hybridoma cell cultures (ATCC HB124) to obtain increased production of monoclonal antibodies (IgG2a), we have selected for a higher secreting but slower growing subpopulation using the level of fluorescent surface-associated antibodies and a fluorescence-activated cell sorter. Cell surface fluorescence was found to be correlated with specific antibody secretion rate over the short term but not with intracellular antibody content. Also, the specific secretion rate of a heterogeneous population of hybridoma cells grown in batch culture has been shown to be inversely correlated with an increase in either the initial cell concentration or the medium antibody concentration. Several experiments suggest that an upper limit exists for medium antibody concentration, above which antibody is degraded at the same rate at which it is produced. Should other cell lines behave similarly, strategies for overproduction of monoclonal antibodies suggested herein could be profitably used in industry.

Protein overproduction in Escherichia coli: RNA stabilization, cell disruption and recovery with a cross-flow microfiltration membrane

After optimizing overproduction of a heterologous gene product (chloramphenicol acetyltransferase, CAT) using an RNA stabilization vector * in Escherichia coli (Chan et al., 1988), a single step cell disruption and recovery method * for obtaining a product stream essentially free of cell debris was developed. The behavior of an RNA stabilization plasmid (pKTN-CAT) containing stabilizing intron RNA was investigated in two different media both in batch and chemostat modes. CAT production of pKTN-CAT was consistently higher (3- to 7-fold) than that of the control lacking the stabilization sequences (pK-CAT). Highest CAT production was observed for cells grown in minimal medium in batch mode and induced for CAT expression early in growth. CAT production of cells grown in the chemostat mode exhibited an optimal dilution rate of about 0.1 h-1. Enhancement of protein production by pKTN-CAT as compared to pK-CAT tended to be higher when grown in rich medium rather than in minimal medium. Presence of the RNA stabilization plasmid did not significantly alter the growth rate of the cell. Using a combination of chemical treatment (1 mM EDTA) and shear stress resulting from cross-flow in a stainless steel microfiltration membrane *, CAT was released into the medium through disruption of the E. coli cells. The permeate flux increased from 2000 to 9000 kg m-2 h-1 with increasing axial Reynolds number from 10,000 to 60,000 or increasing mean shear stress from 12 to 47 Pa. The turbidity of the permeate was approximately 4% that of the retentate over this range of axial flow rates, indicating excellent removal of cell debris. Also, the concentration of CAT in the permeate was equal to that in the retentate over this range of axial flow rates, indicating complete passage of protein through the membrane. Thus, using a combination of chemical treatment and fluid-induced shear stress in a cross-flow membrane module, we were able to disrupt and recover the heterologous protein in a stream low in debris.

Methods for increasing monoclonal antibody production in suspension and entrapped cell cultures: biochemical and flow cytometric analysis as a function of medium serum content

The growth and antibody production of the SP2/0-derived hybridoma HB124 (ATCC) grown in media containing varying amounts of fetal bovine serum (FBS) were monitored using biochemical and flow cytometric methods. Hybridomas grown in 100 ml spinner flasks with RPMI-1640 containing varying amounts of serum demonstrated that cell growth, viability and IgG production show significant changes when serum content is decreased from 10.0 to 5.5 to 1.0 and 0.5%. A longer lag phase resulted when the lower serum content media were used. Cellular rates of glucose uptake showed a significant increase as serum levels were lowered. Similarly, exponential phase IgG production rates increased as the amount of serum was decreased, probably as a result of the decreased rate of exponential growth. Flow cytometric analysis showed a similar increase in cellular IgG content as medium serum levels declined. In contrast, the maximum IgG concentrations were found in flasks containing 1% FBS or above with the lowest concentration in the 0.5% FBS flask being due to the lower numbers of viable cells. Cells grown in microporous hollow fiber reactors were fed with medium containing serum which was decreased stepwise with time. Decreasing medium serum content stepwise from 10 to 2.5% resulted in increased antibody production. However, complete removal of serum from the medium resulted in a significant drop in antibody productivity. Cumulative antibody production was equivalent for cells grown entirely in medium containing 10% FBS and for those which experienced a drop to 2.5% FBS. To compare a defined serum-free medium preparation with medium containing 10% FBS, cells were again grown in batch suspension culture and analyzed. The growth rates were similar but there was a significant difference in IgG production rates. The serum-free culture exhibited both higher cellular production rates and higher IgG concentrations. These results indicate that decreasing medium serum content can adversely affect antibody yield because of lower cell viabilities, not because of lower production rates. Use of a defined serum-free medium, as done in this study, results in higher yields because of a higher IgG production rate as well as good cell growth and viability.

Quantitative Flow Measurements in Bioreactors by Nuclear Magnetic Resonance Imaging

We have developed nuclear magnetic resonance (NMR) flow imaging techniques to measure fluid flow in a cell-free hollow fiber bioreactor (HFBR). Using 1H NMR we track the motion of protons and obtain velocity distributions as a function of position and time. These measurements enable the visualization of flow patterns needed for module design and for establishing desired operating conditions. Uneven flow in the cell-containing region of an HFBR can result in concentration gradients and uneven cell distribution that may lead to reduced cell viability. Results from this non-invasive method could be used to design more efficient cell bioreactors or membrane separation devices.

Changing activity of ribonuclease A during adsorption: a molecular explanation

The activity of ribonuclease A (RNase A) during adsorption onto molecular smooth mica increases from 16% to 78% in a period of 24 h when compared to its activity in free solution at pH 5 and 20 +/- 0.5 degrees C. From electropotential plots, the tertiary structure of RNase A, the characteristics of the mica surface, and direct measurements of the intermolecular forces between two adsorbed enzyme layers, a molecular explanation is offered for the changing activity with time. Initially, the RNase A molecules lie flat-on the mica with their smallest axis perpendicular to and their active site facing the surface. As adsorption proceeds, the molecules slowly reorient until at long times they lie end-on with their largest axis perpendicular to the surface and their active site partially exposed to the free solution. A translational diffusion process is indicated for the phase transition and molecular reorientation of the RNase A molecules.

Stability of group I intron RNA in Escherichia coli and its potential application in a novel expression vector

Intron RNA excised from the primary transcript of the phage T4 td gene was found to be unusually stable in vivo. In contrast to the average half-life of about 1.5 min for a typical Escherichia coli mRNA at 37 degrees C, the half-life of the excised group-I td intron ranged from 12 to 19 min for the linear form and from 22 to 33 min for the circular form. A 631-nucleotide region of the intron that is not essential for splicing was replaced by the chloramphenicol acetyltransferase (CAT) structural gene (cat). Although the presence of the foreign sequence reduced intron stability several-fold, the half-life of the resulting intron-cat hybrid RNA was found to be twice that of the normal cat mRNA. The increase in stability was accompanied by a five- to eight-fold increase in CAT production above that seen with transcriptional activation from the strong Ptac promoter alone. The over-production was both temperature-dependent and partially splicing-dependent. This type of intron fusion represents a novel method of transcript stabilization, which is of potential use to augment other means of increasing gene expression for purposes of product amplification.