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Off-Gas-Based Soft Sensor for Real-Time Monitoring of Biomass and Metabolism in Chinese Hamster Ovary Cell Continuous Processes in Single-Use Bioreactors. Processes (Basel) 2021. [DOI: 10.3390/pr9112073] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/23/2022] Open
Abstract
In mammalian cell culture, especially in pharmaceutical manufacturing and research, biomass and metabolic monitoring are mandatory for various cell culture process steps to develop and, finally, control bioprocesses. As a common measure for biomass, the viable cell density (VCD) or the viable cell volume (VCV) is widely used. This study highlights, for the first time, the advantages of using VCV instead of VCD as a biomass depiction in combination with an oxygen-uptake- rate (OUR)-based soft sensor for real-time biomass estimation and process control in single-use bioreactor (SUBs) continuous processes with Chinese hamster ovary (CHO) cell lines. We investigated a series of 14 technically similar continuous SUB processes, where the same process conditions but different expressing CHO cell lines were used, with respect to biomass growth and oxygen demand to calibrate our model. In addition, we analyzed the key metabolism of the CHO cells in SUB perfusion processes by exometabolomic approaches, highlighting the importance of cell-specific substrate and metabolite consumption and production rate qS analysis to identify distinct metabolic phases. Cell-specific rates for classical mammalian cell culture key substrates and metabolites in CHO perfusion processes showed a good correlation to qOUR, yet, unexpectedly, not for qGluc. Here, we present the soft-sensoring methodology we developed for qPyr to allow for the real-time approximation of cellular metabolism and usage for subsequent, in-depth process monitoring, characterization and optimization.
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Zhang A, Tsang VL, Moore B, Shen V, Huang YM, Kshirsagar R, Ryll T. Advanced process monitoring and feedback control to enhance cell culture process production and robustness. Biotechnol Bioeng 2015; 112:2495-504. [DOI: 10.1002/bit.25684] [Citation(s) in RCA: 50] [Impact Index Per Article: 5.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/10/2015] [Revised: 05/12/2015] [Accepted: 06/18/2015] [Indexed: 12/14/2022]
Affiliation(s)
- An Zhang
- Cell Culture Development; Biogen Idec, Inc.; Research Triangle Park 5000 Davis Drive North Carolina 27709
| | - Valerie Liu Tsang
- Cell Culture Development; Biogen Idec, Inc.; Research Triangle Park 5000 Davis Drive North Carolina 27709
| | - Brandon Moore
- Cell Culture Development; Biogen Idec, Inc.; Research Triangle Park 5000 Davis Drive North Carolina 27709
| | - Vivian Shen
- Cell Culture Development; Biogen Idec, Inc.; Research Triangle Park 5000 Davis Drive North Carolina 27709
| | - Yao-Ming Huang
- Cell Culture Development; Biogen Idec, Inc.; Research Triangle Park 5000 Davis Drive North Carolina 27709
| | - Rashmi Kshirsagar
- Cell Culture Development; Biogen Idec, Inc.; Cambridge Massachusetts
| | - Thomas Ryll
- Cell Culture Development; Biogen Idec, Inc.; Cambridge Massachusetts
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Lambrechts T, Papantoniou I, Sonnaert M, Schrooten J, Aerts JM. Model-based cell number quantification using online single-oxygen sensor data for tissue engineering perfusion bioreactors. Biotechnol Bioeng 2014; 111:1982-92. [PMID: 24771348 DOI: 10.1002/bit.25274] [Citation(s) in RCA: 18] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/12/2014] [Revised: 04/09/2014] [Accepted: 04/15/2014] [Indexed: 01/31/2023]
Abstract
Online and non-invasive quantification of critical tissue engineering (TE) construct quality attributes in TE bioreactors is indispensable for the cost-effective up-scaling and automation of cellular construct manufacturing. However, appropriate monitoring techniques for cellular constructs in bioreactors are still lacking. This study presents a generic and robust approach to determine cell number and metabolic activity of cell-based TE constructs in perfusion bioreactors based on single oxygen sensor data in dynamic perfusion conditions. A data-based mechanistic modeling technique was used that is able to correlate the number of cells within the scaffold (R(2) = 0.80) and the metabolic activity of the cells (R(2) = 0.82) to the dynamics of the oxygen response to step changes in the perfusion rate. This generic non-destructive measurement technique is effective for a large range of cells, from as low as 1.0 × 10(5) cells to potentially multiple millions of cells, and can open-up new possibilities for effective bioprocess monitoring.
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Affiliation(s)
- T Lambrechts
- Division M3-BIORES: Measure, Model & Manage Bioresponses, KU Leuven, Heverlee, Belgium; Prometheus, Division of Skeletal Tissue Engineering, KU Leuven, Leuven, Belgium
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Abstract
Lab-scale stirred-tank bioreactors (0.2-20 l) are used for fundamental research on animal cells and in process development and troubleshooting for large-scale production. In this chapter, different configurations of bioreactor systems are shortly discussed and setting up these different configurations is described. In addition, online measurement and control of bioreactor parameters is described, with special attention to controller settings (PID) and online measurement of oxygen consumption and carbon dioxide production. Finally, methods for determining the oxygen transfer coefficient are described.
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Affiliation(s)
- Dirk E Martens
- Bioprocess Engineering, Wageningen University, Wageningen, The Netherlands,
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El Wajgali A, Esteban G, Fournier F, Pinton H, Marc A. Impact of microcarrier coverage on using permittivity for on-line monitoring high adherent Vero cell densities in perfusion bioreactors. Biochem Eng J 2013. [DOI: 10.1016/j.bej.2012.11.001] [Citation(s) in RCA: 5] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/27/2022]
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Dorresteijn RC, Wieten G, van Santen PT, Philippi MC, de Gooijer CD, Tramper J, Beuvery EC. Current good manufacturing practice in plant automation of biological production processes. Cytotechnology 2012; 23:19-28. [PMID: 22358517 DOI: 10.1023/a:1007923820231] [Citation(s) in RCA: 6] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/12/2022] Open
Abstract
The production of biologicals is subject to strict governmental regulations. These are drawn up in current good manufacturing practices (cGMP), a.o. by the U.S. Food and Drug Administration. To implement cGMP in a production facility, plant automation becomes an essential tool. For this purpose Manufacturing Execution Systems (MES) have been developed that control all operations inside a production facility. The introduction of these recipe-driven control systems that follow ISA S88 standards for batch processes has made it possible to implement cGMP regulations in the control strategy of biological production processes. Next to this, an MES offers additional features such as stock management, planning and routing tools, process-dependent control, implementation of software sensors and predictive models, application of historical data and on-line statistical techniques for trend analysis and detection of instrumentation failures. This paper focuses on the development of new production strategies in which cGMP guidelines are an essential part.
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Affiliation(s)
- R C Dorresteijn
- Laboratory for Product and Process Development, National Institute of Public Health and the Environment, P.O. Box 1, 3720 BA, Bilthoven, The Netherlands
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Production of influenza H1N1 vaccine from MDCK cells using a novel disposable packed-bed bioreactor. Appl Microbiol Biotechnol 2012; 97:1063-70. [PMID: 22945265 DOI: 10.1007/s00253-012-4375-7] [Citation(s) in RCA: 13] [Impact Index Per Article: 1.1] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/03/2012] [Revised: 08/11/2012] [Accepted: 08/14/2012] [Indexed: 10/27/2022]
Abstract
A process for human influenza H1N1 virus vaccine production from Madin-Darby canine kidney (MDCK) cells using a novel packed-bed bioreactor is described in this report. The mini-bioreactor was used to study the relationship between cell density and glucose consumption rate and to optimize the infection parameters of the influenza H1N1 virus (A/New Caledonia/20/99). The MDCK cell culture and virus infection were then monitored in a disposable perfusion bioreactor (AmProtein Current Perfusion Bioreactor) with proportional-integral-derivative control of pH, dissolved O(2) (DO), agitation, and temperature. During 6 days of culture, the total cell number increased from 2.0 × 10(9) to 3.2 × 10(10) cells. The maximum virus titers of 768 hemagglutinin units/100 μL and 7.8 × 10(7) 50 % tissue culture infectious doses/mL were obtained 3 days after infection. These results demonstrate that using a disposable perfusion bioreactor for large-scale cultivation of MDCK cells, which allows for the control of DO, pH, and other conditions, is a convenient and stable platform for industrial-scale production of influenza vaccines.
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Comparison of viable cell concentration estimation methods for a mammalian cell cultivation process. Cytotechnology 2010; 62:413-22. [PMID: 20809261 DOI: 10.1007/s10616-010-9291-z] [Citation(s) in RCA: 11] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/20/2010] [Accepted: 07/09/2010] [Indexed: 10/19/2022] Open
Abstract
Various mechanistic and black-box models were applied for on-line estimations of viable cell concentrations in fed-batch cultivation processes for CHO cells. Data from six fed-batch cultivation experiments were used to identify the underlying models and further six independent data sets were used to determine the performance of the estimators. The performances were quantified by means of the root mean square error (RMSE) between the estimates and the corresponding off-line measured validation data sets. It is shown that even simple techniques based on empirical and linear model approaches provide a fairly good on-line estimation performance. Best results with respect to the validation data sets were obtained with hybrid models, multivariate linear regression technique and support vector regression. Hybrid models provide additional important information about the specific cellular growth rates during the cultivation.
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Goudar C, Joeris K, Cruz C, Zhang C, Konstantinov K. OUR AND CER ESTIMATION IN HIGH DENSITY MAMMALIAN CELL PERFUSION CULTURES. ACTA ACUST UNITED AC 2007. [DOI: 10.3182/20070604-3-mx-2914.00017] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/23/2022]
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Biagiola S, Solsona J, Milocco R. Estimation of kinetic rates in batch Thiobacillus ferrooxidans cultures. J Biotechnol 2001; 84:13-25. [PMID: 11035183 DOI: 10.1016/s0168-1656(00)00337-0] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.1] [Reference Citation Analysis] [Abstract] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022]
Abstract
In this work, the key problem of estimation in bioprocesses when no structural model is available is dealt with. A nonlinear observer-based algorithm is developed in order to estimate kinetic rates in batch bioreactors. The algorithm uses the measurements of biomass concentration and either substrate concentration or redox potential to perform the estimation of the respective specific kinetic rates. For this purpose, a general mathematical model description of the process is provided. The estimation algorithm design is based on a nonlinear reduced-order observer. The observer performance is validated with experimental results on a Thiobacillus ferrooxidans batch culture.
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Affiliation(s)
- S Biagiola
- CONICET and National University of Comahue, Grupo de Control Automático y Sistemas, Facultad de Ingeniería, Universidad Nacional del Comahue, 1400, 8300 Neuquén, Buenos Aires, Argentina.
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Yoon Keun Jung, Hur W. A new method of on-line measurement of buffer capacity and alkali consumption rate of a fermentation process. J Biosci Bioeng 2000. [DOI: 10.1016/s1389-1723(01)80047-5] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/26/2022]
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Ruffieux PA, von Stockar U, Marison IW. Measurement of volumetric (OUR) and determination of specific (qO2) oxygen uptake rates in animal cell cultures. J Biotechnol 1998; 63:85-95. [PMID: 9772750 DOI: 10.1016/s0168-1656(98)00046-7] [Citation(s) in RCA: 83] [Impact Index Per Article: 3.2] [Reference Citation Analysis] [Abstract] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
Abstract
Oxygen is a key substrate in animal cell metabolism. It has been reported that the oxygen uptake rate (OUR) is a good indicator of cellular activity, and even under some conditions, a good indicator of the number of viable cells. The measurement of OUR is difficult due to many different reasons. In particular, the very low specific consumption rate (0.2 x 10(-12) mol cell h-1), the sensitivity of the cells to variations in dissolved oxygen concentration and the difficulty to provide oxygen without damaging the cells are problems which must be taken into account for the development of OUR measurement methods. Different solutions based on an oxygen balance on either the liquid phase or around the entire reactor, and with a variable or stable concentration of dissolved oxygen have been reported. The accuracy of the OUR measurements and the required analytical devices are very different from method to method.
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Affiliation(s)
- P A Ruffieux
- Institute of Chemical Engineering, Swiss Federal Institute of Technology (EPFL), Lausanne, Switzerland
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Abstract
The use of modern analytical online methods such as two-dimensional fluorescence measurements gives new insights into bioprocesses. With the resulting data, it is not only possible to better understand and document, for example, biotransformations, but also to develop efficient control strategies that lead to better productivity and lower costs.
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