1
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Eslami T, Jungbauer A. Control strategy for biopharmaceutical production by model predictive control. Biotechnol Prog 2024; 40:e3426. [PMID: 38199980 DOI: 10.1002/btpr.3426] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/29/2023] [Revised: 10/04/2023] [Accepted: 12/20/2023] [Indexed: 01/12/2024]
Abstract
The biopharmaceutical industry is rapidly advancing, driven by the need for cutting-edge technologies to meet the growing demand for life-saving treatments. In this context, Model Predictive Control (MPC) has emerged as a promising solution to address the complexity of modern biopharmaceutical production processes. Its ability to optimize operations and ensure consistent product yields has made it an attractive option for manufacturers in this sector. Furthermore, MPC's alignment with the Process Analytical Technology (PAT) initiative provides an additional layer of assurance, facilitating real-time monitoring and enabling swift adjustments to maintain process integrity. This comprehensive review delves into the various applications of MPC, ranging from robust control to stochastic model predictive control, thereby equipping biotechnologists and process engineers with a powerful toolset. By harnessing the capabilities of MPC, as elucidated in this review, manufacturers can confidently navigate the intricate bioprocessing landscape and unlock this approach's full potential in their production processes.
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Affiliation(s)
- Touraj Eslami
- Department of Biotechnology, University of Natural Resources and Life Sciences, Vienna, Austria
- Austrian Centre of Industrial Biotechnology, Vienna, Austria
- Evon GmbH, St. Ruprecht an der Raab, Austria
| | - Alois Jungbauer
- Department of Biotechnology, University of Natural Resources and Life Sciences, Vienna, Austria
- Austrian Centre of Industrial Biotechnology, Vienna, Austria
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2
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Rizki Z, Ottens M. Model-based optimization approaches for pressure-driven membrane systems. Sep Purif Technol 2023. [DOI: 10.1016/j.seppur.2023.123682] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 03/30/2023]
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3
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Ouimet JA, Liu X, Brown DJ, Eugene EA, Popps T, Muetzel ZW, Dowling AW, Phillip WA. DATA: Diafiltration Apparatus for high-Throughput Analysis. J Memb Sci 2022. [DOI: 10.1016/j.memsci.2021.119743] [Citation(s) in RCA: 4] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/28/2022]
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4
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Kilmartin CP, Ouimet JA, Dowling AW, Phillip WA. Staged Diafiltration Cascades Provide Opportunities to Execute Highly Selective Separations. Ind Eng Chem Res 2021. [DOI: 10.1021/acs.iecr.1c02984] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Cara P. Kilmartin
- Department of Chemical and Biomolecular Engineering, University of Notre Dame, Notre Dame, Indiana 46556, United States
| | - Jonathan Aubuchon Ouimet
- Department of Chemical and Biomolecular Engineering, University of Notre Dame, Notre Dame, Indiana 46556, United States
| | - Alexander W. Dowling
- Department of Chemical and Biomolecular Engineering, University of Notre Dame, Notre Dame, Indiana 46556, United States
| | - William A. Phillip
- Department of Chemical and Biomolecular Engineering, University of Notre Dame, Notre Dame, Indiana 46556, United States
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5
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Yu Z, Moomaw JF, Thyagarajapuram NR, Geng SB, Bent CJ, Tang Y. A mechanistic model to account for the Donnan and volume exclusion effects in ultrafiltration/diafiltration process of protein formulations. Biotechnol Prog 2020; 37:e3106. [PMID: 33289341 DOI: 10.1002/btpr.3106] [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: 07/23/2020] [Revised: 11/16/2020] [Accepted: 11/24/2020] [Indexed: 11/05/2022]
Abstract
Ultrafiltration/diafiltration (UF/DF) is a typical step in protein drug manufacturing process to concentrate and exchange the protein solution into a desired formulation. However, significant offset of pH and composition from the target formulation have been frequently observed after UF/DF, posing challenges to the stability, performance, and consistency of the final drug product. Such shift can often be attributed to the Donnan and volume exclusion effects. In order to predict and compensate for those effects, a mechanistic model is developed based on the protein charge, mass and charge balances, as well as the equilibrium condition across the membrane. The integrated UF/DF model can be used to predict both the dynamic behavior and the final outcome of the process. Examples of the modeling results for the pH and composition variation during the UF/DF operations are presented for two monoclonal antibody proteins. The model predictions are in good agreement with a comprehensive experimental data set that covers different process steps, protein concentrations, solution matrices, and process scales. The results show that significant pH and excipient concentration shifts are more likely to occur for high protein concentration and low ionic strength matrices. As a special example, a self-buffering protein formulation shows unique pH behavior during DF, which could also be captured with the dynamic model. The capability of the model in predicting the performance of UF/DF process as a function of protein characteristics and formulation conditions makes it a useful tool to improve process understanding and facilitate process development.
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Affiliation(s)
- Zhao Yu
- Bioproduct Research and Development, Lilly Research Laboratories, Eli Lilly and Company, Indianapolis, Indiana, USA
| | - John F Moomaw
- Bioproduct Research and Development, Lilly Research Laboratories, Eli Lilly and Company, Indianapolis, Indiana, USA
| | - Nagarajan R Thyagarajapuram
- Bioproduct Research and Development, Lilly Research Laboratories, Eli Lilly and Company, Indianapolis, Indiana, USA
| | - Steven B Geng
- Bioproduct Research and Development, Lilly Research Laboratories, Eli Lilly and Company, Indianapolis, Indiana, USA
| | - Colin James Bent
- Bioproduct Research and Development, Lilly Research Laboratories, Eli Lilly and Company, Indianapolis, Indiana, USA
| | - Yu Tang
- Bioproduct Research and Development, Lilly Research Laboratories, Eli Lilly and Company, Indianapolis, Indiana, USA
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6
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Wu W, Yenkie KM, Maravelias CT. Synthesis and analysis of separation processes for extracellular chemicals generated from microbial conversions. ACTA ACUST UNITED AC 2019. [DOI: 10.1186/s42480-019-0022-8] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/10/2022]
Abstract
Abstract
Recent advances in metabolic engineering have enabled the production of chemicals via bio-conversion using microbes. However, downstream separation accounts for 60–80% of the total production cost in many cases. Previous work on microbial production of extracellular chemicals has been mainly restricted to microbiology, biochemistry, metabolomics, or techno-economic analysis for specific product examples such as succinic acid, xanthan gum, lycopene, etc. In these studies, microbial production and separation technologies were selected apriori without considering any competing alternatives. However, technology selection in downstream separation and purification processes can have a major impact on the overall costs, product recovery, and purity. To this end, we apply a superstructure optimization based framework that enables the identification of critical technologies and their associated parameters in the synthesis and analysis of separation processes for extracellular chemicals generated from microbial conversions. We divide extracellular chemicals into three categories based on their physical properties, such as water solubility, physical state, relative density, volatility, etc. We analyze three major extracellular product categories (insoluble light, insoluble heavy and soluble) in detail and provide suggestions for additional product categories through extension of our analysis framework. The proposed analysis and results provide significant insights for technology selection and enable streamlined decision making when faced with any microbial product that is released extracellularly. The parameter variability analysis for the product as well as the associated technologies and comparison with novel alternatives is a key feature which forms the basis for designing better bioseparation strategies that have potential for commercial scalability and can compete with traditional chemical production methods.
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Khunnonkwao P, Jantama K, Kanchanatawee S, Galier S, Roux-de Balmann H. A two steps membrane process for the recovery of succinic acid from fermentation broth. Sep Purif Technol 2018. [DOI: 10.1016/j.seppur.2018.06.056] [Citation(s) in RCA: 27] [Impact Index Per Article: 4.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/25/2022]
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8
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Pázmándi M, Maráz A, Ladányi M, Kovács Z. The impact of membrane pretreatment on the enzymatic production of whey-derived galacto-oligosaccharides. J FOOD PROCESS ENG 2017. [DOI: 10.1111/jfpe.12649] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/31/2022]
Affiliation(s)
- Melinda Pázmándi
- Department of Food Engineering; Szent István University; Budapest Hungary
- Department of Microbiology and Biotechnology; Szent István University; Budapest Hungary
| | - Anna Maráz
- Department of Microbiology and Biotechnology; Szent István University; Budapest Hungary
| | - Márta Ladányi
- Department of Biometrics and Agricultural Informatics; Szent István University; Budapest Hungary
| | - Zoltán Kovács
- Department of Food Engineering; Szent István University; Budapest Hungary
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9
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Nambiar AMK, Li Y, Zydney AL. Countercurrent staged diafiltration for formulation of high value proteins. Biotechnol Bioeng 2017; 115:139-144. [PMID: 28865125 DOI: 10.1002/bit.26441] [Citation(s) in RCA: 29] [Impact Index Per Article: 4.1] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/25/2017] [Revised: 08/17/2017] [Accepted: 08/30/2017] [Indexed: 02/05/2023]
Abstract
A number of groups have studied the application of continuous bioreactors and continuous chromatographic systems as part of efforts to develop an integrated continuous biomanufacturing process. The objective of this study was to examine the feasibility of using a countercurrent staged diafiltration process for continuous protein formulation with reduced buffer requirements. Experiments were performed using a polyclonal immunoglobulin (IgG) with Cadence™ Inline Concentrators. Model equations were developed for the product yield, impurity removal, and buffer requirements as a function of the number of stages and the stage conversion (ratio of permeate to feed flow rate). Data from a countercurrent two-stage system were in excellent agreement with model calculations, demonstrating the potential of using countercurrent staged diafiltration for protein formulation. Model simulations demonstrated the importance of the countercurrent staging on both the extent of buffer exchange and the amount of buffer required per kg of formulated product. The staged diafiltration process not only provides for continuous buffer exchange, it could also provide significant reductions in the number of pump passes while providing opportunities for reduced buffer requirements.
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Affiliation(s)
- Anirudh M K Nambiar
- Department of Chemical Engineering, The Pennsylvania State University, University Park, Pennsylvania
| | - Ying Li
- Department of Chemical Engineering, The Pennsylvania State University, University Park, Pennsylvania
| | - Andrew L Zydney
- Department of Chemical Engineering, The Pennsylvania State University, University Park, Pennsylvania
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10
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Baek Y, Yang D, Singh N, Arunkumar A, Ghose S, Li ZJ, Zydney AL. pH variations during diafiltration due to buffer nonidealities. Biotechnol Prog 2017; 33:1555-1560. [DOI: 10.1002/btpr.2544] [Citation(s) in RCA: 9] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/19/2017] [Revised: 08/17/2017] [Indexed: 01/24/2023]
Affiliation(s)
- Youngbin Baek
- Dept. of Chemical Engineering; The Pennsylvania State University, University Park; PA 16802
| | - Deyu Yang
- Dept. of Chemical Engineering; The Pennsylvania State University, University Park; PA 16802
| | - Nripen Singh
- Product Development; Bristol-Myers Squibb; Devens MA 01434
| | | | | | - Zheng Jian Li
- Product Development; Bristol-Myers Squibb; Devens MA 01434
| | - Andrew L. Zydney
- Dept. of Chemical Engineering; The Pennsylvania State University, University Park; PA 16802
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11
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Magarian N, Lee K, Nagpal K, Skidmore K, Mahajan E. Clearance of extractables and leachables from single-use technologies via ultrafiltration/diafiltration operations. Biotechnol Prog 2016; 32:718-24. [DOI: 10.1002/btpr.2277] [Citation(s) in RCA: 18] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/03/2016] [Revised: 04/04/2016] [Indexed: 11/08/2022]
Affiliation(s)
| | - Kate Lee
- Genentech, Inc; South San Francisco CA 94080
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12
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Veigas B, Portugal C, Valério R, Fortunato E, Crespo JG, Baptista PV. Scalable approach for the production of functional DNA based gold nanoprobes. J Memb Sci 2015. [DOI: 10.1016/j.memsci.2015.06.042] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/23/2022]
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13
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Paulen R, Jelemenský M, Fikar M, Kovács Z. Optimal balancing of temporal and buffer costs for ultrafiltration/diafiltration processes under limiting flux conditions. J Memb Sci 2013. [DOI: 10.1016/j.memsci.2013.05.009] [Citation(s) in RCA: 6] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/26/2022]
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14
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Paulen R, Foley G, Fikar M, Kovács Z, Czermak P. Minimizing the process time for ultrafiltration/diafiltration under gel polarization conditions. J Memb Sci 2011. [DOI: 10.1016/j.memsci.2011.06.044] [Citation(s) in RCA: 28] [Impact Index Per Article: 2.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/25/2022]
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15
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Self-sharpening phenomenon arisen by ion-exchange membranes in multi-compartment free-flow isoelectric focusing (IEM-FFIEF). Chem Eng Sci 2009. [DOI: 10.1016/j.ces.2009.08.040] [Citation(s) in RCA: 6] [Impact Index Per Article: 0.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/19/2022]
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16
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Harinarayan C, Skidmore K, Kao Y, Zydney A, van Reis R. Small molecule clearance in ultrafiltration/diafiltration in relation to protein interactions: Study of citrate binding to a Fab. Biotechnol Bioeng 2009; 102:1718-22. [DOI: 10.1002/bit.22196] [Citation(s) in RCA: 19] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/09/2022]
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17
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Bartlett DW, Colcher D, Raubitschek AA. Rapid and efficient production of radiolabeled antibody conjugates using vacuum diafiltration guided by mathematical modeling. Bioconjug Chem 2008; 19:1927-37. [PMID: 18720981 DOI: 10.1021/bc800223x] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.1] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Abstract
Increasing interest in the use of radiolabeled antibodies for cancer imaging and therapy drives the need for more efficient production of the antibody conjugates. Here, we illustrate a method for rapid and efficient production of radiolabeled antibody conjugates using vacuum diafiltration guided by mathematical modeling. We apply this technique to the production of 1,4,7,10-tetraazacyclododecane-1,4,7,10-tetraacetic acid (DOTA)-conjugated antibodies at the milligram and gram production scale and achieve radiolabeling efficiencies >95% using In-111. Using vacuum diafiltration, antibody-chelate conjugation and purification can be accomplished within the same vessel, and the entire process can be completed in <24 h. Vacuum diafiltration also offers safer and gentler processing conditions by eliminating the need to keep the retentate vessel under positive pressure through applied gas pressure or shear-inducing restriction points in the retentate flow path. Experimental data and mathematical model calculations suggest there exists a weak binding affinity (approximately 10(4)M(-1)) between the charged chelate molecules (e.g., DOTA) and the antibodies that slows the removal of excess chelate during purification. By analyzing the radiolabeling efficiency as a function of the number of diavolumes, we demonstrate the importance of balancing the removal of free chelate with the introduction of metal contaminants from the diafiltration buffer and also illustrate how to optimize radiolabeling of antibody conjugates under a variety of operating conditions. This methodology is applicable to the production of antibody conjugates in general.
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Affiliation(s)
- Derek W Bartlett
- Division of Cancer Immunotherapeutics & Tumor Immunology, Beckman Research Institute and City of Hope National Medical Center, Duarte, California 91010, USA
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18
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Comparison of diafiltration and size-exclusion chromatography to recover hemicelluloses from process water from thermomechanical pulping of spruce. Appl Biochem Biotechnol 2007; 137-140:971-83. [DOI: 10.1007/s12010-007-9112-9] [Citation(s) in RCA: 10] [Impact Index Per Article: 0.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/26/2022]
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19
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Economic evaluation of isolation of hemicelluloses from process streams from thermomechanical pulping of spruce. Appl Biochem Biotechnol 2007; 137-140:741-52. [DOI: 10.1007/s12010-007-9094-7] [Citation(s) in RCA: 14] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/23/2022]
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