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Zimoch-Rumanek P, Antos D. Coupling cation and anion exchange chromatography for fast separation of monoclonal antibody charge variants. J Chromatogr A 2024; 1733:465256. [PMID: 39153427 DOI: 10.1016/j.chroma.2024.465256] [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: 06/06/2024] [Revised: 08/04/2024] [Accepted: 08/09/2024] [Indexed: 08/19/2024]
Abstract
A design procedure for the separation of charge variants of a monoclonal antibody (mAb) was developed, which was based on the coupling of cation-exchange chromatography (CEX) and anion-exchange chromatography (AEX) under high loading conditions. The design of the coupled process was supported by a dynamic model. The model was calibrated on the basis of band profiles of variants determined experimentally for the mAb materials of different variant compositions. The numerical simulations were used to select the coupling configuration and the loading conditions that allowed for efficient separation of the mAb materials into three products enriched with each individual variant: the acidic (av), main (mv) and basic (bv) one. In the CEX section, a two-step pH gradient was used to split the loaded mass of mAb into a weakly bound fraction enriched with av and mv, and a strongly bound fraction containing the bv-rich product. The weakly bound fraction was further processed in the AEX section, where the mv-rich product was eluted in flowthrough, while the av-rich product was collected by a step change in pH. The choice of flow distribution and the number of columns in the CEX and AEX sections depended on the variant composition of the mAb material. For the selected configurations, the optimized mAb loading density in the CEX columns ranged from 10 to 26 mg mL-1, while in the AEX columns it was as high as 300 or 600 mg mL-1, depending on the variant composition of the mAb material. By proper selection of the loading condition, a trade-off between yield and purity of the products could be reached.
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Affiliation(s)
| | - Dorota Antos
- Department of Chemical and Process Engineering, Rzeszów University of Technology, Rzeszów/PL, Poland.
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2
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Fioretti I, Müller-Späth T, Aumann L, Sponchioni M. UV-based dynamic control improves the robustness of multicolumn countercurrent solvent gradient purification of oligonucleotides. Biotechnol J 2024; 19:e2400170. [PMID: 39014932 DOI: 10.1002/biot.202400170] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/16/2024] [Revised: 06/21/2024] [Accepted: 06/24/2024] [Indexed: 07/18/2024]
Abstract
Therapeutic oligonucleotides (ONs) have great potential to treat many diseases due to their ability to regulate gene expression. However, the inefficiency of standard purification techniques to separate the target sequence from molecularly similar variants is hindering development of large scale ON manufacturing at a reasonable cost. Multicolumn Countercurrent Solvent Gradient Purification (MCSGP) is a valuable process able to bypass the purity-yield tradeoff typical of single-column operations, and hence to make the ON production more sustainable from both an economic and environmental point of view. However, operating close to the optimum of MCSGP can be challenging, resulting in unstable process performance and in a drift in product quality, especially when running a continuous process for extended periods where process parameters such as temperature are prone to variation. In this work, we demonstrate how greater process robustness is introduced in the design and execution of MCSGP for the purification of a 20mer single-stranded DNA sequence through the implementation of UV-based dynamic control. With this novel approach, the cyclic steady state was reached already in the third cycle and disturbances coming from fluctuations in the feed quality, loading amount and temperature were effectively compensated allowing a stable operation close to the optimum. In response to the perturbations, the controlled process kept the standard deviation on product recovery below 3.4%, while for the non-controlled process it increased up to 27.5%.
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Affiliation(s)
- Ismaele Fioretti
- Department of Chemistry, Materials and Chemical Engineering, Politecnico di Milano, Milano, Italy
| | | | | | - Mattia Sponchioni
- Department of Chemistry, Materials and Chemical Engineering, Politecnico di Milano, Milano, Italy
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3
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Sun YN, Chen WW, Yao SJ, Lin DQ. Model-assisted process development, characterization and design of continuous chromatography for antibody separation. J Chromatogr A 2023; 1707:464302. [PMID: 37607430 DOI: 10.1016/j.chroma.2023.464302] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/28/2023] [Revised: 08/10/2023] [Accepted: 08/14/2023] [Indexed: 08/24/2023]
Abstract
Continuous manufacturing in monoclonal antibody production has generated increased interest due to its consistent quality, high productivity, high equipment utilization, and low cost. One of the major challenges in realizing continuous biological manufacturing lies in implementing continuous chromatography. Given the complex operation mode and various operation parameters, it is challenging to develop a continuous process. Due to the process parameters being mainly determined by the breakthrough curves and elution behaviors, chromatographic modeling has gradually been used to assist in process development and characterization. Model-assisted approaches could realize multi-parameter interaction investigation and multi-objective optimization by integrating continuous process models. These approaches could reduce time and resource consumption while achieving a comprehensive and systematic understanding of the process. This paper reviews the application of modeling tools in continuous chromatography process development, characterization and design. Model-assisted process development approaches for continuous capture and polishing steps are introduced and summarized. The challenges and potential of model-assisted process characterization are discussed, emphasizing the need for further research on the design space determination strategy and parameter robustness analysis method. Additionally, some model applications for process design were highlighted to promote the establishment of the process optimization and process simulation platform.
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Affiliation(s)
- Yan-Na Sun
- Key Laboratory of Biomass Chemical Engineering of Ministry of Education, Zhejiang Key Laboratory of Smart Biomaterials, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou 310058, China
| | - Wu-Wei Chen
- Key Laboratory of Biomass Chemical Engineering of Ministry of Education, Zhejiang Key Laboratory of Smart Biomaterials, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou 310058, China
| | - Shan-Jing Yao
- Key Laboratory of Biomass Chemical Engineering of Ministry of Education, Zhejiang Key Laboratory of Smart Biomaterials, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou 310058, China
| | - Dong-Qiang Lin
- Key Laboratory of Biomass Chemical Engineering of Ministry of Education, Zhejiang Key Laboratory of Smart Biomaterials, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou 310058, China.
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4
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Zimoch P, Rumanek T, Kołodziej M, Piątkowski W, Antos D. Coupling of chromatography and precipitation for adjusting acidic variant content in a monoclonal antibody pool. J Chromatogr A 2023; 1701:464070. [PMID: 37209519 DOI: 10.1016/j.chroma.2023.464070] [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: 04/01/2023] [Revised: 05/04/2023] [Accepted: 05/13/2023] [Indexed: 05/22/2023]
Abstract
The acidic charge variants (av) of monoclonal antibodies (mAb) are often reported to have reduced therapeutic potency compared with the main (mv) and basic variants (bv), therefore reduction in the av content in mAb pools is often prioritized over reduction in the bv content. In previous studies we described two different methods for reducing the av content, which were based on either ion exchange chromatography or selective precipitation in polyethylene glycol (PEG) solutions. In this study, we have developed a coupled process, in which advantages of simplicity and ease in realization of PEG-aided precipitation and high separation selectivity of anion exchange chromatography (AEX) were exploited. The design of AEX was supported by the kinetic-dispersive model, which was supplemented with the colloidal particle adsorption isotherm, whereas the precipitation process and its coupling with AEX was quantified by simple mass balance equations and underlying thermodynamic dependencies. The model was used to assess the performance of the coupling of AEX and precipitation under different operating conditions. The advantage of the coupled process over the stand-alone AEX depended on the demand for the av reduction as well as the initial variant composition of the mAb pool, e.g., the improvement in the throughput provided by the optimized sequence of AEX and PREC varied from 70 to 600% for the initial av content changed from 35 to 50% w/w, and the reduction demand changed from 30 to 60%.
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Affiliation(s)
- Patrycja Zimoch
- Doctoral School of the Rzeszow University of Technology, Poland
| | - Tomasz Rumanek
- Doctoral School of the Rzeszow University of Technology, Poland
| | - Michał Kołodziej
- Department of Chemical and Process Engineering, Rzeszów University of Technology, Rzeszów, Poland
| | - Wojciech Piątkowski
- Department of Chemical and Process Engineering, Rzeszów University of Technology, Rzeszów, Poland
| | - Dorota Antos
- Department of Chemical and Process Engineering, Rzeszów University of Technology, Rzeszów, Poland.
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5
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Kim TK, Bham AA, Fioretti I, Angelo J, Xu X, Ghose S, Morbidelli M, Sponchioni M. Role of the gradient slope during the product internal recycling for the multicolumn countercurrent solvent gradient purification of PEGylated proteins. J Chromatogr A 2023; 1692:463868. [PMID: 36803771 DOI: 10.1016/j.chroma.2023.463868] [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: 11/11/2022] [Revised: 02/06/2023] [Accepted: 02/08/2023] [Indexed: 02/11/2023]
Abstract
Protein PEGylation, i.e. functionalization with poly(ethylene glycol) chains, has been demonstrated an efficient way to improve the therapeutic index of these biopharmaceuticals. We demonstrated that Multicolumn Countercurrent Solvent Gradient Purification (MCSGP) is an efficient process for the separation of PEGylated proteins (Kim et al., Ind. and Eng. Chem. Res. 2021, 60, 29, 10764-10776), thanks to the internal recycling of product-containing side fractions. This recycling phase plays a critical role in the economy of MCSGP as it avoids wasting valuable product, but at the same time impacts its productivity extending the overall process duration. In this study, our aim is to elucidate the role of the gradient slope within this recycling stage on the yield and productivity of MCSGP for two case-studies: PEGylated lysozyme and an industrially relevant PEGylated protein. While all the examples of MCSGP in the literature refer to a single gradient slope in the elution phase, for the first time we systematically investigate three different gradient configurations: i) a single gradient slope throughout the entire elution, ii) recycling with an increased gradient slope, to shed light on the competition between volume of the recycled fraction and required inline dilution and iii) an isocratic elution during the recycling phase. The dual gradient elution proved to be a valuable solution for boosting the recovery of high-value products, with the potential for alleviating the pressure on the upstream processing.
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Affiliation(s)
- Tae Keun Kim
- Department of Chemistry, Materials and Chemical Engineering, Politecnico di Milano, Via Mancinelli 7 20131 Milano, Italy
| | - Abdallah Ayub Bham
- Department of Chemistry, Materials and Chemical Engineering, Politecnico di Milano, Via Mancinelli 7 20131 Milano, Italy
| | - Ismaele Fioretti
- Department of Chemistry, Materials and Chemical Engineering, Politecnico di Milano, Via Mancinelli 7 20131 Milano, Italy
| | - James Angelo
- Biologics Process Development, Global Product Development and Supply, Bristol Myers Squibb, Inc., Devens, MA, 01434, USA
| | - Xuankuo Xu
- Biologics Process Development, Global Product Development and Supply, Bristol Myers Squibb, Inc., Devens, MA, 01434, USA
| | - Sanchayita Ghose
- Biologics Process Development, Global Product Development and Supply, Bristol Myers Squibb, Inc., Devens, MA, 01434, USA
| | - Massimo Morbidelli
- Department of Chemistry, Materials and Chemical Engineering, Politecnico di Milano, Via Mancinelli 7 20131 Milano, Italy
| | - Mattia Sponchioni
- Department of Chemistry, Materials and Chemical Engineering, Politecnico di Milano, Via Mancinelli 7 20131 Milano, Italy.
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Müller-Späth T. Continuous Countercurrent Chromatography in Protein Purification. Methods Mol Biol 2023; 2699:31-50. [PMID: 37646992 DOI: 10.1007/978-1-0716-3362-5_3] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 09/01/2023]
Abstract
Continuous countercurrent chromatography can be applied for both capture and polishing steps in the downstream processing of biopharmaceuticals. This chapter explains the concept of countercurrent operation, focusing on twin-column processes and how it can be used to alleviate the trade-offs of traditional batch chromatography with respect to resin utilization/productivity and yield/purity. CaptureSMB and MCSGP, the main twin-column continuous countercurrent chromatography processes, are explained, and the metrics by which they are compared to single-column chromatography are identified. Practical hints for process design and application examples are provided. Finally, regulatory aspects, scale-up, and UV-based process control are covered.
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Saleh D, Hess R, Ahlers-Hesse M, Rischawy F, Wang G, Grosch JH, Schwab T, Kluters S, Studts J, Hubbuch J. A multiscale modeling method for therapeutic antibodies in ion exchange chromatography. Biotechnol Bioeng 2023; 120:125-138. [PMID: 36226467 DOI: 10.1002/bit.28258] [Citation(s) in RCA: 5] [Impact Index Per Article: 5.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/08/2022] [Revised: 09/09/2022] [Accepted: 10/08/2022] [Indexed: 11/10/2022]
Abstract
The development of biopharmaceutical downstream processes relies on exhaustive experimental studies. The root cause is the poorly understood relationship between the protein structure of monoclonal antibodies (mAbs) and their macroscopic process behavior. Especially the development of preparative chromatography processes is challenged by the increasing structural complexity of novel antibody formats and accelerated development timelines. This study introduces a multiscale in silico model consisting of homology modeling, quantitative structure-property relationships (QSPR), and mechanistic chromatography modeling leading from the amino acid sequence of a mAb to the digital representation of its cation exchange chromatography (CEX) process. The model leverages the mAbs' structural characteristics and experimental data of a diverse set of 21 therapeutic antibodies to predict elution profiles of two mAbs that were removed from the training data set. QSPR modeling identified mAb-specific protein descriptors relevant for the prediction of the thermodynamic equilibrium and the stoichiometric coefficient of the adsorption reaction. The consideration of two discrete conformational states of IgG4 mAbs enabled prediction of split-peak elution profiles. Starting from the sequence, the presented multiscale model allows in silico development of chromatography processes before protein material is available for experimental studies.
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Affiliation(s)
- David Saleh
- Institute of Process Engineering in Life Sciences, Section IV: Biomolecular Separation Engineering, Karlsruhe Institute of Technology (KIT), Karlsruhe, Germany.,Early Stage Bioprocess Development, Boehringer Ingelheim Pharma GmbH & Co. KG, Biberach an der Riss, Germany
| | - Rudger Hess
- Institute of Process Engineering in Life Sciences, Section IV: Biomolecular Separation Engineering, Karlsruhe Institute of Technology (KIT), Karlsruhe, Germany.,Early Stage Bioprocess Development, Boehringer Ingelheim Pharma GmbH & Co. KG, Biberach an der Riss, Germany
| | - Michelle Ahlers-Hesse
- Late Stage DSP Development, Boehringer Ingelheim Pharma GmbH & Co. KG, Biberach an der Riss, Germany
| | - Federico Rischawy
- Institute of Process Engineering in Life Sciences, Section IV: Biomolecular Separation Engineering, Karlsruhe Institute of Technology (KIT), Karlsruhe, Germany.,Late Stage DSP Development, Boehringer Ingelheim Pharma GmbH & Co. KG, Biberach an der Riss, Germany
| | - Gang Wang
- Late Stage DSP Development, Boehringer Ingelheim Pharma GmbH & Co. KG, Biberach an der Riss, Germany
| | - Jan-Hendrik Grosch
- Early Stage Bioprocess Development, Boehringer Ingelheim Pharma GmbH & Co. KG, Biberach an der Riss, Germany
| | - Thomas Schwab
- Early Stage Bioprocess Development, Boehringer Ingelheim Pharma GmbH & Co. KG, Biberach an der Riss, Germany
| | - Simon Kluters
- Late Stage DSP Development, Boehringer Ingelheim Pharma GmbH & Co. KG, Biberach an der Riss, Germany
| | - Joey Studts
- Late Stage DSP Development, Boehringer Ingelheim Pharma GmbH & Co. KG, Biberach an der Riss, Germany
| | - Jürgen Hubbuch
- Institute of Process Engineering in Life Sciences, Section IV: Biomolecular Separation Engineering, Karlsruhe Institute of Technology (KIT), Karlsruhe, Germany
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8
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Khanal O. Mathematical modeling and process analytical technology for continuous chromatography of biopharmaceutical products. Curr Opin Biotechnol 2022; 78:102796. [PMID: 36152423 DOI: 10.1016/j.copbio.2022.102796] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/01/2021] [Revised: 08/13/2022] [Accepted: 08/25/2022] [Indexed: 12/14/2022]
Abstract
Chromatography is a widely used separation method that is inherently a batch operation. However, the demand for higher productivity and lower cost and labor has prompted industries such as the petrochemical and food industries to transition from batch to continuous chromatography. Growing market competition in the biopharmaceutical industry and the rise of novel biotherapeutics modalities have brought about promising continuous chromatography methods as well as next-generation tools to enable continuous operation in bioprocessing. While these continuous chromatography methods outperform their batch counterpart, their implementation presents challenges due to their greater complexity. This review discusses two key technologies that are essential for the implementation of continuous chromatography: mathematical modeling and novel process analytical technologies. Mechanistic-based models not only aid in process development and optimization but also allow for greater process control and automation.
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Affiliation(s)
- Ohnmar Khanal
- Department of Chemical and Biomolecular Engineering, University of Delaware, Newark, DE 19716, USA.
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9
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Kim TK, Sechi B, Romero Conde JJ, Angelo J, Xu X, Ghose S, Morbidelli M, Sponchioni M. Design and economic investigation of a Multicolumn Countercurrent Solvent Gradient Purification unit for the separation of an industrially relevant PEGylated protein. J Chromatogr A 2022; 1681:463487. [PMID: 36115185 DOI: 10.1016/j.chroma.2022.463487] [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: 07/08/2022] [Revised: 08/31/2022] [Accepted: 09/05/2022] [Indexed: 10/14/2022]
Abstract
Conjugation of biopharmaceuticals to polyethylene glycol chains, known as PEGylation, is nowadays an efficient and widely exploited strategy to improve critical properties of the active molecule, including stability, biodistribution profile, and reduced clearance. A crucial step in the manufacturing of PEGylated drugs is the purification. The reference process in industrial settings is single-column chromatography, which can meet the stringent purity requisites only at the expenses of poor product recoveries. A valuable solution to this trade-off is the Multicolumn Countercurrent Solvent Gradient Purification (MCSGP), which allows the internal and automated recycling of product-containing side fractions that are typically discarded in the batch processes. In this study, an ad hoc design procedure was applied to the single-column batch purification of an industrially relevant PEGylated protein, with the aim of defining optimal collection window, elution duration and elution buffer ionic strength to be then transferred to the MCSGP. This significantly alleviates the design of the continuous operation, subjected to manifold process parameters. The MCSGP designed by directly transferring the optimal parameters allowed to improve the yield and productivity by 8.2% and 17.8%, respectively, when compared to the corresponding optimized batch process, ensuring a purity specification of 98.0%. Once the efficacy of MCSGP was demonstrated, a detailed analysis of its cost of goods was performed and compared to the case of single-column purification. To the best of our knowledge, this is the first example of a detailed economic investigation of the MCSGP across different manufacturing scenarios and process cadences of industrial relevance, which demonstrated not only the viability of this continuous technology but also its flexibility.
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Affiliation(s)
- Tae Keun Kim
- Department of Chemistry, Materials and Chemical Engineering, Politecnico di Milano, Via Mancinelli 7, Milano 20131, Italy
| | - Benedetta Sechi
- Department of Chemistry, Materials and Chemical Engineering, Politecnico di Milano, Via Mancinelli 7, Milano 20131, Italy
| | - Juan Jose Romero Conde
- Biologics Process Development, Global Product Development and Supply, Bristol Myers Squibb Inc., Devens, MA 01434, USA
| | - James Angelo
- Biologics Process Development, Global Product Development and Supply, Bristol Myers Squibb Inc., Devens, MA 01434, USA
| | - Xuankuo Xu
- Biologics Process Development, Global Product Development and Supply, Bristol Myers Squibb Inc., Devens, MA 01434, USA
| | - Sanchayita Ghose
- Biologics Process Development, Global Product Development and Supply, Bristol Myers Squibb Inc., Devens, MA 01434, USA
| | - Massimo Morbidelli
- Department of Chemistry, Materials and Chemical Engineering, Politecnico di Milano, Via Mancinelli 7, Milano 20131, Italy
| | - Mattia Sponchioni
- Department of Chemistry, Materials and Chemical Engineering, Politecnico di Milano, Via Mancinelli 7, Milano 20131, Italy.
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10
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Underwood DJ, Bettencourt J, Jawad Z. The manufacturing considerations of bispecific antibodies. Expert Opin Biol Ther 2022; 22:1043-1065. [PMID: 35771976 DOI: 10.1080/14712598.2022.2095900] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/04/2022]
Abstract
INTRODUCTION Antibody therapies have made huge strides in providing safe and efficacious drugs for autoimmune, cancer and infectious disease. These bispecific antibodies can be assembled from the basic building blocks of IgGs, resulting in dozens of formats. AREAS COVERED It is important to consider the manufacturability of these formats early in the antibody discovery phases. Broadly categorizing bispecific antibodies into IgG-like, fragment-based, appended and hybrid formats can help in looking at early manufacturability considerations. EXPERT OPINION Ideally, bispecific antibody manufacturing should contain a minimal number of steps, with processes that give high yields of protein with no contaminants. Many of these have been determined for the fragment-based bispecific blinatumomab and the IgG-like bispecifics from hybridomas. However, for new formats, these need to be considered early in the research and development pipeline. The hybrid formats offer an unusual alternative in generating high pure yields of bispecific molecules if the engineering challenges can be deciphered.
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Affiliation(s)
| | | | - Zahra Jawad
- Agenus inc., 3 Forbes Road, Lexington, MA, 02421-7305, United States.,Creasallis ltd, Babraham Research Campus, Babraham, Cambridgeshire, CB22 3AT, United Kingdom
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11
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Continuous Affinity Purification of Adeno-Associated Virus Using Periodic Counter-Current Chromatography. Pharmaceutics 2022; 14:pharmaceutics14071346. [PMID: 35890242 PMCID: PMC9323845 DOI: 10.3390/pharmaceutics14071346] [Citation(s) in RCA: 5] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/19/2022] [Revised: 06/11/2022] [Accepted: 06/23/2022] [Indexed: 11/17/2022] Open
Abstract
Replacing batch unit operations of biopharmaceuticals by continuous manufacturing is a maturing concept, with periodic counter-current chromatography (PCC) favoured to replace batch chromatography. Continuous affinity capture of adeno-associated virus (AAV) using PCC has the potential to cope with the high doses required for AAV therapies thanks to its inherent high throughput. The implementation of continuous AAV affinity capture using a four-column PCC process is described herein. First, elution buffer screening was used to optimize virus recovery. Second, breakthrough curves were generated and described using a mechanistic model, which was later used to characterize the loading zone of the PCC. The experimental runs achieved a stable cyclic steady state yielding virus recoveries in line with the optimized batch process (>82%), with almost a three-fold improvement in productivity. The PCC affinity capture process developed here can bolster further improvements to process economics and manufacturing footprint, thereby contributing to the integrated continuous manufacturing concept.
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12
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Domonkos D, Könczöl K, Török I. Design of mammalian cell-based biotechnology plants. DRUG DISCOVERY TODAY. TECHNOLOGIES 2021; 40:3-11. [PMID: 34916019 DOI: 10.1016/j.ddtec.2021.08.004] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Received: 07/22/2020] [Revised: 06/13/2021] [Accepted: 08/05/2021] [Indexed: 11/29/2022]
Abstract
This review provides an overview of the various theoretical and practical aspects of biotech plant design. It covers engineering, quality, regulatory, safety, environmental and economical points to be considered. Current knowledge and future trends as well as their impact on the planning and design are also discussed.
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Affiliation(s)
- David Domonkos
- University of Debrecen, Egyetem tér 1, H-4032 Debrecen, Hungary.
| | | | - Imre Török
- Zolend Ltd., Házgyár utca 17, H-4031 Debrecen, Hungary
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13
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Separation of charge variants of a monoclonal antibody by overloaded ion exchange chromatography. J Chromatogr A 2021; 1658:462607. [PMID: 34656842 DOI: 10.1016/j.chroma.2021.462607] [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: 08/19/2021] [Revised: 09/24/2021] [Accepted: 10/01/2021] [Indexed: 11/21/2022]
Abstract
A procedure for adjusting the content of charge variants of monoclonal antibody by ion exchange chromatography has been developed. The band splitting phenomenon was utilized to split the protein load into two parts, i.e., the flowthrough and bound fractions, which were either enriched or depleted with some of variants. The phenomenon was triggered by thermodynamic effects resulting from oversaturation of the resin binding sites at high column loadings as well as from kinetic effects arising from limited rates of mass transport. Cation exchange chromatography (CEX) and anion exchange chromatography (AEX) separations were examined, with the reverse order of the variant elution: acidic, main, basic in CEX, and basic, main, acidic in AEX, and the corresponding reverse enrichment tendency in the collected fractions. The separations were performed by pH gradient, whose course was simplified to two stages: isocratic loading and washing at mild pH to load and partly elute the protein, followed by a rapid pH change towards non-binding conditions to desorb the remains of the protein load. To improve yield of the operation, possibility of recycling of waste fractions was considered. To predict the process performance, a dynamic model was developed, which accounted for both adsorption kinetics and thermodynamics.
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14
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Fast and Flexible mRNA Vaccine Manufacturing as a Solution to Pandemic Situations by Adopting Chemical Engineering Good Practice—Continuous Autonomous Operation in Stainless Steel Equipment Concepts. Processes (Basel) 2021. [DOI: 10.3390/pr9111874] [Citation(s) in RCA: 12] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/20/2022] Open
Abstract
SARS-COVID-19 vaccine supply for the total worldwide population has a bottleneck in manufacturing capacity. Assessment of existing messenger ribonucleic acid (mRNA) vaccine processing shows a need for digital twins enabled by process analytical technology approaches in order to improve process transfer for manufacturing capacity multiplication, a reduction in out-of-specification batch failures, qualified personal training for faster validation and efficient operation, optimal utilization of scarce buffers and chemicals and speed-up of product release by continuous manufacturing. In this work, three manufacturing concepts for mRNA-based vaccines are evaluated: Batch, full-continuous and semi-continuous. Technical transfer from batch single-use to semi-continuous stainless-steel, i.e., plasmid deoxyribonucleic acid (pDNA) in batch and mRNA in continuous operation mode, is recommended, in order to gain: faster plant commissioning and start-up times of about 8–12 months and a rise in dose number by a factor of about 30 per year, with almost identical efforts in capital expenditures (CAPEX) and personnel resources, which are the dominant bottlenecks at the moment, at about 25% lower operating expenses (OPEX). Consumables are also reduceable by a factor of 6 as outcome of this study. Further optimization potential is seen at consequent digital twin and PAT (Process Analytical Technology) concept integration as key-enabling technologies towards autonomous operation including real-time release-testing.
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15
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Jing S, Shi C, Leong HY, Yuan J, Gao D, Wang H, Yao S, Lin D. A novel twin-column continuous chromatography approach for separation and enrichment of monoclonal antibody charge variants. Eng Life Sci 2021; 21:382-391. [PMID: 34140849 PMCID: PMC8182273 DOI: 10.1002/elsc.202000094] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/28/2021] [Revised: 04/13/2021] [Accepted: 04/20/2021] [Indexed: 11/29/2022] Open
Abstract
Downstream processing of mAb charge variants is difficult owing to their similar molecular structures and surface charge properties. This study aimed to apply a novel twin-column continuous chromatography (called N-rich mode) to separate and enrich acidic variants of an IgG1 mAb. Besides, a comparison study with traditional scaled-up batch-mode cation exchange (CEX) chromatography was conducted. For the N-rich process, two 3.93 mL columns were used, and the buffer system, flow rate and elution gradient slope were optimized. The results showed that 1.33 mg acidic variants with nearly 100% purity could be attained after a 22-cycle accumulation. The yield was 86.21% with the productivity of 7.82 mg/L/h. On the other hand, for the batch CEX process, 4.15 mL column was first used to optimize the separation conditions, and then a scaled-up column of 88.20 mL was used to separate 1.19 mg acidic variants with the purity of nearly 100%. The yield was 59.18% with the productivity of 7.78 mg/L/h. By comparing between the N-rich and scaled-up CEX processes, the results indicated that the N-rich method displays a remarkable advantage on the product yield, i.e. 1.46-fold increment without the loss of productivity and purity. Generally, twin-column N-rich continuous chromatography displays a high potential to enrich minor compounds with a higher yield, more flexibility and lower resin cost.
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Affiliation(s)
- Shu‐Ying Jing
- Key Laboratory of Biomass Chemical Engineering of Ministry of EducationCollege of Chemical and Biological EngineeringZhejiang UniversityHangzhouP. R. China
| | - Ce Shi
- Key Laboratory of Biomass Chemical Engineering of Ministry of EducationCollege of Chemical and Biological EngineeringZhejiang UniversityHangzhouP. R. China
| | - Hui Yi Leong
- Key Laboratory of Biomass Chemical Engineering of Ministry of EducationCollege of Chemical and Biological EngineeringZhejiang UniversityHangzhouP. R. China
| | - Jun‐Jie Yuan
- BioRay Pharmaceutical Co., Ltd.TaizhouP. R. China
| | - Dong Gao
- BioRay Pharmaceutical Co., Ltd.TaizhouP. R. China
| | - Hai‐Bin Wang
- BioRay Pharmaceutical Co., Ltd.TaizhouP. R. China
| | - Shan‐Jing Yao
- Key Laboratory of Biomass Chemical Engineering of Ministry of EducationCollege of Chemical and Biological EngineeringZhejiang UniversityHangzhouP. R. China
| | - Dong‐Qiang Lin
- Key Laboratory of Biomass Chemical Engineering of Ministry of EducationCollege of Chemical and Biological EngineeringZhejiang UniversityHangzhouP. R. China
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16
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Saleh D, Hess R, Ahlers-Hesse M, Beckert N, Schönberger M, Rischawy F, Wang G, Bauer J, Blech M, Kluters S, Studts J, Hubbuch J. Modeling the impact of amino acid substitution in a monoclonal antibody on cation exchange chromatography. Biotechnol Bioeng 2021; 118:2923-2933. [PMID: 33871060 DOI: 10.1002/bit.27798] [Citation(s) in RCA: 8] [Impact Index Per Article: 2.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/09/2020] [Revised: 02/23/2021] [Accepted: 04/15/2021] [Indexed: 01/03/2023]
Abstract
A vital part of biopharmaceutical research is decision making around which lead candidate should be progressed in early-phase development. When multiple antibody candidates show similar biological activity, developability aspects are taken into account to ease the challenges of manufacturing the potential drug candidate. While current strategies for developability assessment mainly focus on drug product stability, only limited information is available on how antibody candidates with minimal differences in their primary structure behave during downstream processing. With increasing time-to-market pressure and an abundance of monoclonal antibodies (mAbs) in development pipelines, developability assessments should also consider the ability of mAbs to integrate into the downstream platform. This study investigates the influence of amino acid substitutions in the complementarity-determining region (CDR) of a full-length IgG1 mAb on the elution behavior in preparative cation exchange chromatography. Single amino acid substitutions within the investigated mAb resulted in an additional positive charge in the light chain (L) and heavy chain (H) CDR, respectively. The mAb variants showed an increased retention volume in linear gradient elution compared with the wild-type antibody. Furthermore, the substitution of tryptophan with lysine in the H-CDR3 increased charge heterogeneity of the product. A multiscale in silico analysis, consisting of homology modeling, protein surface analysis, and mechanistic chromatography modeling increased understanding of the adsorption mechanism. The results reveal the potential effects of lead optimization during antibody drug discovery on downstream processing.
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Affiliation(s)
- David Saleh
- Late Stage DSP Development, Boehringer Ingelheim, Biberach, Germany.,Institute of Engineering in Life Sciences, Section IV: Biomolecular Separation Engineering, Karlsruhe Institute of Technology (KIT), Karlsruhe, Germany
| | - Rudger Hess
- Late Stage DSP Development, Boehringer Ingelheim, Biberach, Germany.,Institute of Engineering in Life Sciences, Section IV: Biomolecular Separation Engineering, Karlsruhe Institute of Technology (KIT), Karlsruhe, Germany
| | | | - Nicole Beckert
- Pharmaceutical Development Biologics, Boehringer Ingelheim, Biberach, Germany
| | | | - Federico Rischawy
- Late Stage DSP Development, Boehringer Ingelheim, Biberach, Germany.,Institute of Engineering in Life Sciences, Section IV: Biomolecular Separation Engineering, Karlsruhe Institute of Technology (KIT), Karlsruhe, Germany
| | - Gang Wang
- Late Stage DSP Development, Boehringer Ingelheim, Biberach, Germany
| | - Joschka Bauer
- Pharmaceutical Development Biologics, Boehringer Ingelheim, Biberach, Germany
| | - Michaela Blech
- Pharmaceutical Development Biologics, Boehringer Ingelheim, Biberach, Germany
| | - Simon Kluters
- Late Stage DSP Development, Boehringer Ingelheim, Biberach, Germany
| | - Joey Studts
- Late Stage DSP Development, Boehringer Ingelheim, Biberach, Germany
| | - Jürgen Hubbuch
- Institute of Engineering in Life Sciences, Section IV: Biomolecular Separation Engineering, Karlsruhe Institute of Technology (KIT), Karlsruhe, Germany
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17
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De Luca C, Felletti S, Bozza D, Lievore G, Morbidelli M, Sponchioni M, Cavazzini A, Catani M, Cabri W, Macis M, Ricci A. Process Intensification for the Purification of Peptidomimetics: The Case of Icatibant through Multicolumn Countercurrent Solvent Gradient Purification (MCSGP). Ind Eng Chem Res 2021. [DOI: 10.1021/acs.iecr.1c00520] [Citation(s) in RCA: 7] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/08/2023]
Affiliation(s)
- Chiara De Luca
- Department of Chemistry and Pharmaceutical Sciences, University of Ferrara, via L. Borsari 46, Ferrara, 44121, Italy
| | - Simona Felletti
- Department of Chemistry and Pharmaceutical Sciences, University of Ferrara, via L. Borsari 46, Ferrara, 44121, Italy
| | - Desiree Bozza
- Department of Chemistry and Pharmaceutical Sciences, University of Ferrara, via L. Borsari 46, Ferrara, 44121, Italy
| | - Giulio Lievore
- Department of Chemistry and Pharmaceutical Sciences, University of Ferrara, via L. Borsari 46, Ferrara, 44121, Italy
| | - Massimo Morbidelli
- Department of Chemistry, Materials and Chemical Engineering Giulio Natta, Politecnico di Milano, via Mancinelli 7, Milan, 20131, Italy
| | - Mattia Sponchioni
- Department of Chemistry, Materials and Chemical Engineering Giulio Natta, Politecnico di Milano, via Mancinelli 7, Milan, 20131, Italy
| | - Alberto Cavazzini
- Department of Chemistry and Pharmaceutical Sciences, University of Ferrara, via L. Borsari 46, Ferrara, 44121, Italy
| | - Martina Catani
- Department of Chemistry and Pharmaceutical Sciences, University of Ferrara, via L. Borsari 46, Ferrara, 44121, Italy
| | - Walter Cabri
- Department of Chemistry “Giacomo Ciamician”, Alma Mater Studiorum − University of Bologna, Via Selmi 2, Bologna, 40126, Italy
- Fresenius Kabi iPSUM Srl, I&D, Via San Leonardo 23, Villadose (Rovigo), 45010, Italy
| | - Marco Macis
- Fresenius Kabi iPSUM Srl, I&D, Via San Leonardo 23, Villadose (Rovigo), 45010, Italy
| | - Antonio Ricci
- Fresenius Kabi iPSUM Srl, I&D, Via San Leonardo 23, Villadose (Rovigo), 45010, Italy
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18
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Mendes JP, Silva RJS, Berg M, Mathiasson L, Peixoto C, Alves PM, Carrondo MJT. Oncolytic virus purification with periodic counter-current chromatography. Biotechnol Bioeng 2021; 118:3522-3532. [PMID: 33818758 DOI: 10.1002/bit.27779] [Citation(s) in RCA: 7] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/06/2020] [Revised: 03/08/2021] [Accepted: 03/25/2021] [Indexed: 11/11/2022]
Abstract
Virus-based biologicals are one of the most promising biopharmaceuticals of the 21st century medicine and play a significant role in the development of innovative therapeutic, prophylactic, and clinical applications. Oncolytic virus manufacturing scale can range from 5 L in research and development up to 50 L for clinical studies and reach hundreds of liters for commercial scale. The inherent productivity and high integration potential of periodic counter-current chromatography (PCC) offer a transversal solution to decrease equipment footprint and the reduction of several non-value-added unit operations. We report on the design of an efficient PCC process applied to the intermediate purification of oncolytic adenovirus. The developed ion-exchange chromatographic purification method was carried out using a four-column setup for three different scenarios: (i) variation in the feedstock, (ii) potential use of a post-load washing step to improve virus recovery, and (iii) stability during extended operation. Obtained virus recoveries (57%-86%) and impurity reductions (>80% DNA, and >70% total protein) match or overcome batch purification. Regarding process stability and automation, our results show that not only the dynamic control strategy used is able to suppress perturbations in the sample inlet but also allows for unattended operation in the case of ion exchange capture.
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Affiliation(s)
- João P Mendes
- iBET, Instituto de Biologia Experimental e Tecnológica, Oeiras, Portugal.,Instituto de Tecnologia Química e Biológica António Xavier, Universidade Nova de Lisboa, Oeiras, Portugal
| | - Ricardo J S Silva
- iBET, Instituto de Biologia Experimental e Tecnológica, Oeiras, Portugal.,Instituto de Tecnologia Química e Biológica António Xavier, Universidade Nova de Lisboa, Oeiras, Portugal
| | | | | | - Cristina Peixoto
- iBET, Instituto de Biologia Experimental e Tecnológica, Oeiras, Portugal.,Instituto de Tecnologia Química e Biológica António Xavier, Universidade Nova de Lisboa, Oeiras, Portugal
| | - Paula M Alves
- iBET, Instituto de Biologia Experimental e Tecnológica, Oeiras, Portugal.,Instituto de Tecnologia Química e Biológica António Xavier, Universidade Nova de Lisboa, Oeiras, Portugal
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19
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PAT for Continuous Chromatography Integrated into Continuous Manufacturing of Biologics towards Autonomous Operation. Processes (Basel) 2021. [DOI: 10.3390/pr9030472] [Citation(s) in RCA: 9] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/31/2022] Open
Abstract
This study proposes a reliable inline PAT concept for the simultaneous monitoring of different product components after chromatography. The feed for purification consisted of four main components, IgG monomer, dimer, and two lower molecular weight components of 4.4 kDa and 1 kDa molecular weight. The proposed measurement setup consists of a UV–VIS diode-array detector and a fluorescence detector. Applying this system, a R2 of 0.93 for the target component, a R2 of 0.67 for the dimer, a R2 of 0.91 for the first side component and a R2 of 0.93 for the second side component is achieved. Root mean square error for IgG monomer was 0.027 g/L, for dimer 0.0047 g/L, for side component 1 0.016 g/L and for the side component 2 0.014 g/L. The proposed measurement concept tracked component concentration reliably down to 0.05 g/L. Zero-point fluctuations were kept within a standard deviation of 0.018 g/L for samples with no IgG concentration but with side components present, allowing a reliable detection of the target component. The main reason inline concentration measurements have not been established yet, is the false-positive measurement of target components when side components are present. This problem was eliminated using the combination of fluorescence and UV–VIS data for the test system. The use of this measurement system is simulated for the test system, allowing an automatic fraction cut at 0.05 g/L. In this simulation a consistent yield of >99% was achieved. Process disturbances for processed feed volume, feed purity and feed IgG concentration can be compensated with this setup. Compared to a timed process control, yield can be increased by up to 12.5%, if unexpected process disturbances occur.
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20
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Löfgren A, Gomis-Fons J, Andersson N, Nilsson B, Berghard L, Lagerquist Hägglund C. An integrated continuous downstream process with real-time control: A case study with periodic countercurrent chromatography and continuous virus inactivation. Biotechnol Bioeng 2021; 118:1664-1676. [PMID: 33459355 DOI: 10.1002/bit.27681] [Citation(s) in RCA: 8] [Impact Index Per Article: 2.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/16/2020] [Revised: 11/19/2020] [Accepted: 01/12/2021] [Indexed: 11/11/2022]
Abstract
Integrated continuous downstream processes with process analytical technology offer a promising opportunity to reduce production costs and increase process flexibility and adaptability. In this case study, an integrated continuous process was used to purify a recombinant protein on laboratory scale in a two-system setup that can be used as a general downstream setup offering multiproduct and multipurpose manufacturing capabilities. The process consisted of continuous solvent/detergent virus inactivation followed by periodic countercurrent chromatography in the capture step, and a final chromatographic polishing step. A real-time controller was implemented to ensure stable operation by adapting the downstream process to external changes. A concentration disturbance was introduced to test the controller. After the disturbance was applied, the product output recovered within 6 h, showing the effectiveness of the controller. In a comparison of the process with and without the controller, the product output per cycle increased by 27%, the resin utilization increased from 71.4% to 87.9%, and the specific buffer consumption was decreased by 21% with the controller, while maintaining a similar yield and purity as in the process without the disturbance. In addition, the integrated continuous process outperformed the batch process, increasing the productivity by 95% and the yield by 28%.
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Affiliation(s)
- Anton Löfgren
- Department of Chemical Engineering, Lund University, Lund, Sweden
| | - Joaquín Gomis-Fons
- Department of Chemical Engineering, Lund University, Lund, Sweden.,Royal Institute of Technology, Competence Centre for Advanced BioProduction by Continuous Processing, Stockholm, Sweden
| | - Niklas Andersson
- Department of Chemical Engineering, Lund University, Lund, Sweden
| | - Bernt Nilsson
- Department of Chemical Engineering, Lund University, Lund, Sweden.,Royal Institute of Technology, Competence Centre for Advanced BioProduction by Continuous Processing, Stockholm, Sweden
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21
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Towards Autonomous Operation by Advanced Process Control—Process Analytical Technology for Continuous Biologics Antibody Manufacturing. Processes (Basel) 2021. [DOI: 10.3390/pr9010172] [Citation(s) in RCA: 21] [Impact Index Per Article: 7.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/03/2023] Open
Abstract
Continuous manufacturing opens up new operation windows with improved product quality in contrast to documented lot deviations in batch or fed-batch operations. A more sophisticated process control strategy is needed to adjust operation parameters and keep product quality constant during long-term operations. In the present study, the applicability of a combination of spectroscopic methods was evaluated to enable Advanced Process Control (APC) in continuous manufacturing by Process Analytical Technology (PAT). In upstream processing (USP) and aqueous two-phase extraction (ATPE), Raman-, Fourier-transformed infrared (FTIR), fluorescence- and ultraviolet/visible- (UV/Vis) spectroscopy have been successfully applied for titer and purity prediction. Raman spectroscopy was the most versatile and robust method in USP, ATPE, and precipitation and is therefore recommended as primary PAT. In later process stages, the combination of UV/Vis and fluorescence spectroscopy was able to overcome difficulties in titer and purity prediction induced by overlapping side component spectra. Based on the developed spectroscopic predictions, dynamic control of unit operations was demonstrated in sophisticated simulation studies. A PAT development workflow for holistic process development was proposed.
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22
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Advanced control strategies for bioprocess chromatography: Challenges and opportunities for intensified processes and next generation products. J Chromatogr A 2021; 1639:461914. [PMID: 33503524 DOI: 10.1016/j.chroma.2021.461914] [Citation(s) in RCA: 15] [Impact Index Per Article: 5.0] [Reference Citation Analysis] [Abstract] [Key Words] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/13/2020] [Revised: 01/05/2021] [Accepted: 01/13/2021] [Indexed: 02/08/2023]
Abstract
Recent advances in process analytical technologies and modelling techniques present opportunities to improve industrial chromatography control strategies to enhance process robustness, increase productivity and move towards real-time release testing. This paper provides a critical overview of batch and continuous industrial chromatography control systems for therapeutic protein purification. Firstly, the limitations of conventional industrial fractionation control strategies using in-line UV spectroscopy and on-line HPLC are outlined. Following this, an evaluation of monitoring and control techniques showing promise within research, process development and manufacturing is provided. These novel control strategies combine rapid in-line data capture (e.g. NIR, MALS and variable pathlength UV) with enhanced process understanding obtained from mechanistic and empirical modelling techniques. Finally, a summary of the future states of industrial chromatography control systems is proposed, including strategies to control buffer formulation, product fractionation, column switching and column fouling. The implementation of these control systems improves process capabilities to fulfil product quality criteria as processes are scaled, transferred and operated, thus fast tracking the delivery of new medicines to market.
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23
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Lin DQ, Zhang QL, Yao SJ. Model-assisted approaches for continuous chromatography: Current situation and challenges. J Chromatogr A 2020; 1637:461855. [PMID: 33445032 DOI: 10.1016/j.chroma.2020.461855] [Citation(s) in RCA: 15] [Impact Index Per Article: 3.8] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/02/2020] [Revised: 12/01/2020] [Accepted: 12/23/2020] [Indexed: 12/28/2022]
Abstract
Continuous bioprocessing is a promising trend in biopharmaceutical production, and multi-column continuous chromatography shows advantages of high productivity, high resin capacity utilization, small footprint, low buffer consumption and less waste. Due to the complexity and dynamic nature of continuous processing, traditional experiment-based approaches are often time-consuming and inefficient. In this review, model-assisted approaches were focused and their applications in continuous chromatography process development, validation and control were discussed. Chromatographic models are useful in describing particular process performances of continuous capture and polishing with multi-column chromatography. Model-assisted tools showed powerful ability in evaluating multiple operating parameters and identifying optimal points over the entire design space. The residence time distribution models, model-assisted process analytical technologies and model-predictive control strategies were also developed to reveal the propagation of disturbances, enhance real time monitor and achieve adaptive control to match the transient disturbances and deviations of continuous processes. Moreover, artificial neural networks and machine learning concepts were integrated into modeling approaches to improve data treatment. In general, further development in research and applications of model-assisted approaches for continuous chromatography are needed urgently to support the continuous manufacturing.
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Affiliation(s)
- Dong-Qiang Lin
- Key Laboratory of Biomass Chemical Engineering of Ministry of Education, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou310027, China.
| | - Qi-Lei Zhang
- Key Laboratory of Biomass Chemical Engineering of Ministry of Education, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou310027, China
| | - Shan-Jing Yao
- Key Laboratory of Biomass Chemical Engineering of Ministry of Education, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou310027, China
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24
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Luca CD, Felletti S, Lievore G, Buratti A, Vogg S, Morbidelli M, Cavazzini A, Catani M, Macis M, Ricci A, Cabri W. From batch to continuous chromatographic purification of a therapeutic peptide through multicolumn countercurrent solvent gradient purification. J Chromatogr A 2020; 1625:461304. [PMID: 32709347 DOI: 10.1016/j.chroma.2020.461304] [Citation(s) in RCA: 10] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/27/2020] [Revised: 05/27/2020] [Accepted: 06/01/2020] [Indexed: 12/22/2022]
Abstract
A twin-column Multicolumn Countercurrent Solvent Gradient Purification (MCSGP) process has been developed for the purification of a therapeutic peptide, glucagon, from a crude synthetic mixture. This semi-continuous process uses two identical columns operating either in interconnected or in batch mode, thus enabling the internal recycle of the portions of the eluting stream which do not comply with purity specifications. Because of this feature, which actually results in the simulated countercurrent movement of the stationary phase with respect to the mobile one, the yield-purity trade-off typical of traditional batch preparative chromatography can be alleviated. Moreover, the purification process can be completely automatized. Aim of this work is to present a simple procedure for the development of the MCSGP process based on a single batch experiment, in the case of a therapeutic peptide of industrial relevance. This allowed to recover roughly 90% of the injected glucagon in a purified pool with a purity of about 90%. A comparison between the performance of the MCSGP process and the classical single column batch process indicates that percentage increase in the recovery of target product is +23% when transferring the method from batch conditions to MCSGP, with an unchanged purity of around 89%. This improvement comes at the expenses of a reduction of about 38% in productivity.
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Affiliation(s)
- Chiara De Luca
- Dept. of Chemistry and Pharmaceutical Sciences, University of Ferrara, via L. Borsari 46, 44121 Ferrara, Italy
| | - Simona Felletti
- Dept. of Chemistry and Pharmaceutical Sciences, University of Ferrara, via L. Borsari 46, 44121 Ferrara, Italy
| | - Giulio Lievore
- Dept. of Chemistry and Pharmaceutical Sciences, University of Ferrara, via L. Borsari 46, 44121 Ferrara, Italy
| | - Alessandro Buratti
- Dept. of Chemistry and Pharmaceutical Sciences, University of Ferrara, via L. Borsari 46, 44121 Ferrara, Italy
| | - Sebastian Vogg
- Institute for Chemical and Bioengineering, ETH Zurich, Vladimir-Prelog-Weg 1, 8093 Zurich, Switzerland
| | - Massimo Morbidelli
- Institute for Chemical and Bioengineering, ETH Zurich, Vladimir-Prelog-Weg 1, 8093 Zurich, Switzerland
| | - Alberto Cavazzini
- Dept. of Chemistry and Pharmaceutical Sciences, University of Ferrara, via L. Borsari 46, 44121 Ferrara, Italy
| | - Martina Catani
- Dept. of Chemistry and Pharmaceutical Sciences, University of Ferrara, via L. Borsari 46, 44121 Ferrara, Italy.
| | - Marco Macis
- Fresenius Kabi iPSUM, via San Leonardo 23, 45010, Villadose, Rovigo, Italy
| | - Antonio Ricci
- Fresenius Kabi iPSUM, via San Leonardo 23, 45010, Villadose, Rovigo, Italy.
| | - Walter Cabri
- Fresenius Kabi iPSUM, via San Leonardo 23, 45010, Villadose, Rovigo, Italy; Department of Chemistry "G. Ciamician", University of Bologna, via Selmi 2, 40126, Bologna, Italy
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25
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Jing SY, Gou JX, Gao D, Wang HB, Yao SJ, Lin DQ. Separation of monoclonal antibody charge variants using cation exchange chromatography: Resins and separation conditions optimization. Sep Purif Technol 2020. [DOI: 10.1016/j.seppur.2019.116136] [Citation(s) in RCA: 9] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/30/2022]
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26
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Distinct and Quantitative Validation Method for Predictive Process Modelling in Preparative Chromatography of Synthetic and Bio-Based Feed Mixtures Following a Quality-by-Design (QbD) Approach. Processes (Basel) 2019. [DOI: 10.3390/pr7090580] [Citation(s) in RCA: 17] [Impact Index Per Article: 3.4] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022] Open
Abstract
Process development, especially in regulated industries, where quality-by-design approaches have become a prerequisite, is cost intensive and time consuming. A main factor is the large number of experiments needed. Process modelling can reduce this number significantly by replacing experiments with simulations. However, this requires a validated model. In this paper, a process and model development workflow is presented, which focuses on implementing, parameterizing, and validating the model in four steps. The presented methods are laid out to gain, create, or generate the maximum information and process knowledge needed for successful process development. This includes design of experiments and statistical evaluations showing process robustness, sensitivity of target values to process parameters, and correlations between process and target values. Two case studies are presented. An ion exchange capture step for monoclonal antibodies focusing on high accuracy and low feed consumption; and one case study for small molecules focusing on rapid process development, emphasizing speed of parameter determination.
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27
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Ulmer N, Vogg S, Müller-Späth T, Morbidelli M. Purification of Human Monoclonal Antibodies and Their Fragments. Methods Mol Biol 2019; 1904:163-188. [PMID: 30539470 DOI: 10.1007/978-1-4939-8958-4_7] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.2] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/18/2023]
Abstract
This chapter summarizes the most common chromatographic mAb and mAb fragment purification methods, starting by elucidating the relevant properties of the compounds and introducing the various chromatography modes that are available and useful for this application. A focus is put on the capture step affinity and ion-exchange chromatography. Aspects of scalability play an important role in judging the suitability of the methods. The chapter introduces also analytical chromatographic methods that can be utilized for quantification and purity control of the product. In the case of mAbs, for most purposes the purity obtained using an affinity capture step is sufficient. Polishing steps are required if material of particularly high purity needs to be generated. For mAb fragments, affinity chromatography is not yet fully established, and the capture step potentially may not provide material of high purity. Therefore, the available polishing techniques are touched upon briefly. In the case of mAb isoform and bispecific antibody purification, countercurrent chromatography techniques have proven to be very useful and a part of this chapter has been dedicated to them, paying tribute to the rising interest in these antibody formats in research and industry.
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Affiliation(s)
- Nicole Ulmer
- ETH Zurich, Institute for Chemical and Bioengineering, Zurich, Switzerland
| | - Sebastian Vogg
- ETH Zurich, Institute for Chemical and Bioengineering, Zurich, Switzerland
| | | | - Massimo Morbidelli
- ETH Zurich, Institute for Chemical and Bioengineering, Zurich, Switzerland.
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28
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29
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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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30
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Multi-column displacement chromatography for separation of charge variants of monoclonal antibodies. J Chromatogr A 2019; 1586:40-51. [DOI: 10.1016/j.chroma.2018.11.074] [Citation(s) in RCA: 24] [Impact Index Per Article: 4.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/29/2018] [Revised: 11/26/2018] [Accepted: 11/28/2018] [Indexed: 11/19/2022]
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31
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Papathanasiou MM, Burnak B, Katz J, Müller-Späth T, Morbidelli M, Shah N, Pistikopoulos EN. Control of Small-Scale Chromatographic Systems Under Disturbances. COMPUTER AIDED CHEMICAL ENGINEERING 2019. [DOI: 10.1016/b978-0-12-818597-1.50043-6] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 12/27/2022]
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32
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Development and Validation of Salt Gradient CEX Chromatography Method for Charge Variants Separation and Quantitative Analysis of the IgG mAb-Cetuximab. Chromatographia 2018. [DOI: 10.1007/s10337-018-3627-9] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/17/2023]
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33
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Zobel-Roos S, Stein D, Strube J. Evaluation of Continuous Membrane Chromatography Concepts with an Enhanced Process Simulation Approach. Antibodies (Basel) 2018; 7:E13. [PMID: 31544865 PMCID: PMC6698847 DOI: 10.3390/antib7010013] [Citation(s) in RCA: 17] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/03/2018] [Revised: 02/20/2018] [Accepted: 02/27/2018] [Indexed: 01/26/2023] Open
Abstract
Modern biopharmaceutical products strive for small-scale, low-cost production. Continuous chromatography has shown to be a promising technology because it assures high-capacity utilization, purity and yield increases, and lower facility footprint. Membrane chromatography is a fully disposable low-cost alternative to bead-based chromatography with minor drawbacks in terms of capacity. Hence, continuous membrane chromatography should have a high potential. The evaluation of continuous processes goes often along with process modeling. Only few experiments with small feed demand need to be conducted to estimate the model parameters. Afterwards, a variety of different process setups and working points can be analyzed in a very short time, making the approach very efficient. Since the available modeling approaches for membrane chromatography modules did not fit the used design, a new modeling approach is shown. This combines the general rate model with an advanced fluid dynamic distribution. Model parameter determination and model validation were done with industrial cell cultures containing Immunoglobulin G (IgG). The validated model was used to evaluate the feasibility of the integrated Counter Current Chromatography (iCCC) concept and the sequential chromatography concept for membrane adsorber modules, starting with a laboratory-type module used for sample preparation. A case study representing a fed-batch reactor with a capacity from 20 to 2000 L was performed. Compared to batch runs, a 71% higher capacity, 48.5% higher productivity, and 38% lower eluent consumption could be achieved.
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Affiliation(s)
- Steffen Zobel-Roos
- Institute for Separation and Process Technology, Clausthal University of Technology, Leibnizstraße 15, D-38678 Clausthal-Zellerfeld, Germany.
| | - Dominik Stein
- Institute for Separation and Process Technology, Clausthal University of Technology, Leibnizstraße 15, D-38678 Clausthal-Zellerfeld, Germany.
| | - Jochen Strube
- Institute for Separation and Process Technology, Clausthal University of Technology, Leibnizstraße 15, D-38678 Clausthal-Zellerfeld, Germany.
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34
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Papathanasiou MM, Steinebach F, Morbidelli M, Mantalaris A, Pistikopoulos EN. Intelligent, model-based control towards the intensification of downstream processes. Comput Chem Eng 2017. [DOI: 10.1016/j.compchemeng.2017.01.005] [Citation(s) in RCA: 17] [Impact Index Per Article: 2.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/17/2022]
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35
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Papathanasiou MM, Quiroga-Campano AL, Steinebach F, Elviro M, Mantalaris A, Pistikopoulos EN. Advanced model-based control strategies for the intensification of upstream and downstream processing in mAb production. Biotechnol Prog 2017; 33:966-988. [DOI: 10.1002/btpr.2483] [Citation(s) in RCA: 17] [Impact Index Per Article: 2.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/31/2016] [Revised: 03/10/2017] [Indexed: 01/17/2023]
Affiliation(s)
- Maria M. Papathanasiou
- Dept. of Chemical Engineering; Centre for Process Systems Engineering (CPSE), Imperial College London; London SW7 2AZ U.K
- Artie McFerrin Department of Chemical Engineering; Texas A&M University, College Station; TX 77843
| | - Ana L. Quiroga-Campano
- Dept. of Chemical Engineering; Centre for Process Systems Engineering (CPSE), Imperial College London; London SW7 2AZ U.K
| | - Fabian Steinebach
- Institute for Chemical and Bioengineering; ETH Zurich; olfgang-Pauli-Str. 10/HCI F 129, W Zurich CH-8093 Switzerland
| | - Montaña Elviro
- Dept. of Chemical Engineering; Centre for Process Systems Engineering (CPSE), Imperial College London; London SW7 2AZ U.K
| | - Athanasios Mantalaris
- Dept. of Chemical Engineering; Centre for Process Systems Engineering (CPSE), Imperial College London; London SW7 2AZ U.K
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36
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Gorczyca R, Marek W, Bochenek R, Piątkowski W, Antos D. Protein separation in carousel multicolumn setup. Performance analysis and experimental validation. J Chromatogr A 2016; 1460:40-50. [PMID: 27443251 DOI: 10.1016/j.chroma.2016.06.080] [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: 03/31/2016] [Revised: 06/25/2016] [Accepted: 06/27/2016] [Indexed: 10/21/2022]
Abstract
To overcome limitations of periodic separations of proteins in batch chromatographic columns Carousel Multi-Column Setup (CMS) has been recently suggested and theoretically analyzed in a previous study (R. Bochenek, W. Marek, W. Piątkowski, D. Antos, J. Chromatogr. A, 1301 (2013) 60-72). In this system, feed and mobile phase streams are subsequently delivered through parallel columns to mimic their countercurrent movement with respect to the fluid flow. All fluxes in the system are synchronized to ensure continuous feed delivery, which however causes reduction in the size of the operating window compared to batchwise-operating systems. In this study to improve the performance of CMS, additional process variables have been considered, such as the flow rate gradient and feed concentration. Though altering both variables allowed improving the separation selectivity and extending the operating window, the feed concentration appeared to be the most influential parameter affecting the process performance. Moreover, a procedure for practical realization of protein separations in CMS has been developed, including hints about the process design, configuration of columns and detectors, and use of pumps. As the case study, the separation of a ternary mixture of proteins, i.e., cytochrome C, lysozyme and immunoglobulin G, on hydrophobic interaction columns was used. A target product was a protein with intermediate adsorption strength that was isolated out of a more and less strongly adsorbed compound.
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Affiliation(s)
- Rafał Gorczyca
- Department of Chemical and Process Engineering, Rzeszów University of Technology, Powstańców Warszawy Ave. 6, 35-959 Rzeszów, Poland
| | - Wojciech Marek
- Department of Chemical and Process Engineering, Rzeszów University of Technology, Powstańców Warszawy Ave. 6, 35-959 Rzeszów, Poland
| | - Roman Bochenek
- Department of Chemical and Process Engineering, Rzeszów University of Technology, Powstańców Warszawy Ave. 6, 35-959 Rzeszów, Poland
| | - Wojciech Piątkowski
- Department of Chemical and Process Engineering, Rzeszów University of Technology, Powstańców Warszawy Ave. 6, 35-959 Rzeszów, Poland
| | - Dorota Antos
- Department of Chemical and Process Engineering, Rzeszów University of Technology, Powstańców Warszawy Ave. 6, 35-959 Rzeszów, Poland.
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37
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Oberdieck R, Diangelakis NA, Papathanasiou MM, Nascu I, Pistikopoulos EN. POP – Parametric Optimization Toolbox. Ind Eng Chem Res 2016. [DOI: 10.1021/acs.iecr.6b01913] [Citation(s) in RCA: 71] [Impact Index Per Article: 8.9] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Richard Oberdieck
- Department
of Chemical Engineering, Centre for Process Systems Engineering, Imperial College London, London, United Kingdom
- Artie McFerrin Department of Chemical Engineering, Texas A&M University, College Station, Texas 77843, United States
| | - Nikolaos A. Diangelakis
- Department
of Chemical Engineering, Centre for Process Systems Engineering, Imperial College London, London, United Kingdom
- Artie McFerrin Department of Chemical Engineering, Texas A&M University, College Station, Texas 77843, United States
| | - Maria M. Papathanasiou
- Department
of Chemical Engineering, Centre for Process Systems Engineering, Imperial College London, London, United Kingdom
- Artie McFerrin Department of Chemical Engineering, Texas A&M University, College Station, Texas 77843, United States
| | - Ioana Nascu
- Artie McFerrin Department of Chemical Engineering, Texas A&M University, College Station, Texas 77843, United States
| | - Efstratios N. Pistikopoulos
- Artie McFerrin Department of Chemical Engineering, Texas A&M University, College Station, Texas 77843, United States
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38
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Jacquemart R, Vandersluis M, Zhao M, Sukhija K, Sidhu N, Stout J. A Single-use Strategy to Enable Manufacturing of Affordable Biologics. Comput Struct Biotechnol J 2016; 14:309-18. [PMID: 27570613 PMCID: PMC4990569 DOI: 10.1016/j.csbj.2016.06.007] [Citation(s) in RCA: 60] [Impact Index Per Article: 7.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/29/2016] [Accepted: 06/27/2016] [Indexed: 11/23/2022] Open
Abstract
The current processing paradigm of large manufacturing facilities dedicated to single product production is no longer an effective approach for best manufacturing practices. Increasing competition for new indications and the launch of biosimilars for the monoclonal antibody market have put pressure on manufacturers to produce at lower cost. Single-use technologies and continuous upstream processes have proven to be cost-efficient options to increase biomass production but as of today the adoption has been only minimal for the purification operations, partly due to concerns related to cost and scale-up. This review summarizes how a single-use holistic process and facility strategy can overcome scale limitations and enable cost-efficient manufacturing to support the growing demand for affordable biologics. Technologies enabling high productivity, right-sized, small footprint, continuous, and automated upstream and downstream operations are evaluated in order to propose a concept for the flexible facility of the future.
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Key Words
- Affinity membrane chromatography
- Antibody manufacturing paradigms
- B&E, bind and elute
- CapEx, capital expense
- CoG, cost of goods
- Continuous bioprocessing
- DSP, downstream process
- EBA, expanded bed adsorption
- EMA, European Medicines Agency
- FDA, Food and Drug Administration
- FT, flow through
- Flexible, single-use facilities
- HCP, host cell protein
- MV, membrane volume
- OpEx, operating expense
- PAT, process analytical technology
- Process economics
- SMB, simulated moving bed
- USP, upstream process
- cGMP, current good manufacturing practice
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Affiliation(s)
- Renaud Jacquemart
- Natrix Separations Inc., 5295 John Lucas Drive, Burlington, Ontario L7L 6A8, Canada
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39
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Steinebach F, Müller-Späth T, Morbidelli M. Continuous counter-current chromatography for capture and polishing steps in biopharmaceutical production. Biotechnol J 2016; 11:1126-41. [PMID: 27376629 DOI: 10.1002/biot.201500354] [Citation(s) in RCA: 69] [Impact Index Per Article: 8.6] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/07/2015] [Revised: 12/21/2015] [Accepted: 05/30/2016] [Indexed: 12/11/2022]
Abstract
The economic advantages of continuous processing of biopharmaceuticals, which include smaller equipment and faster, efficient processes, have increased interest in this technology over the past decade. Continuous processes can also improve quality assurance and enable greater controllability, consistent with the quality initiatives of the FDA. Here, we discuss different continuous multi-column chromatography processes. Differences in the capture and polishing steps result in two different types of continuous processes that employ counter-current column movement. Continuous-capture processes are associated with increased productivity per cycle and decreased buffer consumption, whereas the typical purity-yield trade-off of classical batch chromatography can be surmounted by continuous processes for polishing applications. In the context of continuous manufacturing, different but complementary chromatographic columns or devices are typically combined to improve overall process performance and avoid unnecessary product storage. In the following, these various processes, their performances compared with batch processing and resulting product quality are discussed based on a review of the literature. Based on various examples of applications, primarily monoclonal antibody production processes, conclusions are drawn about the future of these continuous-manufacturing technologies.
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Affiliation(s)
- Fabian Steinebach
- Institute for Chemical and Bioengineering, Department of Chemistry and Applied Biosciences, ETH Zurich, Zurich, Switzerland
| | | | - Massimo Morbidelli
- Institute for Chemical and Bioengineering, Department of Chemistry and Applied Biosciences, ETH Zurich, Zurich, Switzerland.
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40
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Center-cut separation of intermediately adsorbing target component by 8-zone simulated moving bed chromatography with internal recycle. J Chromatogr A 2016; 1453:19-33. [DOI: 10.1016/j.chroma.2016.04.083] [Citation(s) in RCA: 9] [Impact Index Per Article: 1.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/25/2015] [Revised: 03/25/2016] [Accepted: 04/28/2016] [Indexed: 11/21/2022]
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41
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Kaltenbrunner O, Diaz L, Hu X, Shearer M. Continuous bind-and-elute protein A capture chromatography: Optimization under process scale column constraints and comparison to batch operation. Biotechnol Prog 2016; 32:938-48. [DOI: 10.1002/btpr.2291] [Citation(s) in RCA: 20] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/24/2015] [Revised: 04/13/2016] [Indexed: 11/10/2022]
Affiliation(s)
- Oliver Kaltenbrunner
- Dept. of Purification Process Development; Amgen Inc., One Amgen Center Drive; Thousand Oaks CA 91320
| | - Luis Diaz
- Dept. of Purification Process Development; Amgen Inc., One Amgen Center Drive; Thousand Oaks CA 91320
| | - Xiaochun Hu
- Dept. of Purification Process Development; Amgen Inc., One Amgen Center Drive; Thousand Oaks CA 91320
| | - Michael Shearer
- Dept. of Purification Process Development; Amgen Inc., One Amgen Center Drive; Thousand Oaks CA 91320
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42
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Baur D, Angarita M, Müller-Späth T, Steinebach F, Morbidelli M. Comparison of batch and continuous multi-column protein A capture processes by optimal design. Biotechnol J 2016; 11:920-31. [PMID: 26992151 DOI: 10.1002/biot.201500481] [Citation(s) in RCA: 71] [Impact Index Per Article: 8.9] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/06/2015] [Revised: 12/23/2015] [Accepted: 03/09/2016] [Indexed: 11/06/2022]
Abstract
Multi-column capture processes show several advantages compared to batch capture. It is however not evident how many columns one should use exactly. To investigate this issue, twin-column CaptureSMB, 3- and 4-column periodic counter-current chromatography (PCC) and single column batch capture are numerically optimized and compared in terms of process performance for capturing a monoclonal antibody using protein A chromatography. Optimization is carried out with respect to productivity and capacity utilization (amount of product loaded per cycle compared to the maximum amount possible), while keeping yield and purity constant. For a wide range of process parameters, all three multi-column processes show similar maximum capacity utilization and performed significantly better than batch. When maximizing productivity, the CaptureSMB process shows optimal performance, except at high feed titers, where batch chromatography can reach higher productivity values than the multi-column processes due to the complete decoupling of the loading and elution steps, albeit at a large cost in terms of capacity utilization. In terms of trade-off, i.e. how much the capacity utilization decreases with increasing productivity, CaptureSMB is optimal for low and high feed titers, whereas the 3-column process is optimal in an intermediate region. Using these findings, the most suitable process can be chosen for different production scenarios.
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Affiliation(s)
- Daniel Baur
- Department of Chemistry and Applied Biosciences, ETH Zurich, Zurich, Switzerland
| | - Monica Angarita
- Department of Chemistry and Applied Biosciences, ETH Zurich, Zurich, Switzerland
| | - Thomas Müller-Späth
- Department of Chemistry and Applied Biosciences, ETH Zurich, Zurich, Switzerland.,ChromaCon AG, Zurich, Switzerland
| | - Fabian Steinebach
- Department of Chemistry and Applied Biosciences, ETH Zurich, Zurich, Switzerland
| | - Massimo Morbidelli
- Department of Chemistry and Applied Biosciences, ETH Zurich, Zurich, Switzerland.
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43
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Papathanasiou MM, Avraamidou S, Oberdieck R, Mantalaris A, Steinebach F, Morbidelli M, Mueller-Spaeth T, Pistikopoulos EN. Advanced control strategies for the multicolumn countercurrent solvent gradient purification process. AIChE J 2016. [DOI: 10.1002/aic.15203] [Citation(s) in RCA: 49] [Impact Index Per Article: 6.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/03/2023]
Affiliation(s)
- Maria M. Papathanasiou
- Dept. of Chemical Engineering, Centre for Process Systems Engineering (CPSE); Imperial College London; SW7 2AZ Lodnon U.K
- Artie McFerrin Dept. of Chemical Engineering; Texas A&M University; College Station TX 77843
| | - Styliani Avraamidou
- Dept. of Chemical Engineering, Centre for Process Systems Engineering (CPSE); Imperial College London; SW7 2AZ Lodnon U.K
- Artie McFerrin Dept. of Chemical Engineering; Texas A&M University; College Station TX 77843
| | - Richard Oberdieck
- Dept. of Chemical Engineering, Centre for Process Systems Engineering (CPSE); Imperial College London; SW7 2AZ Lodnon U.K
- Artie McFerrin Dept. of Chemical Engineering; Texas A&M University; College Station TX 77843
| | - Athanasios Mantalaris
- Dept. of Chemical Engineering, Centre for Process Systems Engineering (CPSE); Imperial College London; SW7 2AZ Lodnon U.K
| | - Fabian Steinebach
- Institute for Chemical and Bioengineering; ETH Zurich; Wolfgang-Pauli-Str. 10/HCI F 129 CH-8093 Zurich Switzerland
| | - Massimo Morbidelli
- Institute for Chemical and Bioengineering; ETH Zurich; Wolfgang-Pauli-Str. 10/HCI F 129 CH-8093 Zurich Switzerland
| | - Thomas Mueller-Spaeth
- Dept. of Chemistry and Applied Biosciences, ChromaCon AG; Technoparkstr. 1 CH-8005 Zurich Switzerland
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44
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Ingold O, Pfister D, Morbidelli M. A reactive continuous chromatographic process for protein PEGylation. REACT CHEM ENG 2016. [DOI: 10.1039/c5re00055f] [Citation(s) in RCA: 7] [Impact Index Per Article: 0.9] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/21/2022]
Abstract
A multicolumn process in the form of a twin-column MCSGP unit is fitted with an additional column to perform a on-column protein PEGylation reaction. Thanks to this rMCSGP process, the conjugation reaction is obtained simultaneously with the purification of the products at high yield and high conversion of the protein.
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Affiliation(s)
- Oliver Ingold
- Institute of Chemical and Bioengineering
- Department of Chemistry and Applied Biosciences
- ETH Zurich
- 8093 Zurich
- Switzerland
| | - David Pfister
- Institute of Chemical and Bioengineering
- Department of Chemistry and Applied Biosciences
- ETH Zurich
- 8093 Zurich
- Switzerland
| | - Massimo Morbidelli
- Institute of Chemical and Bioengineering
- Department of Chemistry and Applied Biosciences
- ETH Zurich
- 8093 Zurich
- Switzerland
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45
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Baur D, Angarita M, Müller-Späth T, Morbidelli M. Optimal model-based design of the twin-column CaptureSMB process improves capacity utilization and productivity in protein A affinity capture. Biotechnol J 2015; 11:135-45. [DOI: 10.1002/biot.201500223] [Citation(s) in RCA: 83] [Impact Index Per Article: 9.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/24/2015] [Revised: 06/07/2015] [Accepted: 08/24/2015] [Indexed: 11/11/2022]
Affiliation(s)
- Daniel Baur
- Department for Chemistry and Applied Biosciences; ETH Zurich; Zurich Switzerland
| | - Monica Angarita
- Department for Chemistry and Applied Biosciences; ETH Zurich; Zurich Switzerland
| | - Thomas Müller-Späth
- Department for Chemistry and Applied Biosciences; ETH Zurich; Zurich Switzerland
- ChromaCon AG; Zurich Switzerland
| | - Massimo Morbidelli
- Department for Chemistry and Applied Biosciences; ETH Zurich; Zurich Switzerland
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46
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Improving the downstream processing of vaccine and gene therapy vectors with continuous chromatography. ACTA ACUST UNITED AC 2015. [DOI: 10.4155/pbp.15.29] [Citation(s) in RCA: 10] [Impact Index Per Article: 1.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/17/2022]
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47
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48
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PAROC—An integrated framework and software platform for the optimisation and advanced model-based control of process systems. Chem Eng Sci 2015. [DOI: 10.1016/j.ces.2015.02.030] [Citation(s) in RCA: 108] [Impact Index Per Article: 12.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/23/2022]
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49
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Faria RP, Rodrigues AE. Instrumental aspects of Simulated Moving Bed chromatography. J Chromatogr A 2015; 1421:82-102. [DOI: 10.1016/j.chroma.2015.08.045] [Citation(s) in RCA: 35] [Impact Index Per Article: 3.9] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/16/2015] [Revised: 08/22/2015] [Accepted: 08/24/2015] [Indexed: 11/24/2022]
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50
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Klutz S, Magnus J, Lobedann M, Schwan P, Maiser B, Niklas J, Temming M, Schembecker G. Developing the biofacility of the future based on continuous processing and single-use technology. J Biotechnol 2015; 213:120-30. [DOI: 10.1016/j.jbiotec.2015.06.388] [Citation(s) in RCA: 123] [Impact Index Per Article: 13.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/09/2014] [Revised: 05/13/2015] [Accepted: 06/08/2015] [Indexed: 11/25/2022]
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