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McRae O, Walls PLL, Natarajan V, Antoniou C, Bird JC. Elucidating the effects of microbubble pinch-off dynamics on mammalian cell viability. Biotechnol Bioeng 2024; 121:524-534. [PMID: 37902645 DOI: 10.1002/bit.28582] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/04/2023] [Revised: 09/22/2023] [Accepted: 10/15/2023] [Indexed: 10/31/2023]
Abstract
In the biotechnology industry, ensuring the health and viability of mammalian cells, especially Chinese Hamster Ovary (CHO) cells, plays a significant role in the successful production of therapeutic agents. These cells are typically cultivated in aerated bioreactors, where they encounter fluid stressors from rapidly deforming bubbles. These stressors can disrupt essential biological processes and potentially lead to cell death. However, the impact of these transient, elevated stressors on cell viability remains elusive. In this study, we first employ /cgqamicrofluidics to expose CHO cells near to bubbles undergoing pinch-off, subsequently collecting and assaying the cells to quantify the reduction in viability. Observing a significant impact, we set out to understand this phenomenon. We leverage computational fluid dynamics and numerical particle tracking to map the stressor field history surrounding a rapidly deforming bubble. Separately, we expose CHO cells to a known stressor level in a flow constriction device, collecting and assaying the cells to quantify the reduction in viability. By integrating the numerical data and results from the flow constriction device experiments, we develop a predictive model for cell viability reduction. We validate this model by comparing its predictions to the earlier microfluidic results, observing good agreement. Our findings provide critical insights into the relationship between bubble-induced fluid stressors and mammalian cell viability, with implications for bioreactor design and cell culture protocol optimization in the biotechnology sector.
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Affiliation(s)
- Oliver McRae
- Department of Mechanical Engineering, Boston University, Boston, Massachusetts, USA
| | - Peter L L Walls
- Department of Mechanical Engineering, Dunwoody College of Technology, Minneapolis, Minnesota, USA
| | | | - Chris Antoniou
- Global Processing Engineering, Biogen, Cambridge, Massachusetts, USA
| | - James C Bird
- Department of Mechanical Engineering, Boston University, Boston, Massachusetts, USA
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2
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Reddy JV, Raudenbush K, Papoutsakis ET, Ierapetritou M. Cell-culture process optimization via model-based predictions of metabolism and protein glycosylation. Biotechnol Adv 2023; 67:108179. [PMID: 37257729 DOI: 10.1016/j.biotechadv.2023.108179] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/27/2022] [Revised: 05/18/2023] [Accepted: 05/21/2023] [Indexed: 06/02/2023]
Abstract
In order to meet the rising demand for biologics and become competitive on the developing biosimilar market, there is a need for process intensification of biomanufacturing processes. Process development of biologics has historically relied on extensive experimentation to develop and optimize biopharmaceutical manufacturing. Experimentation to optimize media formulations, feeding schedules, bioreactor operations and bioreactor scale up is expensive, labor intensive and time consuming. Mathematical modeling frameworks have the potential to enable process intensification while reducing the experimental burden. This review focuses on mathematical modeling of cellular metabolism and N-linked glycosylation as applied to upstream manufacturing of biologics. We review developments in the field of modeling cellular metabolism of mammalian cells using kinetic and stoichiometric modeling frameworks along with their applications to simulate, optimize and improve mechanistic understanding of the process. Interest in modeling N-linked glycosylation has led to the creation of various types of parametric and non-parametric models. Most published studies on mammalian cell metabolism have performed experiments in shake flasks where the pH and dissolved oxygen cannot be controlled. Efforts to understand and model the effect of bioreactor-specific parameters such as pH, dissolved oxygen, temperature, and bioreactor heterogeneity are critically reviewed. Most modeling efforts have focused on the Chinese Hamster Ovary (CHO) cells, which are most commonly used to produce monoclonal antibodies (mAbs). However, these modeling approaches can be generalized and applied to any mammalian cell-based manufacturing platform. Current and potential future applications of these models for Vero cell-based vaccine manufacturing, CAR-T cell therapies, and viral vector manufacturing are also discussed. We offer specific recommendations for improving the applicability of these models to industrially relevant processes.
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Affiliation(s)
- Jayanth Venkatarama Reddy
- Department of Chemical and Biomolecular Engineering, University of Delaware, Newark, DE 19716-3196, USA
| | - Katherine Raudenbush
- Department of Chemical and Biomolecular Engineering, University of Delaware, Newark, DE 19716-3196, USA
| | - Eleftherios Terry Papoutsakis
- Department of Chemical and Biomolecular Engineering, University of Delaware, Newark, DE 19716-3196, USA; Delaware Biotechnology Institute, Department of Biological Sciences, University of Delaware, USA.
| | - Marianthi Ierapetritou
- Department of Chemical and Biomolecular Engineering, University of Delaware, Newark, DE 19716-3196, USA.
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3
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Delbridge J, Barrett T, Ducci A, Micheletti M. Power, mixing and flow dynamics of the novel Allegro™ stirred tank reactor. Chem Eng Sci 2023. [DOI: 10.1016/j.ces.2023.118545] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/11/2023]
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4
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A comprehensive comparison of mixing and mass transfer in shake flasks and their relationship with MAb productivity of CHO cells. Bioprocess Biosyst Eng 2022; 45:1033-1045. [DOI: 10.1007/s00449-022-02722-y] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/21/2021] [Accepted: 03/14/2022] [Indexed: 11/26/2022]
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5
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Šrom O, Trávníková V, Wutz J, Kuschel M, Unsoeld A, Wucherpfennig T, Šoóš M. Characterization of hydrodynamic stress in ambr250® bioreactor system and its impact on mammalian cell culture. Biochem Eng J 2022. [DOI: 10.1016/j.bej.2021.108240] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/15/2022]
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6
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Cell specific variation in viability in suspension in in vitro Poiseuille flow conditions. Sci Rep 2021; 11:13997. [PMID: 34234155 PMCID: PMC8263586 DOI: 10.1038/s41598-021-91865-1] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/19/2021] [Accepted: 05/26/2021] [Indexed: 11/20/2022] Open
Abstract
The influence of Poiseuille flow on cell viability has applications in the areas of cancer metastasis, lab-on-a-chip devices and flow cytometry. Indeed, retaining cell viability is important in the emerging field of adoptive cell therapy, as cells need to be returned to patients’ bodies, while the viability of other cells, which are perhaps less accustomed to suspension in a fluidic environment, is important to retain in flow cytometers and other such devices. Despite this, it is unclear how Poiseuille flow affects cell viability. Following on from previous studies which investigated the viability and inertial positions of circulating breast cancer cells in identical flow conditions, this study investigated the influence that varying flow rate, and the corresponding Reynolds number has on the viability of a range of different circulating cells in laminar pipe flow including primary T-cells, primary fibroblasts and neuroblastoma cells. It was found that Reynolds numbers as high as 9.13 had no effect on T-cells while the viabilities of neuroblastoma cells and intestinal fibroblasts were significantly reduced in comparison. This indicates that in vitro flow devices need to be tailored to cell-specific flow regimes.
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McRae O, Mead KR, Bird JC. Aerosol agitation: Quantifying the hydrodynamic stressors on particulates encapsulated in small droplets. PHYSICAL REVIEW FLUIDS 2021; 6:10.1103/physrevfluids.6.l031601. [PMID: 37309535 PMCID: PMC10259374 DOI: 10.1103/physrevfluids.6.l031601] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 06/14/2023]
Abstract
Lower respiratory tract infections originate from multiple aerosol sources, varying from droplets erupting from bursting bubbles in a toilet or those produced by human speech. A key component of the aerosol-based infection pathway-from source to potential host-is the survival of the pathogen during aerosolization. Due to their finite-time instability, pinch-off processes occurring during aerosolization have the potential to rapidly accelerate the fluid into focused regions of these droplets, stress objects therein, and if powerful enough, disrupt biological life. However, the extent that a pathogen will be exposed to damaging hydrodynamic stressors during the aerosolization process is unknown. Here we compute the probability that particulates will be exposed to a hydrodynamic stressor during the generation of droplets that range in size from one to 100 microns. For example, particulates in water droplets less than 5 μm have a 50% chance of being subjected to an energy dissipation rate in excess of 1011 W/m3, hydrodynamic stresses in excess of 104 Pa, and strain rates in excess of 107 s-1, values known to damage certain biological cells. Using a combination of numerical simulations and self-similar dynamics, we show how the exposure within a droplet can be generally predicted from its size, surface tension, and density, even across different aerosolization mechanisms. Collectively, these results introduce aerosol agitation as a potential factor in pathogen transmission and implicate the pinch-off singularity flow as setting the distribution of hydrodynamic stressors experienced within the droplet.
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Affiliation(s)
- Oliver McRae
- Department of Mechanical Engineering, Boston University, Boston, Massachusetts 02215, USA
| | - Kenneth R. Mead
- Division of Field Studies and Engineering, National Institute for Occupational Safety and Health, Centers for Disease Control and Prevention, Cincinnati, Ohio 45226, USA
| | - James C. Bird
- Department of Mechanical Engineering, Boston University, Boston, Massachusetts 02215, USA
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Walther J, McLarty J, Johnson T. The effects of alternating tangential flow (ATF) residence time, hydrodynamic stress, and filtration flux on high‐density perfusion cell culture. Biotechnol Bioeng 2018; 116:320-332. [DOI: 10.1002/bit.26811] [Citation(s) in RCA: 26] [Impact Index Per Article: 4.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/13/2017] [Revised: 06/02/2018] [Accepted: 07/26/2018] [Indexed: 01/06/2023]
Affiliation(s)
- Jason Walther
- Bioprocess Development, SanofiFramingham Massachusetts
| | - Jean McLarty
- Bioprocess Development, SanofiFramingham Massachusetts
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9
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Delafosse A, Calvo S, Collignon ML, Toye D. Comparison of hydrodynamics in standard stainless steel and single-use bioreactors by means of an Euler-Lagrange approach. Chem Eng Sci 2018. [DOI: 10.1016/j.ces.2018.01.034] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/17/2022]
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10
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Wang H, Xia J, Zheng Z, Zhuang YP, Yi X, Zhang D, Wang P. Hydrodynamic investigation of a novel shear-generating device for the measurement of anchorage-dependent cell adhesion intensity. Bioprocess Biosyst Eng 2018; 41:1371-1382. [DOI: 10.1007/s00449-018-1964-6] [Citation(s) in RCA: 10] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/03/2017] [Accepted: 06/05/2018] [Indexed: 01/09/2023]
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11
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Quantifying the potential for bursting bubbles to damage suspended cells. Sci Rep 2017; 7:15102. [PMID: 29118382 PMCID: PMC5678173 DOI: 10.1038/s41598-017-14531-5] [Citation(s) in RCA: 22] [Impact Index Per Article: 3.1] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/16/2017] [Accepted: 10/09/2017] [Indexed: 11/12/2022] Open
Abstract
Bubbles that rise to the surface of a cell suspension can damage cells when they pop. This phenomenon is particularly problematic in the biotechnology industry, as production scale bioreactors require continuous injection of oxygen bubbles to maintain cell growth. Previous studies have linked cell damage to high energy dissipation rates (EDR) and have predicted that for small bubbles the EDR could exceed values that would kill many cells used in bioreactors, including Chinese Hamster Ovary (CHO) cells. However, it’s unclear how many cells would be damaged by a particular bursting bubble, or more precisely how much volume around the bubble experiences these large energy dissipation rates. Here we quantify these volumes using numerical simulations and demonstrate that even though the volume exceeding a particular EDR increases with bubble size, on a volume-to-volume basis smaller bubbles have a more significant impact. We validate our model with high-speed experiments and present our results in a non-dimensionalized framework, enabling predictions for a variety of liquids and bubble sizes. The results are not restricted to bubbles in bioreactors and may be relevant to a variety of applications ranging from fermentation processes to characterizing the stress levels experienced by microorganisms within the sea surface microlayer.
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12
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Ultra scale-down approaches to enhance the creation of bioprocesses at scale: impacts of process shear stress and early recovery stages. Curr Opin Chem Eng 2016. [DOI: 10.1016/j.coche.2016.09.012] [Citation(s) in RCA: 17] [Impact Index Per Article: 2.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/19/2022]
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13
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Application of EulerLagrange CFD for quantitative evaluating the effect of shear force on Carthamus tinctorius L. cell in a stirred tank bioreactor. Biochem Eng J 2016. [DOI: 10.1016/j.bej.2016.07.006] [Citation(s) in RCA: 31] [Impact Index Per Article: 3.9] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/18/2022]
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14
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Reimonn TM, Park SY, Agarabi CD, Brorson KA, Yoon S. Effect of amino acid supplementation on titer and glycosylation distribution in hybridoma cell cultures-Systems biology-based interpretation using genome-scale metabolic flux balance model and multivariate data analysis. Biotechnol Prog 2016; 32:1163-1173. [PMID: 27452371 DOI: 10.1002/btpr.2335] [Citation(s) in RCA: 9] [Impact Index Per Article: 1.1] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/02/2015] [Revised: 05/17/2016] [Indexed: 01/24/2023]
Abstract
Genome-scale flux balance analysis (FBA) is a powerful systems biology tool to characterize intracellular reaction fluxes during cell cultures. FBA estimates intracellular reaction rates by optimizing an objective function, subject to the constraints of a metabolic model and media uptake/excretion rates. A dynamic extension to FBA, dynamic flux balance analysis (DFBA), can calculate intracellular reaction fluxes as they change during cell cultures. In a previous study by Read et al. (2013), a series of informed amino acid supplementation experiments were performed on twelve parallel murine hybridoma cell cultures, and this data was leveraged for further analysis (Read et al., Biotechnol Prog. 2013;29:745-753). In order to understand the effects of media changes on the model murine hybridoma cell line, a systems biology approach is applied in the current study. Dynamic flux balance analysis was performed using a genome-scale mouse metabolic model, and multivariate data analysis was used for interpretation. The calculated reaction fluxes were examined using partial least squares and partial least squares discriminant analysis. The results indicate media supplementation increases product yield because it raises nutrient levels extending the growth phase, and the increased cell density allows for greater culture performance. At the same time, the directed supplementation does not change the overall metabolism of the cells. This supports the conclusion that product quality, as measured by glycoform assays, remains unchanged because the metabolism remains in a similar state. Additionally, the DFBA shows that metabolic state varies more at the beginning of the culture but less by the middle of the growth phase, possibly due to stress on the cells during inoculation. © 2016 American Institute of Chemical Engineers Biotechnol. Prog., 32:1163-1173, 2016.
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Affiliation(s)
- Thomas M Reimonn
- Department of Chemical Engineering, University of Massachusetts Lowell, Lowell
| | - Seo-Young Park
- Department of Chemical Engineering, University of Massachusetts Lowell, Lowell
| | - Cyrus D Agarabi
- Division II, Office of Biotechnology Products, Office of Pharmaceutical Quality, CDER, FDA, Silver Springs, MD, USA
| | - Kurt A Brorson
- Division II, Office of Biotechnology Products, Office of Pharmaceutical Quality, CDER, FDA, Silver Springs, MD, USA
| | - Seongkyu Yoon
- Department of Chemical Engineering, University of Massachusetts Lowell, Lowell.
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15
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Large-Eddy Simulations of microcarrier exposure to potentially damaging eddies inside mini-bioreactors. Biochem Eng J 2016. [DOI: 10.1016/j.bej.2015.10.020] [Citation(s) in RCA: 22] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/23/2022]
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16
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Neunstoecklin B, Villiger TK, Lucas E, Stettler M, Broly H, Morbidelli M, Soos M. Pilot-scale verification of maximum tolerable hydrodynamic stress for mammalian cell culture. Appl Microbiol Biotechnol 2015; 100:3489-98. [DOI: 10.1007/s00253-015-7193-x] [Citation(s) in RCA: 7] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/18/2015] [Revised: 11/17/2015] [Accepted: 11/20/2015] [Indexed: 10/22/2022]
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17
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Sousa MFQ, Silva MM, Giroux D, Hashimura Y, Wesselschmidt R, Lee B, Roldão A, Carrondo MJT, Alves PM, Serra M. Production of oncolytic adenovirus and human mesenchymal stem cells in a single-use, Vertical-Wheel bioreactor system: Impact of bioreactor design on performance of microcarrier-based cell culture processes. Biotechnol Prog 2015; 31:1600-12. [DOI: 10.1002/btpr.2158] [Citation(s) in RCA: 47] [Impact Index Per Article: 5.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/23/2015] [Revised: 08/07/2015] [Indexed: 01/29/2023]
Affiliation(s)
- Marcos F. Q. Sousa
- Inst. de Tecnologia Química e Biológica António Xavier, Universidade Nova de Lisboa; Av. da República 2780-157 Oeiras Portugal
- iBET, Inst. de Biologia Experimental e Tecnológica; Apartado 12 Oeiras 2780-901 Portugal
| | - Marta M. Silva
- Inst. de Tecnologia Química e Biológica António Xavier, Universidade Nova de Lisboa; Av. da República 2780-157 Oeiras Portugal
- iBET, Inst. de Biologia Experimental e Tecnológica; Apartado 12 Oeiras 2780-901 Portugal
| | | | | | | | | | - António Roldão
- Inst. de Tecnologia Química e Biológica António Xavier, Universidade Nova de Lisboa; Av. da República 2780-157 Oeiras Portugal
- iBET, Inst. de Biologia Experimental e Tecnológica; Apartado 12 Oeiras 2780-901 Portugal
| | - Manuel J. T. Carrondo
- iBET; Inst. de Biologia Experimental e Tecnológica; Apartado 12 Oeiras 2780-901 Portugal
- Dept. de Química, Faculdade de Ciências e Tecnologia; Universidade Nova De Lisboa; 2829-516 Monte da Caparica Portugal
| | - Paula M. Alves
- Inst. de Tecnologia Química e Biológica António Xavier, Universidade Nova de Lisboa; Av. da República 2780-157 Oeiras Portugal
- iBET, Inst. de Biologia Experimental e Tecnológica; Apartado 12 Oeiras 2780-901 Portugal
| | - Margarida Serra
- Inst. de Tecnologia Química e Biológica António Xavier, Universidade Nova de Lisboa; Av. da República 2780-157 Oeiras Portugal
- iBET, Inst. de Biologia Experimental e Tecnológica; Apartado 12 Oeiras 2780-901 Portugal
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18
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Delafosse A, Calvo S, Collignon ML, Delvigne F, Crine M, Toye D. Euler–Lagrange approach to model heterogeneities in stirred tank bioreactors – Comparison to experimental flow characterization and particle tracking. Chem Eng Sci 2015. [DOI: 10.1016/j.ces.2015.05.045] [Citation(s) in RCA: 16] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/23/2022]
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19
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Neunstoecklin B, Stettler M, Solacroup T, Broly H, Morbidelli M, Soos M. Determination of the maximum operating range of hydrodynamic stress in mammalian cell culture. J Biotechnol 2015; 194:100-9. [DOI: 10.1016/j.jbiotec.2014.12.003] [Citation(s) in RCA: 31] [Impact Index Per Article: 3.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/27/2014] [Revised: 11/08/2014] [Accepted: 12/09/2014] [Indexed: 10/24/2022]
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21
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Kaiser SC, Kraume M, Eibl D, Eibl R. Single-Use Bioreactors for Animal and Human Cells. CELL ENGINEERING 2015. [DOI: 10.1007/978-3-319-10320-4_14] [Citation(s) in RCA: 12] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 01/11/2023]
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22
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Adaptation for survival: Phenotype and transcriptome response of CHO cells to elevated stress induced by agitation and sparging. J Biotechnol 2014; 189:94-103. [DOI: 10.1016/j.jbiotec.2014.08.042] [Citation(s) in RCA: 35] [Impact Index Per Article: 3.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/28/2014] [Revised: 08/25/2014] [Accepted: 08/30/2014] [Indexed: 11/21/2022]
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23
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Relationship between preparation of cells for therapy and cell quality using artificial neural network analysis. Artif Intell Med 2014; 62:119-27. [DOI: 10.1016/j.artmed.2014.07.003] [Citation(s) in RCA: 7] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/28/2014] [Revised: 04/29/2014] [Accepted: 07/12/2014] [Indexed: 11/23/2022]
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24
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Nienow AW, Scott WH, Hewitt CJ, Thomas CR, Lewis G, Amanullah A, Kiss R, Meier SJ. Scale-down studies for assessing the impact of different stress parameters on growth and product quality during animal cell culture. Chem Eng Res Des 2013. [DOI: 10.1016/j.cherd.2013.04.002] [Citation(s) in RCA: 39] [Impact Index Per Article: 3.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/26/2022]
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25
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Development of a Scale-Down Model of hydrodynamic stress to study the performance of an industrial CHO cell line under simulated production scale bioreactor conditions. J Biotechnol 2013; 164:41-9. [DOI: 10.1016/j.jbiotec.2012.11.012] [Citation(s) in RCA: 68] [Impact Index Per Article: 6.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/27/2012] [Revised: 10/27/2012] [Accepted: 11/26/2012] [Indexed: 01/11/2023]
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26
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Hu W, Berdugo C, Chalmers JJ. The potential of hydrodynamic damage to animal cells of industrial relevance: current understanding. Cytotechnology 2011; 63:445-60. [PMID: 21785843 PMCID: PMC3176934 DOI: 10.1007/s10616-011-9368-3] [Citation(s) in RCA: 102] [Impact Index Per Article: 7.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/20/2008] [Accepted: 06/11/2011] [Indexed: 11/25/2022] Open
Abstract
Suspension animal cell culture is now routinely scaled up to bioreactors on the order of 10,000 L, and greater, to meet commercial demand. However, the concern of the 'shear sensitivity' of animal cells still remains, not only within the bioreactor, but also in the downstream processing. As the productivities continue to increase, titer of ~10 g/L are now reported with cell densities greater than 2 × 10(7) cells/mL. Such high, and potentially higher cell densities will inevitably translate to increased demand in mass transfer and mixing. In addition, achieving productivity gains in both the upstream stage and downstream processes can subject the cells to aggressive environments such as those involving hydrodynamic stresses. The perception of 'shear sensitivity' has historically put an arbitrary upper limit on agitation and aeration in bioreactor operation; however, as cell densities and productivities continue to increase, mass transfer requirements can exceed those imposed by these arbitrary low limits. Therefore, a better understanding of how animal cells, used to produce therapeutic products, respond to hydrodynamic forces in both qualitative and quantitative ways will allow an experimentally based, higher, "upper limit" to be created to guide the design and operation of future commercial, large scale bioreactors. With respect to downstream hydrodynamic conditions, situations have already been achieved in which practical limits with respect to hydrodynamic forces have been experienced. This review mainly focuses on publications from both the academy and industry regarding the effect of hydrodynamic forces on industrially relevant animal cells, and not on the actual scale-up of bioreactors. A summary of implications and remaining challenges will also be presented.
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Affiliation(s)
- Weiwei Hu
- Cell Culture Development, Biogen Idec Inc., 5000 Davis Drive, RTP, NC 27709 USA
| | - Claudia Berdugo
- Scientist / Research & Development, BD Biosciences, 54 Loveton Circle, Sparks, MD 21152 USA
| | - Jeffrey J. Chalmers
- William G. Lowrie Department of Chemical and Biomolecular Engineering, The Ohio State University, 140 West 19th Ave., Columbus, OH 43210 USA
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Sorg R, Tanzeglock T, Soos M, Morbidelli M, Périlleux A, Solacroup T, Broly H. Minimizing hydrodynamic stress in mammalian cell culture through the lobed Taylor-Couette bioreactor. Biotechnol J 2011; 6:1504-15. [PMID: 21766459 DOI: 10.1002/biot.201000477] [Citation(s) in RCA: 26] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/22/2010] [Revised: 05/04/2011] [Accepted: 06/27/2011] [Indexed: 11/08/2022]
Abstract
The objective of the present study was to investigate the effect of hydrodynamic stress heterogeneity on metabolism and productivity of an industrial mammalian cell line. For this purpose, a novel Lobed Taylor-Couette (LTC) mixing unit combining a narrow distribution of hydrodynamic stresses and a membrane aeration system to prevent cell damage by bubble bursting was developed. A hydrodynamic analysis of the LTC was developed to reproduce, in a uniform hydrodynamic environment, the same hydrodynamic stress encountered locally by cells in a stirred tank, particularly at the large scale, e.g., close and far from the impeller. The developed LTC was used to simulate the stress values near the impeller of a laboratory stirred tank bioreactor, equal to about 0.4 Pa, which is however below the threshold value leading to cell death. It was found that the cells actively change their metabolism by increasing lactate production and decreasing titer while the consumption of the main nutrients remains substantially unchanged. When considering average stress values ranging from 1 to 10 Pa found by other researchers to cause physiological response of cells to the hydrodynamic stress in heterogeneous stirred vessels, our results are close to the lower boundary of this interval.
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Affiliation(s)
- Robin Sorg
- Department of Chemistry and Applied Biosciences, Institute for Chemical and Bioengineering, ETH Zurich, Zurich, Switzerland
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28
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Godoy-Silva R, Chalmers JJ, Casnocha SA, Bass LA, Ma N. Physiological responses of CHO cells to repetitive hydrodynamic stress. Biotechnol Bioeng 2009; 103:1103-17. [PMID: 19405151 DOI: 10.1002/bit.22339] [Citation(s) in RCA: 65] [Impact Index Per Article: 4.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/05/2022]
Abstract
A majority of the previous investigations on the hydrodynamic sensitivity of mammalian cells have focused on lethal effects as determined by cell death or lysis. In this study, we investigated the effect of hydrodynamic stress on CHO cells in a fed-batch process using a previously reported system which subjects cells to repetitive, high levels of hydrodynamic stress, quantified by energy dissipation rate (EDR). The results indicated that cell growth and monoclonal antibody production of the test cells were very resistant to the hydrodynamic stress. Compared to the control, no significant variation was observed at the highest EDR tested, 6.4 x 10(6) W/m(3). Most product quality attributes were not affected by intense hydrodynamic stress either. The only significant impact was on glycosylation. A shift of glycosylation pattern was observed at EDR levels at or higher than 6.0 x 10(4) W/m(3), which is two orders of magnitude lower than the EDR where physical cell damage, as measured by lactate dehydrogenase release, was observed. While not as extensively investigated, a second monoclonal antibody produced in a different CHO clone exhibited the same glycosylation change at an intensive EDR, 2.9 x 10(5) W/m(3). Conversely, a low EDR of 0.9 x 10(2) W/m(3) had no effect on the glycosylation pattern. As 6.0 x 10(4) W/m(3), the lowest EDR that triggers the glycosylation shift, is about one order of magnitude higher than the estimated, maximum EDR in typically operated, large-scale stirred tank bioreactors, further studies in a lower EDR range of 1 x 10(3)-6.0 x 10(4) W/m(3) are needed to assess the glycosylation shift effect under typical large-scale bioreactor operation conditions. Follow-up studies in stirred tanks are also needed to confirm the glycosylation shift effect and to validate the repetitive hydrodynamic stress model.
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Affiliation(s)
- Ruben Godoy-Silva
- Bioprocess R&D, Global Biologics, Pfizer, Inc., 700 Chesterfield Parkway West, Chesterfield, Missouri 63017, USA
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Shenkman RM, Godoy-Silva R, Papas KK, Chalmers JJ. Effects of energy dissipation rate on islets of Langerhans: implications for isolation and transplantation. Biotechnol Bioeng 2009; 103:413-23. [PMID: 19191351 PMCID: PMC2832830 DOI: 10.1002/bit.22241] [Citation(s) in RCA: 13] [Impact Index Per Article: 0.9] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/09/2022]
Abstract
Acute physical stresses can occur in the procurement and isolation process and potentially can contribute to islet death or malfunction upon transplantation. A contractional flow device, previously used to subject suspended cells to well-defined hydrodynamic forces, has been modified and used to assess the vulnerability of porcine islets of Langerhans to hydrodynamic forces. The flow profiles and velocity gradients in this modified device were modeled using commercial CFD software and characterized, as in previous studies, with the scalar parameter, energy dissipation rate (EDR). Porcine islets were stressed in a single pass at various stress levels (i.e., values of EDR). Membrane integrity, oxygen uptake rate, caspase 3/7 activity, and insulin release were not affected by the levels of fluid stress tested up to an EDR of 2 x 10(3) W/m(3). Visual observation of the stressed islets suggested that cells at the islet exterior were peeled away at EDR greater than 10,000 W/m(3), however, this observation could not be confirmed using image analysis software, which determined the ratio of surface perimeter to total area. The result of this study suggests an upper limit in fluid stress to which islets can be subjected. Such upper limits assist in the design and operation of future islet processing equipment and processes.
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Affiliation(s)
- Rustin M Shenkman
- Department of Chemical and Biomolecular Engineering, The Ohio State University, 140 W 19th Ave, Columbus, Ohio 43210, USA
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Hu W, Gladue R, Hansen J, Wojnar C, Chalmers JJ. Growth inhibition of dinoflagellate algae in shake flasks: Not due to shear this time! Biotechnol Prog 2009; 26:79-87. [DOI: 10.1002/btpr.301] [Citation(s) in RCA: 5] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/09/2022]
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