1
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Pybus LP, Heise C, Nagy T, Heeran C, Dover T, Raven J, Kori J, Burton G, Sakuyama H, Hastings B, Lyons M, Nakai S, Haigh J. A modular and multi-functional purification strategy that enables a common framework for manufacturing scale integrated and continuous biomanufacturing. Biotechnol Prog 2024; 40:e3456. [PMID: 38494903 DOI: 10.1002/btpr.3456] [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: 06/06/2023] [Revised: 01/17/2024] [Accepted: 03/05/2024] [Indexed: 03/19/2024]
Abstract
Biopharmaceutical manufacture is transitioning from batch to integrated and continuous biomanufacturing (ICB). The common framework for most ICB, potentially enables a global biomanufacturing ecosystem utilizing modular and multi-function manufacturing equipment. Integrating unit operation hardware and software from multiple suppliers, complex supply chains enabled by multiple customized single-use flow paths, and large volume buffer production/storage make this ICB vision difficult to achieve with commercially available manufacturing equipment. Thus, we developed SymphonX™, a downstream processing skid with advanced buffer management capabilities, a single disposable generic flow path design that provides plug-and-play flexibility across all downstream unit operations and a single interface to reduce operational risk. Designed for multi-product and multi-process cGMP facilities, SymphonX™ can perform stand-alone batch processing or ICB. This study utilized an Apollo™ X CHO-DG44 mAb-expressing cell line in a steady-state perfusion bioreactor, harvesting product continuously with a cell retention device and connected SymphonX™ purification skids. The downstream process used the same chemistry (resins, buffer composition, membrane composition) as our historical batch processing platform, with SymphonX™ in-line conditioning and buffer concentrates. We used surge vessels between unit operations, single-column chromatography (protein A, cation and anion exchange) and two-tank batch virus inactivation. After the first polishing step (cation exchange), we continuously pooled product for 6 days. These 6 day pools were processed in batch-mode from anion exchange to bulk drug substance. This manufacturing scale proof-of-concept ICB produced 0.54 kg/day of drug substance with consistent product quality attributes and demonstrated successful bioburden control for unit-operations undergoing continuous operation.
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Affiliation(s)
- Leon P Pybus
- Process Development, FUJIFILM Diosynth Biotechnologies, Billingham, UK
| | - Charles Heise
- Process Development, FUJIFILM Diosynth Biotechnologies, Billingham, UK
| | - Tibor Nagy
- Process Development, FUJIFILM Diosynth Biotechnologies, Billingham, UK
| | - Carmen Heeran
- Process Development, FUJIFILM Diosynth Biotechnologies, Billingham, UK
| | - Terri Dover
- Process Development, FUJIFILM Diosynth Biotechnologies, Billingham, UK
| | - John Raven
- Process Development, FUJIFILM Diosynth Biotechnologies, Billingham, UK
| | - Junichi Kori
- Bio Science & Engineering Laboratories, FUJIFILM Corporation, Kaisei, Japan
| | - Graeme Burton
- Process Development, FUJIFILM Diosynth Biotechnologies, Billingham, UK
| | - Hiroshi Sakuyama
- Bio Science & Engineering Laboratories, FUJIFILM Corporation, Kaisei, Japan
| | - Benjamin Hastings
- Process Development, FUJIFILM Diosynth Biotechnologies, Billingham, UK
| | - Michelle Lyons
- Process Development, FUJIFILM Diosynth Biotechnologies, Billingham, UK
| | - Shinichi Nakai
- Bio Science & Engineering Laboratories, FUJIFILM Corporation, Kaisei, Japan
| | - Jonathan Haigh
- Process Development, FUJIFILM Diosynth Biotechnologies, Billingham, UK
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2
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Kozaili J, Rayfield W, Gospodarek A, Brower M, Strauss D. Adapting virus filtration to continuous processing: Effects of product and process variability on filtration performance. Biotechnol Prog 2024; 40:e3407. [PMID: 38146086 DOI: 10.1002/btpr.3407] [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: 06/30/2023] [Revised: 10/02/2023] [Accepted: 10/23/2023] [Indexed: 12/27/2023]
Abstract
Virus filtration (VF) is an important unit operation in the manufacture of biotherapeutics that provides robust removal of potential virus contaminants. Small virus removal can be impacted by the low operating pressures and potential depressurization events that are often associated with continuous operations where increased operational flexibility for higher loading at low flux and low pressure is required. In this study, we evaluated the impact of low flux (7 LMH) and pressure interruptions on minute virus of mice (MVM) removal. We used long-term filtrations conducted to a target throughput of 1000 L/m2 with four different monoclonal antibodies on small-scale hollow fiber virus filters with a hydrophilic modified polyvinylidene fluoride membrane. These conditions are certainly challenging for any VF operation and ensuring robust viral clearance under such conditions is critical to the design and implementation of continuous VF. Planova BioEX filters effectively removed MVM at 4 log or greater when run continuously for up to 6 days. Interestingly, pressure increases associated with filter fouling over the duration of long-term filtrations were shown to be reflective of load material variability and could be remediated by implementation of an inline prefilter. Pressure interruptions had minimal impact on overall MVM logarithmic reduction value. Effective virus removal was achieved with pressure increases being largely product-specific, which demonstrates the capability of the virus filter to remove virus independent of pressure increases that are expected to occur with increased protein load.
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Affiliation(s)
- Julie Kozaili
- Asahi Kasei Bioprocess America, Inc., Glenview, Illinois, USA
| | | | | | - Mark Brower
- Merck & Co., Inc., Kenilworth, New Jersey, USA
| | - Daniel Strauss
- Asahi Kasei Bioprocess America, Inc., Glenview, Illinois, USA
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3
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Fuchs M, Bhawnani R, Sripada SA, Molek J, Ghodbane M. Predictive modeling of single pass tangential flow filtration for continuous biomanufacturing. Biotechnol Prog 2023; 39:e3353. [PMID: 37155963 DOI: 10.1002/btpr.3353] [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: 02/16/2023] [Revised: 04/17/2023] [Accepted: 04/25/2023] [Indexed: 05/10/2023]
Abstract
Opportunities for process intensification have made continuous biomanufacturing an area of active research. While tangential flow filtration (TFF) is typically employed within the biologics purification train to increase drug substance concentration, single-pass TFF (SPTFF) modifies its format by enabling continuity of this process and achieving a multifold concentration factor through a single-pass over the filtration membranes. In continuous processes feed concentration and flow rate are determined by the preceding unit operations. Therefore, tight control of SPTFF output concentration must be achieved through precise design of the membrane configuration, unlike TFF. However, predictive modeling can be utilized to identify configurations that achieve a desired target concentration across ranges of possible feed conditions with minimal experimental data, hence enabling accelerated process development and design flexibility. We hereby describe the development of a mechanistic model predicting SPTFF performance across a wide design space using the well-established stagnant film model, which we demonstrate is more accurate at higher feed flow rates. The flux excursion dataset was generated within time constraints and with minimal material consumption, showing the method's ability to be quickly adapted. While this approach eliminates characterizing complex physicochemical model variables or the need for users with specialized training, the model and its assumptions become inaccurate at low flow rates, below 25 L/m2 /h, and high conversions, above 0.9. As this low flow rate, high conversion operating regime is relevant for continuous biomanufacturing, we explore the assumptions and challenges involved in predicting and modeling SPTFF processes, while suggesting added characterization to gain further process insight.
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Affiliation(s)
- Madeline Fuchs
- Biopharm Drug Substance Development, GlaxoSmithKline, King of Prussia, Pennsylvania, USA
| | - Rajan Bhawnani
- Biopharm Drug Substance Development, GlaxoSmithKline, King of Prussia, Pennsylvania, USA
| | - Sobhana A Sripada
- Biopharm Drug Substance Development, GlaxoSmithKline, King of Prussia, Pennsylvania, USA
| | - Jessica Molek
- Biopharm Drug Substance Development, GlaxoSmithKline, King of Prussia, Pennsylvania, USA
- MSAT Specialty Large Molecule, GlaxoSmithKline, King of Prussia, Pennsylvania, USA
| | - Mehdi Ghodbane
- Biopharm Drug Substance Development, GlaxoSmithKline, King of Prussia, Pennsylvania, USA
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4
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Agrawal P, Wilkstein K, Guinn E, Mason M, Serrano Martinez CI, Saylae J. A Review of Tangential Flow Filtration: Process Development and Applications in the Pharmaceutical Industry. Org Process Res Dev 2023. [DOI: 10.1021/acs.oprd.2c00291] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 04/03/2023]
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5
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Schmitz F, Kruse T, Minceva M, Kampmann M. Integrated double flow-through purification of monoclonal antibodies using membrane adsorbers and single-pass tangential flow filtration. Biochem Eng J 2023. [DOI: 10.1016/j.bej.2023.108913] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 03/29/2023]
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6
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Continuous depth filtration in perfusion cell culture. J Memb Sci 2022. [DOI: 10.1016/j.memsci.2022.121204] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/21/2022]
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7
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Thakur G, Bansode V, Rathore AS. Continuous manufacturing of monoclonal antibodies: Automated downstream control strategy for dynamic handling of titer variations. J Chromatogr A 2022; 1682:463496. [PMID: 36126561 DOI: 10.1016/j.chroma.2022.463496] [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: 08/04/2022] [Revised: 09/06/2022] [Accepted: 09/08/2022] [Indexed: 11/16/2022]
Abstract
Handling long-term dynamic variability in harvest titer is a critical challenge in continuous downstream manufacturing. This challenge is becoming increasingly important with the advent of high-titer clones and modern upstream perfusion processes where the titer can vary significantly across the course of a campaign. In this paper, we present a strategy for real-time, dynamic adjustment of the entire downstream train, including capture chromatography, viral inactivation, depth filtration, polishing chromatography, and single-pass formulation, to accommodate variations in titer from 1-7 g/L. The strategy was tested in real time in a continuous downstream purification process of 36 h duration with induced titer variations. The dynamic control strategy leverages real-time NIR-based concentration sensors in the harvest material to continuously track the titer, integrated with an in-house Python-based control system that operates a BioSMB for carrying out capture and polishing chromatography, as well as a series of pumps and solenoid valves for carrying out viral inactivation and formulation. A set of 9 different methods, corresponding to the different harvest titers have been coded onto the Python controller. The methods have a varying number of chromatography columns (3-6 for Protein A and 2-10 for CEX), designed to ensure proper scheduling and optimize productivity across the entire titer variation space. The approach allows for a wide range of titers to be processed on a single integrated setup without having to change equipment or to re-design each time. The strategy also overcomes a key unexplored challenge in continuous processing, namely hand-shaking the downstream train to upstream conditions with long-term titer variability while maintaining automated operation with high productivity and robustness.
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Affiliation(s)
- Garima Thakur
- Department of Chemical Engineering, Indian Institute of Technology, Hauz Khas, New Delhi 110016, India
| | - Vikrant Bansode
- Department of Chemical Engineering, Indian Institute of Technology, Hauz Khas, New Delhi 110016, India
| | - Anurag S Rathore
- Department of Chemical Engineering, Indian Institute of Technology, Hauz Khas, New Delhi 110016, India.
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8
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Sun YN, Shi C, Zhong XZ, Chen XJ, Chen R, Zhang QL, Yao SJ, Jungbauer A, Lin DQ. Model-based evaluation and model-free strategy for process development of three-column periodic counter-current chromatography. J Chromatogr A 2022; 1677:463311. [PMID: 35843202 DOI: 10.1016/j.chroma.2022.463311] [Citation(s) in RCA: 5] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/01/2022] [Revised: 07/04/2022] [Accepted: 07/06/2022] [Indexed: 10/17/2022]
Abstract
Multi-column counter-current chromatography is an advanced technology used for continuous capture processes to improve process productivity, resin capacity utilization and product consistency. However, process development is difficult due to process complexity. In this work, some general and convenient guidances for three-column periodic counter-current chromatography (3C-PCC) were developed. Boundaries and distributions of operating windows of 3C-PCC processes were clarified by model-based predictions. Interactive effects of feed concentration (c0), resin properties (qmax and De), recovery and regeneration times (tRR) were evaluated over a wide range for maximum productivity (Pmax). Furthermore, variation of Pmax was analyzed considering the constraint factors (capacity utilization target and flow rate limitation). The plateau value of Pmax was determined by qmax and tRR. The operating conditions for Pmax were controlled by qmax, tRR and c0 interactively, and a critical concentration existed to judge whether the operating conditions of Pmax under constraints. Based on the comprehensive understanding on 3C-PCC processes, a model-free strategy was proposed for process development. The optimal operating conditions could be determined based on a set of breakthrough curves, which was used to optimize process performance and screen resins. The approach proposed was validated using monoclonal antibody (mAb) capture with a 3C-PCC system under various mAb and feed concentrations. The results demonstrated that a thorough model-based process understanding on multi-column counter-current chromatography is important and could improve process development and establish a model-free strategy for more convenient applications.
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Affiliation(s)
- Yan-Na Sun
- Zhejiang Key Laboratory of Smart Biomaterials, Key Laboratory of Biomass Chemical Engineering of Ministry of Education, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou 310027, China
| | - Ce Shi
- Shanghai Engineering Research Center of Anti-Tumor Biological Drugs, Shanghai Henlius Biotech, Inc., Shanghai, China
| | - Xue-Zhao Zhong
- Shanghai Engineering Research Center of Anti-Tumor Biological Drugs, Shanghai Henlius Biotech, Inc., Shanghai, China
| | - Xu-Jun Chen
- Shanghai Engineering Research Center of Anti-Tumor Biological Drugs, Shanghai Henlius Biotech, Inc., Shanghai, China
| | - Ran Chen
- Shanghai Engineering Research Center of Anti-Tumor Biological Drugs, Shanghai Henlius Biotech, Inc., Shanghai, China
| | - Qi-Lei Zhang
- Zhejiang Key Laboratory of Smart Biomaterials, Key Laboratory of Biomass Chemical Engineering of Ministry of Education, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou 310027, China
| | - Shan-Jing Yao
- Zhejiang Key Laboratory of Smart Biomaterials, Key Laboratory of Biomass Chemical Engineering of Ministry of Education, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou 310027, China
| | - Alois Jungbauer
- Department of Biotechnology, University of Natural Resources and Life Sciences, Vienna, Austria
| | - Dong-Qiang Lin
- Zhejiang Key Laboratory of Smart Biomaterials, Key Laboratory of Biomass Chemical Engineering of Ministry of Education, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou 310027, China.
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9
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Chen R, Chen XJ, Shi C, Jiao B, Shi Y, Yao B, Lin DQ, Gong W, Hsu S. Converting a mAb downstream process from batch to continuous using process modeling and process analytical technology. Biotechnol J 2022; 17:e2100351. [PMID: 35908168 DOI: 10.1002/biot.202100351] [Citation(s) in RCA: 5] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/06/2021] [Revised: 07/28/2022] [Accepted: 07/28/2022] [Indexed: 11/06/2022]
Abstract
The biopharmaceutical market is driving the revolution from traditional batch processes to continuous manufacturing for higher productivity and lower costs. In this work, a batch mAb downstream process has been converted into an integrated continuous process with the combination of multiple techniques. For process intensification, two batch mode unit operations (protein A capture chromatography, ultrafiltration/diafiltration) are converted into continuous ones; For continuity, surge tanks were used between adjacent steps, and level signals were used to trigger process start or stop, forming a holistic continuous process. For process automation, manual operations (e.g., pH and conductivity adjustment) were changed into automatic operation and load mass was controlled with process analytical technology (PAT). A model-based simulation was applied to estimate the loading conditions for the continuous capture process, resulting in 21% resin capacity utilization and 28% productivity improvement as compared to the batch process. Automatic load mass control of cation exchange chromatography was achieved through a customized in-line protein quantity monitoring system, with a difference of less than 1.3% as compared to off-line analysis. Total process time was shortened from 4 days (batch process) to less than 24 hours using the continuous downstream process with the overall productivity of 23.8 g mAb /day for the bench-scale system. Comparable yield and quality data were obtained in three test runs, indicating a successful conversion from a batch process to a continuous process. The insight of this work could be a reference to other similar situations. This article is protected by copyright. All rights reserved.
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Affiliation(s)
- Ran Chen
- Shanghai Engineering Research Center of Anti-tumor Biological Drugs, Shanghai Henlius Biotech, Inc., Shanghai, China
| | - Xu-Jun Chen
- Shanghai Engineering Research Center of Anti-tumor Biological Drugs, Shanghai Henlius Biotech, Inc., Shanghai, China
| | - Ce Shi
- Key Laboratory of Biomass Chemical Engineering of Ministry of Education, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou, China
| | - Biao Jiao
- Shanghai Engineering Research Center of Anti-tumor Biological Drugs, Shanghai Henlius Biotech, Inc., Shanghai, China
| | - Ye Shi
- Shanghai Engineering Research Center of Anti-tumor Biological Drugs, Shanghai Henlius Biotech, Inc., Shanghai, China
| | - Bin Yao
- Shanghai Engineering Research Center of Anti-tumor Biological Drugs, Shanghai Henlius Biotech, Inc., Shanghai, China
| | - Dong-Qiang Lin
- Key Laboratory of Biomass Chemical Engineering of Ministry of Education, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou, China
| | - Wei Gong
- Shanghai Engineering Research Center of Anti-tumor Biological Drugs, Shanghai Henlius Biotech, Inc., Shanghai, China
| | - Simon Hsu
- Shanghai Engineering Research Center of Anti-tumor Biological Drugs, Shanghai Henlius Biotech, Inc., Shanghai, China
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10
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Thakur G, Masampally V, Kulkarni A, Rathore AS. Process Analytical Technology (PAT) Implementation for Membrane Operations in Continuous Manufacturing of mAbs: Model-Based Control of Single-Pass Tangential Flow Ultrafiltration. AAPS J 2022; 24:83. [DOI: 10.1208/s12248-022-00731-z] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/02/2022] [Accepted: 06/30/2022] [Indexed: 11/30/2022] Open
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11
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Defining the optimal operating conditions and configuration of a single-pass tangential flow filtration (SPTFF) system via CFD modelling. Sep Purif Technol 2022. [DOI: 10.1016/j.seppur.2022.120776] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/19/2022]
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12
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Schwarz H, Fons JG, Isaksson M, Scheffel J, Andersson N, Andersson A, Castan A, Solbrand A, Hober S, Nilsson B, Chotteau V. Integrated continuous biomanufacturing on pilot scale for acid-sensitive monoclonal antibodies. Biotechnol Bioeng 2022; 119:2152-2166. [PMID: 35470430 PMCID: PMC9541590 DOI: 10.1002/bit.28120] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/19/2022] [Revised: 04/21/2022] [Accepted: 04/23/2022] [Indexed: 11/07/2022]
Abstract
In this study, we demonstrated the first, to our knowledge, integrated continuous bioprocess (ICB) designed for the production of acid-sensitive monoclonal antibodies, prone to aggregate at low pH, on pilot scale. A high cell density perfusion culture, stably maintained at 100 x 106 cells/mL, was integrated with the downstream process, consisting of a capture step with the recently developed Protein A ligand, ZCa ; a solvent/detergent-based virus inactivation; and two ion exchange chromatography steps. The use of a mild pH in the downstream process makes this ICB suitable for the purification of acid-sensitive monoclonal antibodies. Integration and automation of the downstream process were achieved using the Orbit software, and the same equipment and control system were used in initial small-scale trials and the pilot-scale downstream process. High recovery yields of around 90% and a productivity close to 1 g purified antibody/L/day were achieved, with a stable glycosylation pattern and efficient removal of impurities, such as host cell proteins and DNA. Finally, negligible levels of antibody aggregates were detected owing to the mild conditions used throughout the process. The present work paves the way for future industrial-scale integrated continuous biomanufacturing of all types of antibodies, regardless of acid stability. This article is protected by copyright. All rights reserved.
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Affiliation(s)
- Hubert Schwarz
- Dept. of Industrial Biotechnology, KTH Royal Institute of Technology, Stockholm, Sweden.,AdBIOPRO, Competence Centre for Advanced BioProduction by Continuous Processing, Sweden
| | - Joaquín Gomis Fons
- Dept. of Chemical Engineering, Lund University, Lund, Sweden.,AdBIOPRO, Competence Centre for Advanced BioProduction by Continuous Processing, Sweden
| | - Madelène Isaksson
- Dept. of Chemical Engineering, Lund University, Lund, Sweden.,AdBIOPRO, Competence Centre for Advanced BioProduction by Continuous Processing, Sweden
| | - Julia Scheffel
- Dept. of Protein Science, KTH Royal Institute of Technology, Stockholm, Sweden.,AdBIOPRO, Competence Centre for Advanced BioProduction by Continuous Processing, Sweden
| | | | - Andreas Andersson
- Cytiva, Uppsala, Sweden.,AdBIOPRO, Competence Centre for Advanced BioProduction by Continuous Processing, Sweden
| | - Andreas Castan
- Cytiva, Uppsala, Sweden.,AdBIOPRO, Competence Centre for Advanced BioProduction by Continuous Processing, Sweden
| | - Anita Solbrand
- Cytiva, Uppsala, Sweden.,AdBIOPRO, Competence Centre for Advanced BioProduction by Continuous Processing, Sweden
| | - Sophia Hober
- Dept. of Protein Science, KTH Royal Institute of Technology, Stockholm, Sweden.,AdBIOPRO, Competence Centre for Advanced BioProduction by Continuous Processing, Sweden
| | - Bernt Nilsson
- Dept. of Chemical Engineering, Lund University, Lund, Sweden.,AdBIOPRO, Competence Centre for Advanced BioProduction by Continuous Processing, Sweden
| | - Veronique Chotteau
- Dept. of Industrial Biotechnology, KTH Royal Institute of Technology, Stockholm, Sweden.,AdBIOPRO, Competence Centre for Advanced BioProduction by Continuous Processing, Sweden
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13
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Szkodny AC, Lee KH. Biopharmaceutical Manufacturing: Historical Perspectives and Future Directions. Annu Rev Chem Biomol Eng 2022; 13:141-165. [PMID: 35300518 DOI: 10.1146/annurev-chembioeng-092220-125832] [Citation(s) in RCA: 15] [Impact Index Per Article: 7.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/09/2022]
Abstract
This review describes key milestones related to the production of biopharmaceuticals-therapies manufactured using recombinant DNA technology. The market for biopharmaceuticals has grown significantly since the first biopharmaceutical approval in 1982, and the scientific maturity of the technologies used in their manufacturing processes has grown concomitantly. Early processes relied on established unit operations, with research focused on process scale-up and improved culture productivity. In the early 2000s, changes in regulatory frameworks and the introduction of Quality by Design emphasized the importance of developing manufacturing processes to deliver a desired product quality profile. As a result, companies adopted platform processes and focused on understanding the dynamic interplay between product quality and processing conditions. The consistent and reproducible manufacturing processes of today's biopharmaceutical industry have set high standards for product efficacy, quality, and safety, and as the industry continues to evolve in the coming decade, intensified processing capabilities for an expanded range of therapeutic modalities will likely become routine. Expected final online publication date for the Annual Review of Chemical and Biomolecular Engineering, Volume 13 is October 2022. Please see http://www.annualreviews.org/page/journal/pubdates for revised estimates.
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Affiliation(s)
- Alana C Szkodny
- Department of Chemical and Biomolecular Engineering, University of Delaware, Newark, Delaware 19716, USA; ;
| | - Kelvin H Lee
- Department of Chemical and Biomolecular Engineering, University of Delaware, Newark, Delaware 19716, USA; ;
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14
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Enablers of continuous processing of biotherapeutic products. Trends Biotechnol 2022; 40:804-815. [PMID: 35034769 DOI: 10.1016/j.tibtech.2021.12.003] [Citation(s) in RCA: 9] [Impact Index Per Article: 4.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/08/2021] [Revised: 12/07/2021] [Accepted: 12/08/2021] [Indexed: 11/21/2022]
Abstract
The benefits of continuous processing over batch manufacturing are widely acknowledged across the biopharmaceutical industry, primary of which are higher productivity and greater consistency in product quality. Furthermore, the reduced equipment and facility footprint lead to significantly lower capital costs. Technology enablers have a major role in this migration from batch to continuous processing. In this review, we highlight the various enablers that are facilitating adoption of continuous upstream and downstream bioprocessing. This includes new bioreactors and cell retention devices for upstream operations, and on-column and continuous flow refolding, novel continuous chromatography, and single-pass filtration systems for downstream processes. We also elucidate the significant roles of process integration and control as well as of data analytics in these processes.
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15
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Modelling and optimization of single-pass tangential flow ultrafiltration for continuous manufacturing of monoclonal antibodies. Sep Purif Technol 2021. [DOI: 10.1016/j.seppur.2021.119341] [Citation(s) in RCA: 7] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/22/2022]
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16
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Yehl CJ, Zydney AL. High Performance Countercurrent Membrane Purification for protein separations. J Memb Sci 2021. [DOI: 10.1016/j.memsci.2021.119396] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/20/2022]
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17
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Kateja N, Tiwari A, Thakur G, Rathore AS. Complete or periodic continuity in continuous manufacturing platforms for production of monoclonal antibodies? Biotechnol J 2021; 16:e2000524. [PMID: 33773062 DOI: 10.1002/biot.202000524] [Citation(s) in RCA: 12] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Abstract] [Key Words] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/14/2020] [Revised: 03/21/2021] [Accepted: 03/22/2021] [Indexed: 11/09/2022]
Abstract
BACKGROUND Monoclonal antibodies (mAbs) currently dominate the biotherapeutic market. This has resulted in significant efforts towards the development of a continuous integrated platform for the manufacturing of mAbs. MAIN METHODS AND MAJOR RESULTS In this study, a continuous mAb platform has been developed consisting of an Acoustic Wave Separator, a Cadence BioSMB PD system, a customized coiled flow reactor, a modular single-pass TFF kit, an in-line diafiltration module, and a continuous dead-end filtration skid. A three-step chromatographic purification was performed in the platform consisting of Protein A capture chromatography followed by an anion exchange membrane directly coupled to a cation exchange chromatography. Two operational case studies have been executed on the platform, namely complete continuous ("CC") and periodic continuous ("PC") modes of operation. The CC mode was designed to ensure that each unit operation had completely continuous inflow and outflow by increasing the number of columns, filtration modules and tanks, while the PC mode operated in periodic pulses with scheduled flow and hold steps. Both modes were designed to handle the same flow rate and titers from the upstream bioreactor or fed-batch harvest tank, and were compared in terms of productivity and operational complexity. Both modes offer viable options for continuous processing of mAbs and result in achievement of target critical quality attribute profiles of the final drug product over 24 h of operation. CONCLUSIONS AND IMPLICATIONS It was found that the CC mode was superior in terms of specific productivity (20-50% higher) and consumable utilization (20% lower resin utilization), while the PC mode was operationally simpler and had lower facility costs due to significant reductions in the number of auxiliary equipment (pumps, columns, tanks, and valves). The work successfully highlighted the pros and cons of both approaches, and demonstrates that while several groups have amply shown the superiority of continuous processing over batch mode, there are intermediate variants which may be optimal in a given situation.
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Affiliation(s)
- Nikhil Kateja
- Department of Chemical Engineering, Indian Institute of Technology Delhi, Hauz Khas, India
| | - Anamika Tiwari
- Department of Chemical Engineering, Indian Institute of Technology Delhi, Hauz Khas, India
| | - Garima Thakur
- Department of Chemical Engineering, Indian Institute of Technology Delhi, Hauz Khas, India
| | - Anurag S Rathore
- Department of Chemical Engineering, Indian Institute of Technology Delhi, Hauz Khas, India
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18
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Rathore AS, Nikita S, Thakur G, Deore N. Challenges in process control for continuous processing for production of monoclonal antibody products. Curr Opin Chem Eng 2021. [DOI: 10.1016/j.coche.2021.100671] [Citation(s) in RCA: 11] [Impact Index Per Article: 3.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/01/2023]
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19
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Coffman J, Brower M, Connell-Crowley L, Deldari S, Farid SS, Horowski B, Patil U, Pollard D, Qadan M, Rose S, Schaefer E, Shultz J. A common framework for integrated and continuous biomanufacturing. Biotechnol Bioeng 2021; 118:1721-1735. [PMID: 33491769 PMCID: PMC8248397 DOI: 10.1002/bit.27690] [Citation(s) in RCA: 28] [Impact Index Per Article: 9.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/17/2020] [Revised: 12/31/2020] [Accepted: 01/12/2021] [Indexed: 12/29/2022]
Abstract
There is a growing application of integrated and continuous bioprocessing (ICB) for manufacturing recombinant protein therapeutics produced from mammalian cells. At first glance, the newly evolved ICB has created a vast diversity of platforms. A closer inspection reveals convergent evolution: nearly all of the major ICB methods have a common framework that could allow manufacturing across a global ecosystem of manufacturers using simple, yet effective, equipment designs. The framework is capable of supporting the manufacturing of most major biopharmaceutical ICB and legacy processes without major changes in the regulatory license. This article reviews the ICB that are being used, or are soon to be used, in a GMP manufacturing setting for recombinant protein production from mammalian cells. The adaptation of the various ICB modes to the common ICB framework will be discussed, along with the pros and cons of such adaptation. The equipment used in the common framework is generally described. This review is presented in sufficient detail to enable discussions of IBC implementation strategy in biopharmaceutical companies and contract manufacturers, and to provide a road map for vendors equipment design. An example plant built on the common framework will be discussed. The flexibility of the plant is demonstrated with batches as small as 0.5 kg or as large as 500 kg. The yearly output of the plant is as much as 8 tons.
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Affiliation(s)
- Jonathan Coffman
- BioProcess Technology and Engineering, BioProcess Development, R&D, Astrazeneca, Gaithersburg, Maryland, USA
| | - Mark Brower
- Merck and Company, Kennilworth, New Jersey, USA
| | | | - Sevda Deldari
- BioProcess Technology and Engineering, BioProcess Development, R&D, Astrazeneca, Gaithersburg, Maryland, USA
| | - Suzanne S Farid
- Department of Biochemical Engineering, University College London, London, UK
| | | | - Ujwal Patil
- BioProcess Technology and Engineering, BioProcess Development, R&D, Astrazeneca, Gaithersburg, Maryland, USA
| | | | | | - Steven Rose
- BioProcess Technology and Engineering, BioProcess Development, R&D, Astrazeneca, Gaithersburg, Maryland, USA
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20
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Gerstweiler L, Bi J, Middelberg AP. Continuous downstream bioprocessing for intensified manufacture of biopharmaceuticals and antibodies. Chem Eng Sci 2021. [DOI: 10.1016/j.ces.2020.116272] [Citation(s) in RCA: 12] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/08/2023]
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21
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Continuous single pass diafiltration with alternating permeate flow direction for high efficiency buffer exchange. J Memb Sci 2021. [DOI: 10.1016/j.memsci.2020.118695] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/22/2022]
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22
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23
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Coolbaugh MJ, Varner CT, Vetter TA, Davenport EK, Bouchard B, Fiadeiro M, Tugcu N, Walther J, Patil R, Brower K. Pilot-scale demonstration of an end-to-end integrated and continuous biomanufacturing process. Biotechnol Bioeng 2021; 118:3287-3301. [PMID: 33410159 DOI: 10.1002/bit.27670] [Citation(s) in RCA: 27] [Impact Index Per Article: 9.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/11/2020] [Revised: 12/09/2020] [Accepted: 01/04/2021] [Indexed: 12/15/2022]
Abstract
There has been increasing momentum recently in the biopharmaceutical industry to transition from traditional batch processes to next-generation integrated and continuous biomanufacturing. This transition from batch to continuous is expected to offer several advantages which, taken together, could significantly improve access to biologics drugs for patients. Despite this recent momentum, there has not been a commercial implementation of a continuous bioprocess reported in the literature. In this study, we describe a successful pilot-scale proof-of-concept demonstration of an end-to-end integrated and continuous bioprocess for the production of a monoclonal antibody (mAb). This process incorporated all of the key unit operations found in a typical mAb production process, including the final steps of virus removal filtration, ultrafiltration, diafiltration, and formulation. The end-to-end integrated process was operated for a total of 25 days and produced a total of 4.9 kg (200 g/day or 2 g/L BRX/day) of the drug substance from a 100-L perfusion bioreactor (BRX) with acceptable product quality and minimal operator intervention. This successful proof-of-concept demonstrates that end-to-end integrated continuous bioprocessing is achievable with current technologies and represents an important step toward the realization of a commercial integrated and continuous bioprocessing process.
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Affiliation(s)
| | - Chad T Varner
- Global CMC Development, Sanofi, Framingham, Massachusetts, USA
| | - Tarl A Vetter
- Global CMC Development, Sanofi, Framingham, Massachusetts, USA.,Gene Therapy Development, Pfizer, Chesterfield, Missouri, USA
| | - Emily K Davenport
- Global CMC Development, Sanofi, Framingham, Massachusetts, USA.,Process Science, Novartis Gene Therapies, San Diego, California, USA
| | - Brad Bouchard
- Global CMC Development, Sanofi, Framingham, Massachusetts, USA.,Process Development Systems, Moderna, Norton, Massachusetts, USA
| | - Marcus Fiadeiro
- Global CMC Development, Sanofi, Framingham, Massachusetts, USA
| | - Nihal Tugcu
- Global CMC Development, Sanofi, Framingham, Massachusetts, USA
| | - Jason Walther
- Global CMC Development, Sanofi, Framingham, Massachusetts, USA
| | - Rohan Patil
- Global CMC Development, Sanofi, Framingham, Massachusetts, USA
| | - Kevin Brower
- Global CMC Development, Sanofi, Framingham, Massachusetts, USA
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24
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Khanal O, Lenhoff AM. Developments and opportunities in continuous biopharmaceutical manufacturing. MAbs 2021; 13:1903664. [PMID: 33843449 PMCID: PMC8043180 DOI: 10.1080/19420862.2021.1903664] [Citation(s) in RCA: 24] [Impact Index Per Article: 8.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/04/2020] [Revised: 02/25/2021] [Accepted: 03/11/2021] [Indexed: 12/12/2022] Open
Abstract
Today's biologics manufacturing practices incur high costs to the drug makers, which can contribute to high prices for patients. Timely investment in the development and implementation of continuous biomanufacturing can increase the production of consistent-quality drugs at a lower cost and a faster pace, to meet growing demand. Efficient use of equipment, manufacturing footprint, and labor also offer the potential to improve drug accessibility. Although technological efforts enabling continuous biomanufacturing have commenced, challenges remain in the integration, monitoring, and control of traditionally segmented unit operations. Here, we discuss recent developments supporting the implementation of continuous biomanufacturing, along with their benefits.
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Affiliation(s)
- Ohnmar Khanal
- Department of Chemical and Biomolecular Engineering, University of Delaware, Newark, DE
| | - Abraham M. Lenhoff
- Department of Chemical and Biomolecular Engineering, University of Delaware, Newark, DE
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25
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Thakur G, Thori S, Rathore AS. Implementing PAT for single-pass tangential flow ultrafiltration for continuous manufacturing of monoclonal antibodies. J Memb Sci 2020. [DOI: 10.1016/j.memsci.2020.118492] [Citation(s) in RCA: 10] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/23/2022]
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26
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Nadar S, Shooter G, Somasundaram B, Shave E, Baker K, Lua LHL. Intensified Downstream Processing of Monoclonal Antibodies Using Membrane Technology. Biotechnol J 2020; 16:e2000309. [PMID: 33006254 DOI: 10.1002/biot.202000309] [Citation(s) in RCA: 13] [Impact Index Per Article: 3.3] [Reference Citation Analysis] [Abstract] [Key Words] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/07/2022]
Abstract
The need to intensify downstream processing of monoclonal antibodies to complement the advances in upstream productivity has led to increased attention toward implementing membrane technologies. With the industry moving toward continuous operations and single use processes, membrane technologies show promise in fulfilling the industry needs due to their operational flexibility and ease of implementation. Recently, the applicability of membrane-based unit operations in integrating the downstream process has been explored. In this article, the major developments in the application of membrane-based technologies in the bioprocessing of monoclonal antibodies are reviewed. The recent progress toward developing intensified end-to-end bioprocesses and the critical role membrane technology will play in achieving this goal are focused upon.
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Affiliation(s)
- Sathish Nadar
- Australian Research Council Training Centre for Biopharmaceutical Innovation, Australian Institute for Bioengineering and Nanotechnology, The University of Queensland, Corner College and Cooper Roads, Brisbane, Queensland, 4072, Australia
| | - Gary Shooter
- Australian Research Council Training Centre for Biopharmaceutical Innovation, Australian Institute for Bioengineering and Nanotechnology, The University of Queensland, Corner College and Cooper Roads, Brisbane, Queensland, 4072, Australia
| | - Balaji Somasundaram
- Protein Expression Facility, The University of Queensland, Corner College and Cooper Roads, Brisbane, Queensland, 4072, Australia
| | - Evan Shave
- Australian Research Council Training Centre for Biopharmaceutical Innovation, Australian Institute for Bioengineering and Nanotechnology, The University of Queensland, Corner College and Cooper Roads, Brisbane, Queensland, 4072, Australia.,Pharma services group, Thermo Fisher Scientific, 37 Kent St, Woolloongabba, Brisbane, Queensland, 4102, Australia
| | - Kym Baker
- Pharma services group, Thermo Fisher Scientific, 37 Kent St, Woolloongabba, Brisbane, Queensland, 4102, Australia
| | - Linda H L Lua
- Australian Research Council Training Centre for Biopharmaceutical Innovation, Australian Institute for Bioengineering and Nanotechnology, The University of Queensland, Corner College and Cooper Roads, Brisbane, Queensland, 4072, Australia.,Protein Expression Facility, The University of Queensland, Corner College and Cooper Roads, Brisbane, Queensland, 4072, Australia
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27
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Kruse T, Kampmann M, Rüddel I, Greller G. An alternative downstream process based on aqueous two-phase extraction for the purification of monoclonal antibodies. Biochem Eng J 2020. [DOI: 10.1016/j.bej.2020.107703] [Citation(s) in RCA: 11] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/14/2022]
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28
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Xu J, Xu X, Huang C, Angelo J, Oliveira CL, Xu M, Xu X, Temel D, Ding J, Ghose S, Borys MC, Li ZJ. Biomanufacturing evolution from conventional to intensified processes for productivity improvement: a case study. MAbs 2020; 12:1770669. [PMID: 32425110 PMCID: PMC7531520 DOI: 10.1080/19420862.2020.1770669] [Citation(s) in RCA: 34] [Impact Index Per Article: 8.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/10/2023] Open
Abstract
Process intensification has shown great potential to increase productivity and reduce costs in biomanufacturing. This case study describes the evolution of a manufacturing process from a conventional processing scheme at 1000-L scale (Process A, n = 5) to intensified processing schemes at both 1000-L (Process B, n = 8) and 2000-L scales (Process C, n = 3) for the production of a monoclonal antibody by a Chinese hamster ovary cell line. For the upstream part of the process, we implemented an intensified seed culture scheme to enhance cell densities at the seed culture step (N-1) prior to the production bioreactor (N) by using either enriched N-1 seed culture medium for Process B or by operating the N-1 step in perfusion mode for Process C. The increased final cell densities at the N-1 step allowed for much higher inoculation densities in the production bioreactor operated in fed-batch mode and substantially increased titers by 4-fold from Process A to B and 8-fold from Process A to C, while maintaining comparable final product quality. Multiple changes were made to intensify the downstream process to accommodate the increased titers. New high-capacity resins were implemented for the Protein A and anion exchange chromatography (AEX) steps, and the cation exchange chromatography (CEX) step was changed from bind-elute to flow-through mode for the streamlined Process B. Multi-column chromatography was developed for Protein A capture, and an integrated AEX-CEX pool-less polishing steps allowed semi-continuous Process C with increased productivity as well as reductions in resin requirements, buffer consumption, and processing times. A cost-of-goods analysis on consumables showed 6.7–10.1 fold cost reduction from the conventional Process A to the intensified Process C. The hybrid-intensified process described here is easy to implement in manufacturing and lays a good foundation to develop a fully continuous manufacturing with even higher productivity in the future.
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Affiliation(s)
- Jianlin Xu
- Global Product Development and Supply, Bristol-Myers Squibb Company , Devens, MA, USA
| | - Xuankuo Xu
- Global Product Development and Supply, Bristol-Myers Squibb Company , Devens, MA, USA
| | - Chao Huang
- Global Product Development and Supply, Bristol-Myers Squibb Company , Devens, MA, USA
| | - James Angelo
- Global Product Development and Supply, Bristol-Myers Squibb Company , Devens, MA, USA
| | | | - Mengmeng Xu
- Global Product Development and Supply, Bristol-Myers Squibb Company , Devens, MA, USA
| | - Xia Xu
- Global Product Development and Supply, Bristol-Myers Squibb Company , Devens, MA, USA
| | - Deniz Temel
- Global Product Development and Supply, Bristol-Myers Squibb Company , Devens, MA, USA
| | - Julia Ding
- Global Product Development and Supply, Bristol-Myers Squibb Company , Devens, MA, USA
| | - Sanchayita Ghose
- Global Product Development and Supply, Bristol-Myers Squibb Company , Devens, MA, USA
| | - Michael C Borys
- Global Product Development and Supply, Bristol-Myers Squibb Company , Devens, MA, USA
| | - Zheng Jian Li
- Global Product Development and Supply, Bristol-Myers Squibb Company , Devens, MA, USA
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29
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Tan R, Franzreb M. Continuous ultrafiltration/diafiltration using a 3D-printed two membrane single pass module. Biotechnol Bioeng 2019; 117:654-661. [PMID: 31788780 DOI: 10.1002/bit.27233] [Citation(s) in RCA: 12] [Impact Index Per Article: 2.4] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/01/2019] [Revised: 10/25/2019] [Accepted: 11/22/2019] [Indexed: 02/06/2023]
Abstract
A 3D printed ultrafiltration/diafiltration (UF/DF) module is presented allowing the continuous, simultaneous concentration of retained (bio-)molecules and reduction or exchange of the salt buffer. Differing from the single-pass UF concepts known from the literature, DF operation does not require the application of several steps or units with intermediating dilution. In contrast, the developed module uses two membranes confining the section in which the molecules are concentrated while the sample is passing. Simultaneously to this concentration process, the two membranes allow a perpendicular in and outflow of DF buffer reducing the salt content in this section. The module showed the continuous concentration of a dissolved protein up to a factor of 4.6 while reducing the salt concentration down to 47% of the initial concentration along a flow path length of only 5 cm. Due to single-pass operation the module shows concentration polarization effects reducing the effective permeability of the applied membrane in case of higher concentration factors. However, because of its simple design and the capability to simultaneously run UF and DF processes in a single module, the development could be economically beneficial for small scale UF/DF applications.
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Affiliation(s)
- Ruijie Tan
- Bioengineering and Biosystem, Institute of Functional Interfaces, Karlsruhe Institute of Technology, Karlsruhe, Germany
| | - Matthias Franzreb
- Bioengineering and Biosystem, Institute of Functional Interfaces, Karlsruhe Institute of Technology, Karlsruhe, Germany
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30
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Model-Based Design and Process Optimization of Continuous Single Pass Tangential Flow Filtration Focusing on Continuous Bioprocessing. Processes (Basel) 2019. [DOI: 10.3390/pr7060317] [Citation(s) in RCA: 24] [Impact Index Per Article: 4.8] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/11/2023] Open
Abstract
In this study the Single-Pass-Tangential-Flow-Filtration (SPTFF) concept for continuous ultrafiltration in bioprocessing is investigated. Based on a previously validated physico-chemical model for a single ultrafiltration cassette, the transfer to a multistage SPTFF is predicted and validated experimentally by concentration steps for bovine serum albumin (BSA) and the monoclonal antibody immunoglobulin G (IgG) are compared. The model applied for the ultrafiltration membrane contains the Stagnant Film Model (SFM) for concentration polarization, as well as the Osmotic Pressure Model (OPM) and the Boundary Layer Model (BLM) for the mass transfer through the membrane. In addition, pressure drop correlations as a function of the Reynolds number are included to describe the development of the transmembrane pressure over the length of the module. The outcome of this study shows the potential to improve this multi-parameter dependent unit operation by a model-based optimization allowing significant reduction of experimental efforts and applying the Quality by Design (QbD) approach consistently. Consequently, a versatile tool for conceptual process design is presented and further application is discussed.
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31
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Jabra MG, Yehl CJ, Zydney AL. Multistage continuous countercurrent diafiltration for formulation of monoclonal antibodies. Biotechnol Prog 2019; 35:e2810. [DOI: 10.1002/btpr.2810] [Citation(s) in RCA: 17] [Impact Index Per Article: 3.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/25/2019] [Revised: 02/15/2019] [Accepted: 03/20/2019] [Indexed: 01/10/2023]
Affiliation(s)
- Mario G. Jabra
- Department of Chemical EngineeringThe Pennsylvania State University University Park Pennsylvania
| | - Christopher J. Yehl
- Department of Chemical EngineeringThe Pennsylvania State University University Park Pennsylvania
| | - Andrew L. Zydney
- Department of Chemical EngineeringThe Pennsylvania State University University Park Pennsylvania
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32
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Yang O, Qadan M, Ierapetritou M. Economic Analysis of Batch and Continuous Biopharmaceutical Antibody Production: A Review. J Pharm Innov 2019; 14:1-19. [PMID: 30923586 PMCID: PMC6432653 DOI: 10.1007/s12247-018-09370-4] [Citation(s) in RCA: 38] [Impact Index Per Article: 7.6] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/30/2023]
Abstract
PURPOSE There is a growing interest in continuous biopharmaceutical processing due to the advantages of small footprint, increased productivity, consistent product quality, high process flexibility and robustness, facility cost-effectiveness, and reduced capital and operating cost. To support the decision making of biopharmaceutical manufacturing, comparisons between conventional batch and continuous processing are provided. METHODS Various process unit operations in different operating modes are summarized. Software implementation, as well as computational methods used, are analyzed pointing to the advantages and disadvantages that have been highlighted in the literature. Economic analysis methods and their applications in different parts of the processes are also discussed with examples from publications in the last decade. RESULTS The results of the comparison between batch and continuous process operation alternatives are discussed. Possible improvements in process design and analysis are recommended. The methods used here do not reflect Lilly's cost structures or economic evaluation methods. CONCLUSION This paper provides a review of the work that has been published in the literature on computational process design and economic analysis methods on continuous biopharmaceutical antibody production and its comparison with a conventional batch process.
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Affiliation(s)
- Ou Yang
- Department of Chemical and Biochemical Engineering, Rutgers—The State University of New Jersey, 98 Brett Road, Piscataway, New Jersey 08854-8058, United States
| | - Maen Qadan
- Eli Lilly and Company, Lilly Corporate Center, Indianapolis, IN 46285, United States
| | - Marianthi Ierapetritou
- Department of Chemical and Biochemical Engineering, Rutgers—The State University of New Jersey, 98 Brett Road, Piscataway, New Jersey 08854-8058, United States
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33
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Burgstaller D, Jungbauer A, Satzer P. Continuous integrated antibody precipitation with two-stage tangential flow microfiltration enables constant mass flow. Biotechnol Bioeng 2019; 116:1053-1065. [PMID: 30636284 PMCID: PMC6667901 DOI: 10.1002/bit.26922] [Citation(s) in RCA: 26] [Impact Index Per Article: 5.2] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/13/2018] [Revised: 12/27/2018] [Accepted: 01/09/2019] [Indexed: 01/20/2023]
Abstract
Continuous precipitation is a new unit operation for the continuous capture of antibodies. The capture step is based on continuous precipitation with PEG6000 and Zn++ in a tubular reactor integrated with a two‐stage continuous tangential flow filtration unit. The precipitate cannot be separated with centrifugation, because a highly compressed sediment results in poor resolubilization. We developed a new two‐stage tangential flow microfiltration method, where part of the concentrated retentate of the first stage was directly fed to the second stage, together with the wash buffer. Thus, the precipitate was concentrated and washed in a continuous process. We obtained 97% antibody purity, a 95% process yield during continuous operation, and a fivefold reduction in pre‐existing high‐molecular‐weight impurities. For other unit operations, surge tanks are often required, due to interruptions in the product mass flow out of the unit operation (e.g., the bind/elute mode in periodic counter‐current chromatography). Our setup required no surge tanks; thus, it provided a truly continuous antibody capture operation with uninterrupted product mass flow. Continuous virus inactivation and other flow‐through unit operations can be readily integrated downstream of the capture step to create truly continuous, integrated, downstream antibody processing without the need for hold tanks.
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Affiliation(s)
- Daniel Burgstaller
- Department of Biotechnology, University of Natural Resources and Life Sciences,, Vienna, Austria
| | - Alois Jungbauer
- Department of Biotechnology, University of Natural Resources and Life Sciences,, Vienna, Austria.,Austrian Centre of Industrial Biotechnology (ACIB), Vienna, Austria
| | - Peter Satzer
- Department of Biotechnology, University of Natural Resources and Life Sciences,, Vienna, Austria
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34
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Yehl CJ, Jabra MG, Zydney AL. Hollow fiber countercurrent dialysis for continuous buffer exchange of high‐value biotherapeutics. Biotechnol Prog 2018; 35:e2763. [DOI: 10.1002/btpr.2763] [Citation(s) in RCA: 15] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/10/2018] [Accepted: 12/03/2018] [Indexed: 12/20/2022]
Affiliation(s)
- Christopher J. Yehl
- Dept. of Chemical EngineeringThe Pennsylvania State University University Park PA, 16802
| | - Mario G. Jabra
- Dept. of Chemical EngineeringThe Pennsylvania State University University Park PA, 16802
| | - Andrew L. Zydney
- Dept. of Chemical EngineeringThe Pennsylvania State University University Park PA, 16802
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35
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Arnold L, Lee K, Rucker‐Pezzini J, Lee JH. Implementation of Fully Integrated Continuous Antibody Processing: Effects on Productivity and COGm. Biotechnol J 2018; 14:e1800061. [DOI: 10.1002/biot.201800061] [Citation(s) in RCA: 63] [Impact Index Per Article: 10.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/26/2018] [Revised: 04/23/2018] [Indexed: 01/11/2023]
Affiliation(s)
- Lindsay Arnold
- Biopharmaceutical DevelopmentMedImmune1 MedImmune Way20878 GaithersburgMDUSA
| | - Kenneth Lee
- Biopharmaceutical DevelopmentMedImmune1 MedImmune Way20878 GaithersburgMDUSA
| | | | - Jeong H. Lee
- Biopharmaceutical DevelopmentMedImmune1 MedImmune Way20878 GaithersburgMDUSA
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