1
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Raza H, Tang T, Gao B, Phuangthong C, Chen CB, Pinto NDS. Evaluation of various membranes at different fluxes to enable large-volume single-use perfusion bioreactors. Biotechnol Bioeng 2024. [PMID: 38702962 DOI: 10.1002/bit.28722] [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: 10/07/2023] [Revised: 03/30/2024] [Accepted: 04/13/2024] [Indexed: 05/06/2024]
Abstract
The growing demand for biological therapeutics has increased interest in large-volume perfusion bioreactors, but the operation and scalability of perfusion membranes remain a challenge. This study evaluates perfusion cell culture performance and monoclonal antibody (mAb) productivity at various membrane fluxes (1.5-5 LMH), utilizing polyvinylidene difluoride (PVDF), polyethersulfone (PES), or polysulfone (PS) membranes in tangential flow filtration mode. At low flux, culture with PVDF membrane maintained higher cell culture growth, permeate titer (1.06-1.34 g/L) and sieving coefficients (≥83%) but showed lower permeate volumetric throughput and higher transmembrane pressure (TMP) (>1.50 psi) in the later part of the run compared to cultures with PES and PS membrane. However, as permeate flux increased, the total mass of product decreased by around 30% for cultures with PVDF membrane, while it remained consistent with PES and PS membrane, and at the highest flux studied, PES membrane generated 12% more product than PVDF membrane. This highlights that membrane selection for large-volume perfusion bioreactors depends on the productivity and permeate flux required. Since operating large-volume perfusion bioreactors at low flux would require several cell retention devices and a complex setup, PVDF membranes are suitable for low-volume operations at low fluxes whereas PES membranes can be a desirable alternative for large-volume higher demand products at higher fluxes.
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Affiliation(s)
- Hassan Raza
- Biologics Process Research & Development, Merck & Co., Inc., Rahway, New Jersey, USA
| | - Tiffany Tang
- Biologics Process Research & Development, Merck & Co., Inc., Rahway, New Jersey, USA
| | - Baizhen Gao
- Biologics Process Research & Development, Merck & Co., Inc., Rahway, New Jersey, USA
| | - Chelsea Phuangthong
- Biologics Process Research & Development, Merck & Co., Inc., Rahway, New Jersey, USA
| | | | - Nuno D S Pinto
- Biologics Process Research & Development, Merck & Co., Inc., Rahway, New Jersey, USA
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2
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WuDunn D, Squeri A, Vu J, Dhingra A, Coffman J, Lee K. Effect of inner diameter, filter length, and pore size on hollow fiber filter fouling during perfusion cell culture. Biotechnol Prog 2024; 40:e3440. [PMID: 38343012 DOI: 10.1002/btpr.3440] [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: 09/10/2023] [Revised: 12/05/2023] [Accepted: 01/24/2024] [Indexed: 02/23/2024]
Abstract
As the need for higher volumetric productivity in biomanufacturing grows, biopharmaceutical companies are increasingly investing in a perfusion cell culture process, most commonly one that uses a hollow fiber filter as the cell retention device. A current challenge with using hollow fiber filters is fouling of the membrane, which reduces product sieving and can increase transmembrane pressure (TMP) past process limitations. In this work, the impact of hollow fiber filter geometries on product sieving and hydraulic membrane resistance profiles is evaluated in a tangential flow filtration (TFF) perfusion system. The hollow fibers tested had lengths ranging from 19.8 to 41.5 cm, inner diameters (IDs) ranging from 1.0 to 2.6 mm, and pore sizes of 0.2 or 0.65 μm. The results showed that the shortest hollow fibers experienced higher product sieving while larger IDs contributed to both higher product sieving and lower hydraulic membrane resistances, illustrating the impact of filter geometry on process performance. The results also showed 0.2 μm pore size filters maintain higher product sieving, but also higher membrane resistances compared to 0.65 μm pore size filters. This study highlights the need for optimized hollow fiber filter geometries to maximize use of the membrane area, which in turn can reduce production costs and increase scalability of the perfusion process.
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Affiliation(s)
- Dominique WuDunn
- BioProcess Technologies & Engineering, BioPharmaceuticals Development, R&D, AstraZeneca, Gaithersburg, Maryland, USA
| | - Andrea Squeri
- BioProcess Technologies & Engineering, BioPharmaceuticals Development, R&D, AstraZeneca, Gaithersburg, Maryland, USA
| | - Jimmy Vu
- BioProcess Technologies & Engineering, BioPharmaceuticals Development, R&D, AstraZeneca, Gaithersburg, Maryland, USA
| | - Ashna Dhingra
- BioProcess Technologies & Engineering, BioPharmaceuticals Development, R&D, AstraZeneca, Gaithersburg, Maryland, USA
| | - Jon Coffman
- BioProcess Technologies & Engineering, BioPharmaceuticals Development, R&D, AstraZeneca, Gaithersburg, Maryland, USA
| | - Ken Lee
- BioProcess Technologies & Engineering, BioPharmaceuticals Development, R&D, AstraZeneca, Gaithersburg, Maryland, USA
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3
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Zhang Y, Madabhushi S, Tang T, Raza H, Busch DJ, Zhao X, Ormes J, Xu S, Moroney J, Jiang R, Lin H, Liu R. Contributions of Chinese hamster ovary cell derived extracellular vesicles and other cellular materials to hollow fiber filter fouling during perfusion manufacturing of monoclonal antibodies. Biotechnol Bioeng 2024; 121:1674-1687. [PMID: 38372655 DOI: 10.1002/bit.28674] [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: 09/28/2023] [Revised: 02/04/2024] [Accepted: 02/06/2024] [Indexed: 02/20/2024]
Abstract
Hollow fiber filter fouling is a common issue plaguing perfusion production process for biologics therapeutics, but the nature of filter foulant has been elusive. Here we studied cell culture materials especially Chinese hamster ovary (CHO) cell-derived extracellular vesicles in perfusion process to determine their role in filter fouling. We found that the decrease of CHO-derived small extracellular vesicles (sEVs) with 50-200 nm in diameter in perfusion permeates always preceded the increase in transmembrane pressure (TMP) and subsequent decrease in product sieving, suggesting that sEVs might have been retained inside filters and contributed to filter fouling. Using scanning electron microscopy and helium ion microscopy, we found sEV-like structures in pores and on foulant patches of hollow fiber tangential flow filtration filter (HF-TFF) membranes. We also observed that the Day 28 TMP of perfusion culture correlated positively with the percentage of foulant patch areas. In addition, energy dispersive X-ray spectroscopy-based elemental mapping microscopy and spectroscopy analysis suggests that foulant patches had enriched cellular materials but not antifoam. Fluorescent staining results further indicate that these cellular materials could be DNA, proteins, and even adherent CHO cells. Lastly, in a small-scale HF-TFF model, addition of CHO-specific sEVs in CHO culture simulated filter fouling behaviors in a concentration-dependent manner. Based on these results, we proposed a mechanism of HF-TFF fouling, in which filter pore constriction by CHO sEVs is followed by cake formation of cellular materials on filter membrane.
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Affiliation(s)
- Yixiao Zhang
- Bioprocess Research & Development, Merck & Co., Inc., Rahway, New Jersey, USA
| | - Sri Madabhushi
- Bioprocess Research & Development, Merck & Co., Inc., Rahway, New Jersey, USA
| | - Tiffany Tang
- Bioprocess Research & Development, Merck & Co., Inc., Rahway, New Jersey, USA
| | - Hassan Raza
- Bioprocess Research & Development, Merck & Co., Inc., Rahway, New Jersey, USA
| | - David J Busch
- Bioprocess Research & Development, Merck & Co., Inc., Rahway, New Jersey, USA
| | - Xi Zhao
- Sterile and Specialty Products, Pharmaceutical Science & Clinical Supply, Merck & Co., Inc., Rahway, New Jersey, USA
| | - James Ormes
- Analytical Research & Development, Merck & Co., Inc., Rahway, New Jersey, USA
| | - Sen Xu
- Bioprocess Research & Development, Merck & Co., Inc., Rahway, New Jersey, USA
| | - Joseph Moroney
- Bioprocess Research & Development, Merck & Co., Inc., Rahway, New Jersey, USA
| | - Rubin Jiang
- Bioprocess Research & Development, Merck & Co., Inc., Rahway, New Jersey, USA
| | - Henry Lin
- Bioprocess Research & Development, Merck & Co., Inc., Rahway, New Jersey, USA
| | - Ren Liu
- Bioprocess Research & Development, Merck & Co., Inc., Rahway, New Jersey, USA
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4
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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:e3456. [PMID: 38494903 DOI: 10.1002/btpr.3456] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/06/2023] [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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5
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Kaiphanliam KM, Fraser-Hevlin B, Barrow ES, Davis WC, Van Wie BJ. Development of a centrifugal bioreactor for rapid expansion of CD8 cytotoxic T cells for use in cancer immunotherapy. Biotechnol Prog 2023; 39:e3388. [PMID: 37694563 DOI: 10.1002/btpr.3388] [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: 02/23/2023] [Revised: 07/27/2023] [Accepted: 08/22/2023] [Indexed: 09/12/2023]
Abstract
One of the current difficulties limiting the use of adoptive cell therapy (ACT) for cancer treatment is the lack of methods for rapidly expanding T cells. As described in the present report, we developed a centrifugal bioreactor (CBR) that may resolve this manufacturing bottleneck. The CBR operates in perfusion by balancing centrifugal forces with a continuous feed of fresh medium, preventing cells from leaving the expansion culture chamber while maintaining nutrients for growth. A bovine CD8 cytotoxic T lymphocyte (CTL) cell line specific for an autologous target cell infected with a protozoan parasite, Theileria parva, was used to determine the efficacy of the CBR for ACT purposes. Batch culture experiments were conducted to predict how CTLs respond to environmental changes associated with consumption of nutrients and production of toxic metabolites, such as ammonium and lactate. Data from these studies were used to develop a kinetic growth model, allowing us to predict CTL growth in the CBR and determine the optimal operating parameters. The model predicts the maximum cell density the CBR can sustain is 5.5 × 107 cells/mL in a single 11-mL conical chamber with oxygen being the limiting factor. Experimental results expanding CTLs in the CBR are in 95% agreement with the kinetic model. The prototype CBR described in this report can be used to develop a CBR for use in cancer immunotherapy.
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Affiliation(s)
- Kitana M Kaiphanliam
- Voiland School of Chemical Engineering and Bioengineering, Washington State University, Pullman, Washington, USA
| | - Brenden Fraser-Hevlin
- Voiland School of Chemical Engineering and Bioengineering, Washington State University, Pullman, Washington, USA
| | - Eric S Barrow
- Voiland College of Engineering and Architecture Professional Shops, Washington State University, Pullman, Washington, USA
| | - William C Davis
- Department of Veterinary Microbiology and Pathology, Washington State University, Pullman, Washington, USA
| | - Bernard J Van Wie
- Voiland School of Chemical Engineering and Bioengineering, Washington State University, Pullman, Washington, USA
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6
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Madabhushi SR, Huang C, Wang X, Bui A, Atieh TB, Rayfield WJ, Jayapal KP, Lin H. An innovative strategy to recycle permeate in biologics continuous manufacturing process to improve material efficiency and sustainability. Biotechnol Prog 2022; 38:e3262. [DOI: 10.1002/btpr.3262] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/10/2022] [Revised: 04/04/2022] [Accepted: 04/07/2022] [Indexed: 11/08/2022]
Affiliation(s)
| | - Chung‐Jr Huang
- Biologics Upstream Process Development Merck & Co., Inc. Kenilworth New Jersey USA
| | - Xiaowen Wang
- Biologics Upstream Process Development Merck & Co., Inc. Kenilworth New Jersey USA
| | - Ashley Bui
- Biologics Upstream Process Development Merck & Co., Inc. Kenilworth New Jersey USA
| | - Tariq Bassam Atieh
- Biologics Upstream Process Development Merck & Co., Inc. Kenilworth New Jersey USA
| | - William J. Rayfield
- Biologics Downstream Process Development Merck & Co., Inc. Kenilworth New Jersey USA
| | - Karthik P. Jayapal
- Biologics Upstream Process Development Merck & Co., Inc. Kenilworth New Jersey USA
| | - Henry Lin
- Biologics Upstream Process Development Merck & Co., Inc. Kenilworth New Jersey USA
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7
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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: 26] [Impact Index Per Article: 8.7] [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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8
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Erickson J, Baker J, Barrett S, Brady C, Brower M, Carbonell R, Charlebois T, Coffman J, Connell-Crowley L, Coolbaugh M, Fallon E, Garr E, Gillespie C, Hart R, Haug A, Nyberg G, Phillips M, Pollard D, Qadan M, Ramos I, Rogers K, Schaefer G, Walther J, Lee K. End-to-end collaboration to transform biopharmaceutical development and manufacturing. Biotechnol Bioeng 2021; 118:3302-3312. [PMID: 33480041 PMCID: PMC8451863 DOI: 10.1002/bit.27688] [Citation(s) in RCA: 18] [Impact Index Per Article: 6.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/21/2020] [Revised: 12/18/2020] [Accepted: 01/18/2021] [Indexed: 12/24/2022]
Abstract
An ambitious 10‐year collaborative program is described to invent, design, demonstrate, and support commercialization of integrated biopharmaceutical manufacturing technology intended to transform the industry. Our goal is to enable improved control, robustness, and security of supply, dramatically reduced capital and operating cost, flexibility to supply an extremely diverse and changing portfolio of products in the face of uncertainty and changing demand, and faster product development and supply chain velocity, with sustainable raw materials, components, and energy use. The program is organized into workstreams focused on end‐to‐end control strategy, equipment flexibility, next generation technology, sustainability, and a physical test bed to evaluate and demonstrate the technologies that are developed. The elements of the program are synergistic. For example, process intensification results in cost reduction as well as increased sustainability. Improved robustness leads to less inventory, which improves costs and supply chain velocity. Flexibility allows more products to be consolidated into fewer factories, reduces the need for new facilities, simplifies the acquisition of additional capacity if needed, and reduces changeover time, which improves cost and velocity. The program incorporates both drug substance and drug product manufacturing, but this paper will focus on the drug substance elements of the program.
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Affiliation(s)
- John Erickson
- National Institute for Innovation in Manufacturing Biopharmaceuticals, Newark, Delaware, USA
| | - Jeffrey Baker
- Office of Biotechnology Products (OBP), Center for Drug Evaluation and Research (CDER), U.S. Food and Drug Administration, Silver Spring, Maryland, USA
| | - Shawn Barrett
- Global CMC Development, Sanofi, Framingham, Massachusetts, USA
| | - Ciaran Brady
- Biologics MS&T, Bristol-Myers Squibb, Devens, Massachusetts, USA
| | - Mark Brower
- Biologics Process Research and Development, Merck & Co., Inc., Kenilworth, New Jersey, USA
| | - Ruben Carbonell
- National Institute for Innovation in Manufacturing Biopharmaceuticals, Raleigh, North Carolina, USA
| | - Tim Charlebois
- BioTx Pharmaceutical Sciences, Pfizer, Andover, Massachusetts, USA
| | - Jon Coffman
- Biopharmaceutical Development, AstraZeneca, Gaithersburg, Maryland, USA
| | | | | | - Eric Fallon
- Manufacturing Science and Technology, Drug Substance, Genentech, Inc., Oceanside, California, USA
| | - Eric Garr
- Biologics MS&T, Bristol-Myers Squibb, Devens, Massachusetts, USA
| | - Christopher Gillespie
- Biologics Process Research and Development, Merck & Co., Inc., Kenilworth, New Jersey, USA
| | - Roger Hart
- Process Development, Amgen, Cambridge, Massachusetts, USA
| | - Allison Haug
- National Institute for Innovation in Manufacturing Biopharmaceuticals, Newark, Delaware, USA
| | - Gregg Nyberg
- Biologics Process Research and Development, Merck & Co., Inc., Kenilworth, New Jersey, USA
| | - Michael Phillips
- Next Generation Processing R&D, MilliporeSigma, Bedford, Massachusetts, USA
| | - David Pollard
- Sartorius Corporate Research, Sartorius, Boston, Massachusetts, USA
| | - Maen Qadan
- Biologics Research and Development, Eli Lilly and Company, Indianapolis, Indiana, USA
| | - Irina Ramos
- Biopharmaceutical Development, AstraZeneca, Gaithersburg, Maryland, USA
| | - Kelley Rogers
- Material Measurement Laboratory and Office of Advanced Manufacturing, National Institute of Standards and Technology, Gaithersburg, Maryland, USA
| | - Gene Schaefer
- API Large Molecule BioTherapeutics Development, Janssen R&D, Malvern, Pennsylvania, USA
| | - Jason Walther
- Global CMC Development, Sanofi, Framingham, Massachusetts, USA
| | - Kelvin Lee
- National Institute for Innovation in Manufacturing Biopharmaceuticals, Newark, Delaware, USA
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9
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Zhang D, Patel P, Strauss D, Qian X, Wickramasinghe SR. Modeling flux in tangential flow filtration using a reverse asymmetric membrane for Chinese hamster ovary cell clarification. Biotechnol Prog 2020; 37:e3115. [PMID: 33350596 DOI: 10.1002/btpr.3115] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/28/2020] [Revised: 12/08/2020] [Accepted: 12/17/2020] [Indexed: 11/09/2022]
Abstract
Tangential flow filtration is advantageous for bioreactor clarification as the permeate stream could be introduced directly to the subsequent product capture step. However, membrane fouling coupled with high product rejection has limited its use. Here, the performance of a reverse asymmetric hollow fiber membrane where the more open pore structure faces the feed stream and the barrier layer faces the permeate stream has been investigated. The open surface contains pores up to 40 μm in diameter while the tighter barrier layer has an average pore size of 0.4 μm. Filtration of Chinese hamster ovary cell feed streams has been investigated under conditions that could be expected in fed batch operations. The performance of the reverse asymmetric membrane is compared to that of symmetric hollow fiber membranes with nominal pore sizes of 0.2 and 0.65 μm. Laser scanning confocal microscopy was used to observe the locations of particle entrapment. The throughput of the reverse asymmetric membrane is significantly greater than the symmetric membranes. The membrane stabilizes an internal high permeability cake that acts like a depth filter. This stabilized cake can remove particulate matter that would foul the barrier layer if it faced the feed stream. An empirical model has been developed to describe the variation of flux and transmembrane pressure drop during filtration using reverse asymmetric membranes. Our results suggest that using a reverse asymmetric membrane could avoid severe flux decline associated with fouling of the barrier layer during bioreactor clarification.
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Affiliation(s)
- Da Zhang
- Ralph E. Martin Department of Chemical Engineering, University of Arkansas, Fayetteville, Arkansas, USA
| | - Parag Patel
- Asahi Kasei Bioprocess America, USA.,Department of Biomedical Engineering, University of Arkansas, Fayetteville, USA
| | - Daniel Strauss
- Asahi Kasei Bioprocess America, USA.,Department of Biomedical Engineering, University of Arkansas, Fayetteville, USA
| | - Xianghong Qian
- Asahi Kasei Bioprocess America, USA.,Department of Biomedical Engineering, University of Arkansas, Fayetteville, USA
| | - S Ranil Wickramasinghe
- Ralph E. Martin Department of Chemical Engineering, University of Arkansas, Fayetteville, Arkansas, USA
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