The Integrated Simulation and Assessment of the Impacts of Process Change in Biotherapeutic Antibody Production

Designing cost-effective biopharmaceutical facilities using mixed-integer optimization

Chromatography operations are identified as critical steps in a monoclonal antibody (mAb) purification process and can represent a significant proportion of the purification material costs. This becomes even more critical with increasing product titers that result in higher mass loads onto chromatography columns, potentially causing capacity bottlenecks. In this work, a mixed-integer nonlinear programming (MINLP) model was created and applied to an industrially relevant case study to optimize the design of a facility by determining the most cost-effective chromatography equipment sizing strategies for the production of mAbs. Furthermore, the model was extended to evaluate the ability of a fixed facility to cope with higher product titers up to 15 g/L. Examination of the characteristics of the optimal chromatography sizing strategies across different titer values enabled the identification of the maximum titer that the facility could handle using a sequence of single column chromatography steps as well as multi-column steps. The critical titer levels for different ratios of upstream to dowstream trains where multiple parallel columns per step resulted in the removal of facility bottlenecks were identified. Different facility configurations in terms of number of upstream trains were considered and the trade-off between their cost and ability to handle higher titers was analyzed. The case study insights demonstrate that the proposed modeling approach, combining MINLP models with visualization tools, is a valuable decision-support tool for the design of cost-effective facility configurations and to aid facility fit decisions. 2013.

Advances in the production and downstream processing of antibodies

Sales of monoclonal antibody (mAbs) therapies exceeded $ 40 billion in 2010 and are expected to reach $ 70 billion by 2015. The majority of the approved antibodies are targeting cancer and autoimmune diseases with the top 5 grossing antibodies populating these two areas. In addition over 100 monoclonal antibodies are in Phase II and III of clinical development and numerous others are in various pre-clinical and safety studies. Commercial production of monoclonal antibodies is one of the few biotechnology manufacturing areas that has undergone significant improvements and standardization over the last ten years. Platform technologies have been established based on the structural similarities of these molecules and the regulatory requirements. These improvements include better cell lines, advent of high-performing media free of animal-derived components, and advances in bioreactor and purification processes. In this chapter we will examine the progress made in antibody production as well as discuss the future of manufacturing for these molecules, including the emergence of single use technologies.

Purification of antibodies using the synthetic affinity ligand absorbent MAbsorbent A2P

A protocol for the purification of polyclonal antibodies from ovine serum using the synthetic protein A absorbent MAbsorbent A2P is described. Clarified serum is loaded directly onto the affinity column without prior adjustment and albumin and unwanted serum components are washed from the column using a sodium octanoate buffer before elution of bound antibodies. MAbsorbent A2P was shown to bind approximately 27 mg ml(-1) of polyclonal immunoglobulin under overloading conditions, with eluted IgG purities of >90% and minor levels of albumin (approximately 1%). The anticipated time required to complete the purification protocol is 6-7 h. Although the protocol is similar to methods utilized for antibody purification using chromatography with protein A derived from the cell wall of the microorganism Staphylococcus aureus or protein G from Streptococcus as the affinity ligands, affinity absorbents based on synthetic ligands offer a number of advantages to compounds derived from biological sources, in particular robustness, relatively low cost, ease of sanitization and, in principle, lack of biological contamination.