1
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Andersson N, Fons JG, Isaksson M, Tallvod S, Espinoza D, Sjökvist L, Andersson GZ, Nilsson B. Methodology for fast development of digital solutions in integrated continuous downstream processing. Biotechnol Bioeng 2024; 121:2378-2387. [PMID: 37458361 DOI: 10.1002/bit.28501] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/08/2023] [Revised: 06/01/2023] [Accepted: 07/07/2023] [Indexed: 07/25/2024]
Abstract
The methodology for production of biologics is going through a paradigm shift from batch-wise operation to continuous production. Lot of efforts are focused on integration, intensification, and continuous operation for decreased foot-print, material, equipment, and increased productivity and product quality. These integrated continuous processes with on-line analytics become complex processes, which requires automation, monitoring, and control of the operation, even unmanned or remote, which means bioprocesses with high level of automation or even autonomous capabilities. The development of these digital solutions becomes an important part of the process development and needs to be assessed early in the development chain. This work discusses a platform that allows fast development, advanced studies, and validation of digital solutions for integrated continuous downstream processes. It uses an open, flexible, and extendable real-time supervisory controller, called Orbit, developed in Python. Orbit makes it possible to communicate with a set of different physical setups and on the same time perform real-time execution. Integrated continuous processing often implies parallel operation of several setups and network of Orbit controllers makes it possible to synchronize complex process system. Data handling, storage, and analysis are important properties for handling heterogeneous and asynchronous data generated in complex downstream systems. Digital twin applications, such as advanced model-based and plant-wide monitoring and control, are exemplified using computational extensions in Orbit, exploiting data and models. Examples of novel digital solutions in integrated downstream processes are automatic operation parameter optimization, Kalman filter monitoring, and model-based batch-to-batch control.
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Affiliation(s)
- Niklas Andersson
- Department of Chemical Engineering, Lund University, Lund, Sweden
| | | | | | - Simon Tallvod
- Department of Chemical Engineering, Lund University, Lund, Sweden
| | - Daniel Espinoza
- Department of Chemical Engineering, Lund University, Lund, Sweden
| | - Linnea Sjökvist
- Department of Chemical Engineering, Lund University, Lund, Sweden
| | | | - Bernt Nilsson
- Department of Chemical Engineering, Lund University, Lund, Sweden
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2
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Isaksson M, Gomis-Fons J, Andersson N, Nilsson B. An automated buffer management system for small-scale continuous downstream bioprocessing. J Chromatogr A 2023; 1695:463942. [PMID: 37015183 DOI: 10.1016/j.chroma.2023.463942] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/17/2023] [Revised: 03/13/2023] [Accepted: 03/22/2023] [Indexed: 04/05/2023]
Abstract
Buffer management for biopharmaceutical purification processes include buffer preparation, storage of buffers and restocking the buffers when needed. This is usually performed manually by the operators for small scale operations. However, buffer management can become a bottleneck when running integrated continuous purification processes for prolonged times, even at small scale. To address this issue, a buffer management system for the application in continuous lab-scale bioprocessing is presented in this paper. For this purpose, an ÄKTA™ explorer chromatography system was reconfigured to perform the buffer formulation. The system formulated all buffers from stock solutions and water according to pre-specified recipes. A digital twin of the physical system was introduced in the research software Orbit, written in python. Orbit was also used for full automation and control of the buffer system, which could run independently without operator input and handle buffer management for one or several connected buffer-consuming purification systems. The developed buffer management system performed automatic monitoring of buffer volumes, buffer order handling as well as buffer preparation and delivery. To demonstrate the capability of the developed system, it was integrated with a continuous downstream process and supplied all 9 required buffers to the process equipment during a 10-day operation. The buffer management system processed 55 orders and delivered 38 L of buffers, corresponding to 20% of its capacity. The pH and conductivity profiles observed during the purification steps were consistent across the cycles. The deviation in conductivity and pH from the measured average value was within ±0.89% in conductivity and ±0.045 in pH, well within the typical specification for buffer release, indicating that the prepared buffers had the correct composition. The operation of the developed buffer management system was robust and fully automated, and provides one solution to the buffer management bottleneck on lab scale for integrated continuous downstream bioprocessing.
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Affiliation(s)
- Madelène Isaksson
- Department of Chemical Engineering, Lund University, SE-211 00 Lund, Sweden
| | - Joaquín Gomis-Fons
- Department of Chemical Engineering, Lund University, SE-211 00 Lund, Sweden
| | - Niklas Andersson
- Department of Chemical Engineering, Lund University, SE-211 00 Lund, Sweden
| | - Bernt Nilsson
- Department of Chemical Engineering, Lund University, SE-211 00 Lund, Sweden.
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3
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Keulen D, Geldhof G, Bussy OL, Pabst M, Ottens M. Recent advances to accelerate purification process development: a review with a focus on vaccines. J Chromatogr A 2022; 1676:463195. [DOI: 10.1016/j.chroma.2022.463195] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/07/2022] [Revised: 05/24/2022] [Accepted: 06/01/2022] [Indexed: 10/18/2022]
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4
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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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5
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Espinoza D, Andersson N, Nilsson B. Binary separation control in preparative gradient chromatography using iterative learning control. J Chromatogr A 2022; 1673:463078. [DOI: 10.1016/j.chroma.2022.463078] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/16/2022] [Revised: 04/07/2022] [Accepted: 04/19/2022] [Indexed: 12/24/2022]
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6
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Besenhard MO, Tsatse A, Mazzei L, Sorensen E. Recent advances in modelling and control of liquid chromatography. Curr Opin Chem Eng 2021. [DOI: 10.1016/j.coche.2021.100685] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/12/2022]
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7
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Crowell LE, Rodriguez SA, Love KR, Cramer SM, Love JC. Rapid optimization of processes for the integrated purification of biopharmaceuticals. Biotechnol Bioeng 2021; 118:3435-3446. [PMID: 33782945 PMCID: PMC8453909 DOI: 10.1002/bit.27767] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/18/2020] [Revised: 03/11/2021] [Accepted: 03/18/2021] [Indexed: 11/07/2022]
Abstract
Straight‐through chromatography, wherein the eluate from one column passes directly onto another column without adjustment, is one strategy to integrate and intensify manufacturing processes for biologics. Development and optimization of such straight‐through chromatographic processes is a challenge, however. Conventional high‐throughput screening methods optimize each chromatographic step independently, with limited consideration for the connectivity of steps. Here, we demonstrate a method for the development and optimization of fully integrated, multi‐column processes for straight‐through purification. Selection of resins was performed using an in silico tool for the prediction of processes for straight‐through purification based on a one‐time characterization of host‐cell proteins combined with the chromatographic behavior of the product. A two‐step optimization was then conducted to determine the buffer conditions that maximized yield while minimizing process‐ and product‐related impurities. This optimization of buffer conditions included a series of range‐finding experiments on each individual column, similar to conventional screening, followed by the development of a statistical model for the fully integrated, multi‐column process using design of experiments. We used this methodology to develop and optimize integrated purification processes for a single‐domain antibody and a cytokine, obtaining yields of 88% and 86%, respectively, with process‐ and product‐related variants reduced to phase‐appropriate levels for nonclinical material.
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Affiliation(s)
- Laura E. Crowell
- Koch Institute for Integrative Cancer ResearchMassachusetts Institute of TechnologyCambridgeMassachusettsUSA
- Department of Chemical EngineeringMassachusetts Institute of TechnologyCambridgeMassachusettsUSA
| | - Sergio A. Rodriguez
- Koch Institute for Integrative Cancer ResearchMassachusetts Institute of TechnologyCambridgeMassachusettsUSA
- Department of Biological EngineeringMassachusetts Institute of TechnologyCambridgeMassachusettsUSA
| | - Kerry R. Love
- Koch Institute for Integrative Cancer ResearchMassachusetts Institute of TechnologyCambridgeMassachusettsUSA
| | - Steven M. Cramer
- Department of Chemical and Biological EngineeringRensselaer Polytechnic InstituteTroyNew YorkUSA
- Center for Biotechnology and Interdisciplinary StudiesRensselaer Polytechnic InstituteTroyNew YorkUSA
| | - J. Christopher Love
- Koch Institute for Integrative Cancer ResearchMassachusetts Institute of TechnologyCambridgeMassachusettsUSA
- Department of Chemical EngineeringMassachusetts Institute of TechnologyCambridgeMassachusettsUSA
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8
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Crowell LE, Goodwine C, Holt CS, Rocha L, Vega C, Rodriguez SA, Dalvie NC, Tracey MK, Puntel M, Wigdorovitz A, Parreño V, Love KR, Cramer SM, Love JC. Development of a platform process for the production and purification of single-domain antibodies. Biotechnol Bioeng 2021; 118:3348-3358. [PMID: 33624832 PMCID: PMC8451865 DOI: 10.1002/bit.27724] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/18/2020] [Revised: 01/15/2021] [Accepted: 02/19/2021] [Indexed: 01/14/2023]
Abstract
Single‐domain antibodies (sdAbs) offer the affinity and therapeutic value of conventional antibodies, with increased stability and solubility. Unlike conventional antibodies, however, sdAbs do not benefit from a platform manufacturing process. While successful production of a variety of sdAbs has been shown in numerous hosts, purification methods are often molecule specific or require affinity tags, which generally cannot be used in clinical manufacturing due to regulatory concerns. Here, we have developed a broadly applicable production and purification process for sdAbs in Komagataella phaffii (Pichia pastoris) and demonstrated the production of eight different sdAbs at a quality appropriate for nonclinical studies. We developed a two‐step, integrated purification process without the use of affinity resins and showed that modification of a single process parameter, pH of the bridging buffer, was required for the successful purification of a variety of sdAbs. Further, we determined that this parameter can be predicted based only on the biophysical characteristics of the target molecule. Using these methods, we produced nonclinical quality sdAbs as few as 5 weeks after identifying the product sequence. Nonclinical studies of three different sdAbs showed that molecules produced using our platform process conferred protection against viral shedding of rotavirus or H1N1 influenza and were equivalent to similar molecules produced in Escherichia coli and purified using affinity tags.
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Affiliation(s)
- Laura E Crowell
- Koch Institute for Integrative Cancer Research, Massachusetts Institute of Technology, Cambridge, Massachusetts, USA.,Department of Chemical Engineering, Massachusetts Institute of Technology, Cambridge, Massachusetts, USA
| | - Chaz Goodwine
- Department of Chemical and Biological Engineering, Rensselaer Polytechnic Institute, Troy, New York, USA.,Center for Biotechnology and Interdisciplinary Studies, Rensselaer Polytechnic Institute, Troy, New York, USA
| | - Carla S Holt
- Instituto de Virología, Investigación en Ciencias Veterinarias y Agronómicas, Instituto Nacional de Tecnología Agropecuaria, Buenos Aires, Argentina
| | - Lucia Rocha
- Instituto de Virología, Investigación en Ciencias Veterinarias y Agronómicas, Instituto Nacional de Tecnología Agropecuaria, Buenos Aires, Argentina
| | - Celina Vega
- Instituto de Virología, Investigación en Ciencias Veterinarias y Agronómicas, Instituto Nacional de Tecnología Agropecuaria, Buenos Aires, Argentina
| | - Sergio A Rodriguez
- Koch Institute for Integrative Cancer Research, Massachusetts Institute of Technology, Cambridge, Massachusetts, USA.,Department of Biological Engineering, Massachusetts Institute of Technology, Cambridge, Massachusetts, USA
| | - Neil C Dalvie
- Koch Institute for Integrative Cancer Research, Massachusetts Institute of Technology, Cambridge, Massachusetts, USA.,Department of Chemical Engineering, Massachusetts Institute of Technology, Cambridge, Massachusetts, USA
| | - Mary K Tracey
- Koch Institute for Integrative Cancer Research, Massachusetts Institute of Technology, Cambridge, Massachusetts, USA
| | - Mariana Puntel
- Instituto de Virología, Investigación en Ciencias Veterinarias y Agronómicas, Instituto Nacional de Tecnología Agropecuaria, Buenos Aires, Argentina
| | - Andrés Wigdorovitz
- Instituto de Virología, Investigación en Ciencias Veterinarias y Agronómicas, Instituto Nacional de Tecnología Agropecuaria, Buenos Aires, Argentina
| | - Viviana Parreño
- Instituto de Virología, Investigación en Ciencias Veterinarias y Agronómicas, Instituto Nacional de Tecnología Agropecuaria, Buenos Aires, Argentina
| | - Kerry R Love
- Koch Institute for Integrative Cancer Research, Massachusetts Institute of Technology, Cambridge, Massachusetts, USA
| | - Steven M Cramer
- Department of Chemical and Biological Engineering, Rensselaer Polytechnic Institute, Troy, New York, USA.,Center for Biotechnology and Interdisciplinary Studies, Rensselaer Polytechnic Institute, Troy, New York, USA
| | - J Christopher Love
- Koch Institute for Integrative Cancer Research, Massachusetts Institute of Technology, Cambridge, Massachusetts, USA.,Department of Chemical Engineering, Massachusetts Institute of Technology, Cambridge, Massachusetts, USA
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9
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Löfgren A, Gomis-Fons J, Andersson N, Nilsson B, Berghard L, Lagerquist Hägglund C. An integrated continuous downstream process with real-time control: A case study with periodic countercurrent chromatography and continuous virus inactivation. Biotechnol Bioeng 2021; 118:1664-1676. [PMID: 33459355 DOI: 10.1002/bit.27681] [Citation(s) in RCA: 8] [Impact Index Per Article: 2.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/16/2020] [Revised: 11/19/2020] [Accepted: 01/12/2021] [Indexed: 11/11/2022]
Abstract
Integrated continuous downstream processes with process analytical technology offer a promising opportunity to reduce production costs and increase process flexibility and adaptability. In this case study, an integrated continuous process was used to purify a recombinant protein on laboratory scale in a two-system setup that can be used as a general downstream setup offering multiproduct and multipurpose manufacturing capabilities. The process consisted of continuous solvent/detergent virus inactivation followed by periodic countercurrent chromatography in the capture step, and a final chromatographic polishing step. A real-time controller was implemented to ensure stable operation by adapting the downstream process to external changes. A concentration disturbance was introduced to test the controller. After the disturbance was applied, the product output recovered within 6 h, showing the effectiveness of the controller. In a comparison of the process with and without the controller, the product output per cycle increased by 27%, the resin utilization increased from 71.4% to 87.9%, and the specific buffer consumption was decreased by 21% with the controller, while maintaining a similar yield and purity as in the process without the disturbance. In addition, the integrated continuous process outperformed the batch process, increasing the productivity by 95% and the yield by 28%.
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Affiliation(s)
- Anton Löfgren
- Department of Chemical Engineering, Lund University, Lund, Sweden
| | - Joaquín Gomis-Fons
- Department of Chemical Engineering, Lund University, Lund, Sweden.,Royal Institute of Technology, Competence Centre for Advanced BioProduction by Continuous Processing, Stockholm, Sweden
| | - Niklas Andersson
- Department of Chemical Engineering, Lund University, Lund, Sweden
| | - Bernt Nilsson
- Department of Chemical Engineering, Lund University, Lund, Sweden.,Royal Institute of Technology, Competence Centre for Advanced BioProduction by Continuous Processing, Stockholm, Sweden
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10
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Advanced control strategies for bioprocess chromatography: Challenges and opportunities for intensified processes and next generation products. J Chromatogr A 2021; 1639:461914. [PMID: 33503524 DOI: 10.1016/j.chroma.2021.461914] [Citation(s) in RCA: 15] [Impact Index Per Article: 5.0] [Reference Citation Analysis] [Abstract] [Key Words] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/13/2020] [Revised: 01/05/2021] [Accepted: 01/13/2021] [Indexed: 02/08/2023]
Abstract
Recent advances in process analytical technologies and modelling techniques present opportunities to improve industrial chromatography control strategies to enhance process robustness, increase productivity and move towards real-time release testing. This paper provides a critical overview of batch and continuous industrial chromatography control systems for therapeutic protein purification. Firstly, the limitations of conventional industrial fractionation control strategies using in-line UV spectroscopy and on-line HPLC are outlined. Following this, an evaluation of monitoring and control techniques showing promise within research, process development and manufacturing is provided. These novel control strategies combine rapid in-line data capture (e.g. NIR, MALS and variable pathlength UV) with enhanced process understanding obtained from mechanistic and empirical modelling techniques. Finally, a summary of the future states of industrial chromatography control systems is proposed, including strategies to control buffer formulation, product fractionation, column switching and column fouling. The implementation of these control systems improves process capabilities to fulfil product quality criteria as processes are scaled, transferred and operated, thus fast tracking the delivery of new medicines to market.
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11
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Moreno-González M, Keulen D, Gomis-Fons J, Gomez GL, Nilsson B, Ottens M. Continuous adsorption in food industry: The recovery of sinapic acid from rapeseed meal extract. Sep Purif Technol 2021. [DOI: 10.1016/j.seppur.2020.117403] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/23/2022]
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12
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Gomis-Fons J, Yamanee-Nolin M, Andersson N, Nilsson B. Optimal loading flow rate trajectory in monoclonal antibody capture chromatography. J Chromatogr A 2020; 1635:461760. [PMID: 33271430 DOI: 10.1016/j.chroma.2020.461760] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Abstract] [Key Words] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/05/2020] [Revised: 10/23/2020] [Accepted: 11/23/2020] [Indexed: 11/26/2022]
Abstract
In this paper, we determined the optimal flow rate trajectory during the loading phase of a mAb capture column. For this purpose, a multi-objective function was used, consisting of productivity and resin utilization. Several general types of trajectories were considered, and the optimal Pareto points were obtained for all of them. In particular, the presented trajectories include a constant-flow loading process as a nominal approach, a stepwise trajectory, and a linear trajectory. Selected trajectories were then applied in experiments with the state-of-the-art protein A resin mAb Select PrismATM, running in batch mode on a standard single-column chromatography setup, and using both a purified mAb solution as well as a clarified supernatant. The results show that this simple approach, programming the volumetric flow rate according to either of the explored strategies, can improve the process economics by increasing productivity by up to 12% and resin utilization by up to 9% compared to a constant-flow process, while obtaining a yield higher than 99%. The productivity values were similar to the ones obtained in a multi-column continuous process, and ranged from 0.23 to 0.35 mg/min/mL resin. Additionally, it is shown that a model calibration carried out at constant flow can be applied in the simulation and optimization of flow trajectories. The selected processes were scaled up to pilot scale and simulated to prove that even higher productivity and resin utilization can be achieved at larger scales, and therefore confirm that the trajectories are generalizable across process scales for this resin.
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Affiliation(s)
- Joaquín Gomis-Fons
- Department of Chemical Engineering, Lund University, Lund, Sweden; Competence Centre for Advanced BioProduction by Continuous Processing, Royal Institute of Technology, Stockholm, Sweden.
| | | | - Niklas Andersson
- Department of Chemical Engineering, Lund University, Lund, Sweden.
| | - Bernt Nilsson
- Department of Chemical Engineering, Lund University, Lund, Sweden; Competence Centre for Advanced BioProduction by Continuous Processing, Royal Institute of Technology, Stockholm, Sweden.
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13
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14
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Optimization study on periodic counter-current chromatography integrated in a monoclonal antibody downstream process. J Chromatogr A 2020; 1621:461055. [DOI: 10.1016/j.chroma.2020.461055] [Citation(s) in RCA: 11] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/13/2020] [Revised: 03/03/2020] [Accepted: 03/17/2020] [Indexed: 10/24/2022]
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15
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Gomis‐Fons J, Schwarz H, Zhang L, Andersson N, Nilsson B, Castan A, Solbrand A, Stevenson J, Chotteau V. Model‐based design and control of a small‐scale integrated continuous end‐to‐end
mAb
platform. Biotechnol Prog 2020; 36:e2995. [DOI: 10.1002/btpr.2995] [Citation(s) in RCA: 22] [Impact Index Per Article: 5.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/18/2020] [Revised: 03/08/2020] [Accepted: 03/23/2020] [Indexed: 12/14/2022]
Affiliation(s)
| | - Hubert Schwarz
- Department of Industrial Biotechnology School of Engineering Sciences in Chemistry, Biotechnology and Health, Royal Institute of Technology Stockholm Sweden
| | - Liang Zhang
- Department of Industrial Biotechnology School of Engineering Sciences in Chemistry, Biotechnology and Health, Royal Institute of Technology Stockholm Sweden
| | | | - Bernt Nilsson
- Department of Chemical Engineering Lund University Lund Sweden
| | | | | | | | - Véronique Chotteau
- Department of Industrial Biotechnology School of Engineering Sciences in Chemistry, Biotechnology and Health, Royal Institute of Technology Stockholm Sweden
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16
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Thakur G, Hebbi V, Rathore AS. An NIR‐based PAT approach for real‐time control of loading in Protein A chromatography in continuous manufacturing of monoclonal antibodies. Biotechnol Bioeng 2019; 117:673-686. [DOI: 10.1002/bit.27236] [Citation(s) in RCA: 30] [Impact Index Per Article: 6.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/25/2019] [Revised: 10/21/2019] [Accepted: 11/22/2019] [Indexed: 12/25/2022]
Affiliation(s)
- Garima Thakur
- Department of Chemical EngineeringIndian Institute of Technology New Delhi India
| | - Vishwanath Hebbi
- Department of Chemical EngineeringIndian Institute of Technology New Delhi India
| | - Anurag S. Rathore
- Department of Chemical EngineeringIndian Institute of Technology New Delhi India
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17
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Integration of a complete downstream process for the automated lab-scale production of a recombinant protein. J Biotechnol 2019; 301:45-51. [DOI: 10.1016/j.jbiotec.2019.05.013] [Citation(s) in RCA: 11] [Impact Index Per Article: 2.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/11/2018] [Revised: 04/26/2019] [Accepted: 05/26/2019] [Indexed: 11/21/2022]
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18
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Löfgren A, Yamanee‐Nolin M, Tallvod S, Fons JG, Andersson N, Nilsson B. Optimization of integrated chromatography sequences for purification of biopharmaceuticals. Biotechnol Prog 2019; 35:e2871. [PMID: 31207182 PMCID: PMC9285797 DOI: 10.1002/btpr.2871] [Citation(s) in RCA: 9] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/11/2019] [Revised: 05/20/2019] [Accepted: 06/03/2019] [Indexed: 12/30/2022]
Abstract
With continued development of integrated and continuous downstream purification processes, tuning and optimization become increasingly complicated with additional parameters and codependent variables over the sequence. This article offers a novel perspective of nonlinear optimization of integrated sequences with regard to individual column sizes, flow rates, and scheduling. The problem setup itself is a versatile tool to be used in downstream design which is demonstrated in two case studies: a four‐column integrated sequence and a continuously loaded twin‐capture setup with five columns.
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Affiliation(s)
- Anton Löfgren
- Department of Chemical EngineeringLund University Lund Sweden
| | | | - Simon Tallvod
- Department of Chemical EngineeringLund University Lund Sweden
| | - Joaquín G. Fons
- Department of Chemical EngineeringLund University Lund Sweden
| | | | - Bernt Nilsson
- Department of Chemical EngineeringLund University Lund Sweden
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19
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Vecchiarello N, Timmick SM, Goodwine C, Crowell LE, Love KR, Love JC, Cramer SM. A combined screening and in silico strategy for the rapid design of integrated downstream processes for process and product‐related impurity removal. Biotechnol Bioeng 2019; 116:2178-2190. [DOI: 10.1002/bit.27018] [Citation(s) in RCA: 12] [Impact Index Per Article: 2.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/17/2018] [Revised: 04/30/2019] [Accepted: 05/09/2019] [Indexed: 01/12/2023]
Affiliation(s)
- Nicholas Vecchiarello
- Department of Chemical and Biological Engineering Rensselaer Polytechnic Institute Center for Biotechnology and Interdisciplinary Studies Troy New York
| | - Steven M. Timmick
- Department of Chemical and Biological Engineering Rensselaer Polytechnic Institute Center for Biotechnology and Interdisciplinary Studies Troy New York
| | - Chaz Goodwine
- Department of Chemical and Biological Engineering Rensselaer Polytechnic Institute Center for Biotechnology and Interdisciplinary Studies Troy New York
| | - Laura E. Crowell
- Koch Institute for Integrative Cancer Research Massachusetts Institute of Technology Cambridge Massachusetts
- Department of Chemical Engineering Massachusetts Institute of Technology Cambridge Massachusetts
| | - Kerry R. Love
- Koch Institute for Integrative Cancer Research Massachusetts Institute of Technology Cambridge Massachusetts
- Department of Chemical Engineering Massachusetts Institute of Technology Cambridge Massachusetts
| | - J. Christopher Love
- Koch Institute for Integrative Cancer Research Massachusetts Institute of Technology Cambridge Massachusetts
- Department of Chemical Engineering Massachusetts Institute of Technology Cambridge Massachusetts
| | - Steven M. Cramer
- Department of Chemical and Biological Engineering Rensselaer Polytechnic Institute Center for Biotechnology and Interdisciplinary Studies Troy New York
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El‐Sabbahy H, Ward D, Ogonah O, Deakin L, Jellum GM, Bracewell DG. The effect of feed quality due to clarification strategy on the design and performance of protein A periodic counter-current chromatography. Biotechnol Prog 2018; 34:1380-1392. [PMID: 30281957 PMCID: PMC6902848 DOI: 10.1002/btpr.2709] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.2] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/10/2018] [Revised: 08/13/2018] [Indexed: 11/30/2022]
Abstract
The impact of two different quality feeds, derived using two different harvest clarification processes, on protein A periodic counter-current chromatography (PCC) design and performance is investigated. Data from batch experiments were input into a model to design optimal PCC operating parameters specific to each feed material. The two clarification methods were: depth filtration using a wetlaid matrix which has Q-functionality; and a combination of depth filtration and chromatographic clarification, using a Q-functional nonwoven with a high anion exchange capacity (Emphaze™ AEX Hybrid Purifier) in which key impurities such as host cell DNA (HCDNA) and host cell proteins (HCP) are removed. The model predicted 34% better productivity for the chromatographically clarified cell culture fluid (CCCF) using a 4 column system, and productivity gains of 28% using only 3 columns enabling the option to simplify the protein A PCC strategy. Experimental validation of the predicted optimized PCC operating parameters using industrially relevant monoclonal antibody (mAb) CCCF feedstock over 100 cycles showed productivity gains of 49% for the chromatographically clarified material. HCP concentration was 11-fold lower, and HCDNA concentration was reduced by 4.4 Log Reduction Value (LRV) in the protein A PCC eluates. This work, therefore, demonstrates that the removal of HCDNA and HCP during clarification is an effective strategy for improving protein A PCC performance. This was achieved using the Emphaze™ AEX Hybrid Purifier which can be easily incorporated into a batch or continuous process, in a scalable fashion, without adding additional separate unit operations. © 2018 American Institute of Chemical Engineers Biotechnol. Prog., 34:1380-1392, 2018.
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Affiliation(s)
- Hani El‐Sabbahy
- Present address:
Separation and Purification Sciences Div.3M United Kingdom PLC, 3M CentreBracknellRG12 8HTU.K.
| | - David Ward
- Present address:
Separation and Purification Sciences Div.3M United Kingdom PLC, 3M CentreBracknellRG12 8HTU.K.
- Dept. of Biochemical EngineeringUniversity College LondonLondonWC1E 6BTU.K.
| | - Olotu Ogonah
- Dept. of Biochemical EngineeringUniversity College LondonLondonWC1E 6BTU.K.
| | - Lynne Deakin
- Separation and Purification Sciences Div.3M United Kingdom PLC, 3M CentreBracknellRG12 8HTU.K.
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Timmick SM, Vecchiarello N, Goodwine C, Crowell LE, Love KR, Love JC, Cramer SM. An impurity characterization based approach for the rapid development of integrated downstream purification processes. Biotechnol Bioeng 2018; 115:2048-2060. [DOI: 10.1002/bit.26718] [Citation(s) in RCA: 11] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/07/2017] [Revised: 03/09/2018] [Accepted: 04/17/2018] [Indexed: 01/13/2023]
Affiliation(s)
- Steven M. Timmick
- Department of Chemical and Biological Engineering, Center for Biotechnology and Interdisciplinary Studies Rensselaer Polytechnic Institute Troy New York
| | - Nicholas Vecchiarello
- Department of Chemical and Biological Engineering, Center for Biotechnology and Interdisciplinary Studies Rensselaer Polytechnic Institute Troy New York
| | - Chaz Goodwine
- Department of Chemical and Biological Engineering, Center for Biotechnology and Interdisciplinary Studies Rensselaer Polytechnic Institute Troy New York
| | - Laura E. Crowell
- Department of Chemical Engineering, Koch Institute for Integrative Cancer Research Massachusetts Institute of Technology Cambridge Massachusetts
- Department of Chemical Engineering Massachusetts Institute of Technology Cambridge Massachusetts
| | - Kerry R. Love
- Department of Chemical Engineering, Koch Institute for Integrative Cancer Research Massachusetts Institute of Technology Cambridge Massachusetts
- Department of Chemical Engineering Massachusetts Institute of Technology Cambridge Massachusetts
| | - J. Christopher Love
- Department of Chemical Engineering, Koch Institute for Integrative Cancer Research Massachusetts Institute of Technology Cambridge Massachusetts
- Department of Chemical Engineering Massachusetts Institute of Technology Cambridge Massachusetts
| | - Steven M. Cramer
- Department of Chemical and Biological Engineering, Center for Biotechnology and Interdisciplinary Studies Rensselaer Polytechnic Institute Troy New York
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Löfgren A, Andersson N, Sellberg A, Nilsson B, Löfgren M, Wood S. Designing an Autonomous Integrated Downstream Sequence From a Batch Separation Process − An Industrial Case Study. Biotechnol J 2018; 13:e1700691. [DOI: 10.1002/biot.201700691] [Citation(s) in RCA: 10] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/10/2017] [Revised: 12/06/2017] [Indexed: 11/10/2022]
Affiliation(s)
- Anton Löfgren
- Department of Chemical Engineering, Lund University; Box 124, 221 00 Lund Sweden
| | - Niklas Andersson
- Department of Chemical Engineering, Lund University; Box 124, 221 00 Lund Sweden
| | - Anton Sellberg
- Department of Chemical Engineering, Lund University; Box 124, 221 00 Lund Sweden
| | - Bernt Nilsson
- Department of Chemical Engineering, Lund University; Box 124, 221 00 Lund Sweden
| | - Magnus Löfgren
- Swedish Orphan Biovitrum AB, SE-112 76; SE-112 76 Stockholm Sweden
| | - Susanne Wood
- Swedish Orphan Biovitrum AB, SE-112 76; SE-112 76 Stockholm Sweden
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23
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Persson O, Andersson N, Nilsson B. Design of two-column batch-to-batch recirculation to enhance performance in ion-exchange chromatography. J Chromatogr A 2018; 1531:112-121. [DOI: 10.1016/j.chroma.2017.11.035] [Citation(s) in RCA: 8] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/16/2017] [Revised: 11/14/2017] [Accepted: 11/14/2017] [Indexed: 11/30/2022]
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Steinebach F, Ulmer N, Wolf M, Decker L, Schneider V, Wälchli R, Karst D, Souquet J, Morbidelli M. Design and operation of a continuous integrated monoclonal antibody production process. Biotechnol Prog 2017; 33:1303-1313. [DOI: 10.1002/btpr.2522] [Citation(s) in RCA: 86] [Impact Index Per Article: 12.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/01/2017] [Revised: 07/03/2017] [Indexed: 11/11/2022]
Affiliation(s)
- Fabian Steinebach
- Dept. of Chemistry and Applied Biosciences; Inst. for Chemical and Bioengineering; ETH Zurich Zurich 8093 Switzerland
| | - Nicole Ulmer
- Dept. of Chemistry and Applied Biosciences; Inst. for Chemical and Bioengineering; ETH Zurich Zurich 8093 Switzerland
| | - Moritz Wolf
- Dept. of Chemistry and Applied Biosciences; Inst. for Chemical and Bioengineering; ETH Zurich Zurich 8093 Switzerland
| | - Lara Decker
- Dept. of Chemistry and Applied Biosciences; Inst. for Chemical and Bioengineering; ETH Zurich Zurich 8093 Switzerland
| | - Veronika Schneider
- Dept. of Chemistry and Applied Biosciences; Inst. for Chemical and Bioengineering; ETH Zurich Zurich 8093 Switzerland
| | - Ruben Wälchli
- Dept. of Chemistry and Applied Biosciences; Inst. for Chemical and Bioengineering; ETH Zurich Zurich 8093 Switzerland
| | - Daniel Karst
- Dept. of Chemistry and Applied Biosciences; Inst. for Chemical and Bioengineering; ETH Zurich Zurich 8093 Switzerland
| | - Jonathan Souquet
- Biotech Process Science Technology & Innovation; Merck-Serono S.A., 1804 Corsier-sur-Vevey; Switzerland
| | - Massimo Morbidelli
- Dept. of Chemistry and Applied Biosciences; Inst. for Chemical and Bioengineering; ETH Zurich Zurich 8093 Switzerland
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Hughson MD, Cruz TA, Carvalho RJ, Castilho LR. Development of a 3-step straight-through purification strategy combining membrane adsorbers and resins. Biotechnol Prog 2017; 33:931-940. [DOI: 10.1002/btpr.2501] [Citation(s) in RCA: 12] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/30/2016] [Revised: 05/18/2017] [Indexed: 11/06/2022]
Affiliation(s)
- Michael D. Hughson
- Federal University of Rio de Janeiro (UFRJ); COPPE, Chemical Engineering Program, Cell Culture Engineering Laboratory; Ilha do Fundao Rio de Janeiro 21941-972 Brazil
| | - Thayana A. Cruz
- Federal University of Rio de Janeiro (UFRJ); COPPE, Chemical Engineering Program, Cell Culture Engineering Laboratory; Ilha do Fundao Rio de Janeiro 21941-972 Brazil
- Federal University of Rio de Janeiro (UFRJ), IQ, Biochemistry Program; Ilha do Fundao Rio de Janeiro 21941-909 Brazil
| | - Rimenys J. Carvalho
- Federal University of Rio de Janeiro (UFRJ); COPPE, Chemical Engineering Program, Cell Culture Engineering Laboratory; Ilha do Fundao Rio de Janeiro 21941-972 Brazil
| | - Leda R. Castilho
- Federal University of Rio de Janeiro (UFRJ); COPPE, Chemical Engineering Program, Cell Culture Engineering Laboratory; Ilha do Fundao Rio de Janeiro 21941-972 Brazil
- Federal University of Rio de Janeiro (UFRJ), IQ, Biochemistry Program; Ilha do Fundao Rio de Janeiro 21941-909 Brazil
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