1
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Minervini M, Mergy M, Zhu Y, Gutierrez Diaz MA, Pointer C, Shinkazh O, Oppenheim SF, Cramer SM, Przybycien TM, Zydney AL. Continuous precipitation-filtration process for initial capture of a monoclonal antibody product using a four-stage countercurrent hollow fiber membrane washing step. Biotechnol Bioeng 2024; 121:2258-2268. [PMID: 37565527 PMCID: PMC10858288 DOI: 10.1002/bit.28525] [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: 03/03/2023] [Revised: 07/27/2023] [Accepted: 07/29/2023] [Indexed: 08/12/2023]
Abstract
The significant increase in product titers, coupled with the growing focus on continuous bioprocessing, has renewed interest in using precipitation as a low-cost alternative to Protein A chromatography for the primary capture of monoclonal antibody (mAb) products. In this work, a commercially relevant mAb was purified from clarified cell culture fluid using a tubular flow precipitation reactor with dewatering and washing provided by tangential flow microfiltration. The particle morphology was evaluated using an inline high-resolution optical probe, providing quantitative data on the particle size distribution throughout the precipitation process. Data were obtained in both a lab-built 2-stage countercurrent washing system and a commercial countercurrent contacting skid that provided 4 stages of continuous washing. The processes were operated continuously for 2 h with overall mAb yield of 92 ± 3% and DNA removal of nearly 3 logs in the 4-stage system. The high DNA clearance was achieved by selective redissolution of the mAb using a low pH acetate buffer. Host cell protein clearance was 0.59 ± 0.08 logs, comparable to that based on model predictions. The process mass intensity was slightly better than typical Protein A processes and could be significantly improved by preconcentration of the antibody feed material.
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Affiliation(s)
- Mirko Minervini
- Department of Chemical Engineering, The Pennsylvania State University, State College, Pennsylvania, USA
| | - Matthew Mergy
- Department of Chemical and Biological Engineering, Rensselaer Polytechnic Institute, Troy, New York, USA
| | - Yuncan Zhu
- Department of Chemical and Biological Engineering, Rensselaer Polytechnic Institute, Troy, New York, USA
| | - Mario A Gutierrez Diaz
- Department of Chemical and Biological Engineering, Rensselaer Polytechnic Institute, Troy, New York, USA
| | | | | | | | - Steven M Cramer
- Department of Chemical and Biological Engineering, Rensselaer Polytechnic Institute, Troy, New York, USA
| | - Todd M Przybycien
- Department of Chemical and Biological Engineering, Rensselaer Polytechnic Institute, Troy, New York, USA
| | - Andrew L Zydney
- Department of Chemical Engineering, The Pennsylvania State University, State College, Pennsylvania, USA
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2
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Jungbauer A, Ferreira G, Butler M, D'Costa S, Brower K, Rayat A, Willson R. Status and future developments for downstream processing of biological products: Perspectives from the Recovery XIX yield roundtable discussions. Biotechnol Bioeng 2024; 121:2524-2541. [PMID: 38795025 DOI: 10.1002/bit.28738] [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: 12/30/2023] [Revised: 05/07/2024] [Accepted: 05/10/2024] [Indexed: 05/27/2024]
Abstract
Governments and biopharmaceutical organizations aggressively leveraged expeditious communication capabilities, decision models, and global strategies to make a COVID-19 vaccine happen within a period of 12 months. This was an unusual effort and cannot be transferred to normal times. However, this focus on a single vaccine has also led to other treatments and drug developments being sidelined. Society expects the pharmaceutical industry to provide an uninterrupted supply of medicines. However, it is often overlooked how complex the manufacture of these compounds is and what logistics are required, not to mention the time needed to develop new drugs. The overarching theme, therefore, is patient access and how we can help ensure access and extend it to low- and middle-income countries. Despite unceasing efforts to make medications available to all patient populations, this must never be done at the expense of patient safety. A major fraction of the costs in biopharmaceutical manufacturing are for drug discovery, process development, and clinical studies. Infrastructure costs are very difficult to quantify because they often depend on whether a greenfield facility or an existing, depreciated facility is used or adapted for a new product. To accelerate process development concepts of platform process and prior knowledge are increasingly leveraged. While more traditional protein therapeutics continue to dominate the field, we are also experiencing the exciting emergence and evolution of other therapeutic formats (bispecifics, tetravalent mAbs, antibody-drug conjugates, enzymes, peptides, etc.) that offer unique treatment options for patients. Protein modalities are still dominant, but new modalities are being developed that can be learned from including advanced therapeutics-like cell and gene therapies. The industry must develop a model-based strategy for process development and technologies such as continuous integrated biomanufacturing must be adopted. The overall conclusion is that the pandemic pace was unsustainable, focused on vaccine delivery at the expense of other modalities/disease targets, and had implications for professional and personal life (work-life balance). Routinely reducing development time from 10 years to 1 year is nearly impossible to achieve. Environmental aspects of sustainable downstream processing are also described.
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Affiliation(s)
- Alois Jungbauer
- Department of Biotechnology, Institute of Bioprocess Science and Engineering, University of Natural Resources and Life Sciences, Vienna, Austria
| | - Gisela Ferreira
- Process Development, AstraZeneca, Gaithersburg, Maryland, USA
| | - Michelle Butler
- Pharmaceutical Technical Development, F. Hoffmann-La Roche Ltd., Basel, Switzerland
| | - Susan D'Costa
- Technology Development and Manufacturing, Genezen Laboratories, Indianapolis, Indiana, USA
| | - Kevin Brower
- Mammalian Platform, Sanofi, Framingham, Massachusetts, USA
| | - Andrea Rayat
- Department of Biochemical Engineering, University College London, London, UK
| | - Richard Willson
- Department of Chemical and Biomolecular Engineering, University of Houston, Houston, Texas, USA
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3
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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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4
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Brower K, Wiltberger K, Berdugo C, Bosley A, Goodrich E, Pferdeort V, Schaefer G. Process development and characterization for integrated continuous bioprocesses-Highlights from N-mAb. Biotechnol Prog 2024; 40:e3425. [PMID: 38289271 DOI: 10.1002/btpr.3425] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/09/2023] [Revised: 10/31/2023] [Accepted: 12/20/2023] [Indexed: 08/20/2024]
Abstract
The N-mAb case study was produced by the National Institute for Innovation in Manufacturing Biopharmaceuticals (NIIMBL) to support teaching and learning for both industry and to accelerate adoption of advanced manufacturing process technologies such as integrated continuous bioprocesses (ICB) for mAbs. Similar to the A-mAb case study, N-mAb presents the evolution of an integrated control strategy, from early clinical through process validation and commercial manufacturing with a focus on elements that are unique to integrated continuous bioprocesses. This publication presents a summary of the process design and characterization chapters to allow a greater focus on the unique elements relevant to that phase of development.
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Affiliation(s)
- Kevin Brower
- Sanofi, Purification Development-Mammalian Platform, Framingham, Massachusetts, USA
| | - Kelly Wiltberger
- Biogen, Biologics Development, Biogen, Research Triangle Park, North Carolina, USA
| | | | - Allen Bosley
- AstraZeneca, Purification Process Sciences, Gaithersburg, Maryland, USA
| | | | - Valerie Pferdeort
- Biogen, Cell Culture Development, Research Triangle Park, North Carolina, USA
| | - Gene Schaefer
- National Institute for Innovation in Manufacturing Biopharmaceuticals (NIIMBL), Newark, Delaware, USA
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5
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Sharma V, Mottafegh A, Joo JU, Kang JH, Wang L, Kim DP. Toward microfluidic continuous-flow and intelligent downstream processing of biopharmaceuticals. LAB ON A CHIP 2024; 24:2861-2882. [PMID: 38751338 DOI: 10.1039/d3lc01097j] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 05/29/2024]
Abstract
Biopharmaceuticals have emerged as powerful therapeutic agents, revolutionizing the treatment landscape for various diseases, including cancer, infectious diseases, autoimmune and genetic disorders. These biotherapeutics pave the way for precision medicine with their unique and targeted capabilities. The production of high-quality biologics entails intricate manufacturing processes, including cell culture, fermentation, purification, and formulation, necessitating specialized facilities and expertise. These complex processes are subject to rigorous regulatory oversight to evaluate the safety, efficacy, and quality of biotherapeutics prior to clinical approval. Consequently, these drugs undergo extensive purification unit operations to achieve high purity by effectively removing impurities and contaminants. The field of personalized precision medicine necessitates the development of novel and highly efficient technologies. Microfluidic technology addresses unmet needs by enabling precise and compact separation, allowing rapid, integrated and continuous purification modules. Moreover, the integration of intelligent biomanufacturing systems with miniaturized devices presents an opportunity to significantly enhance the robustness of complex downstream processing of biopharmaceuticals, with the benefits of automation and advanced control. This allows seamless data exchange, real-time monitoring, and synchronization of purification steps, leading to improved process efficiency, data management, and decision-making. Integrating autonomous systems into biopharmaceutical purification ensures adherence to regulatory standards, such as good manufacturing practice (GMP), positioning the industry to effectively address emerging market demands for personalized precision nano-medicines. This perspective review will emphasize on the significance, challenges, and prospects associated with the adoption of continuous, integrated, and intelligent methodologies in small-scale downstream processing for various types of biologics. By utilizing microfluidic technology and intelligent systems, purification processes can be enhanced for increased efficiency, cost-effectiveness, and regulatory compliance, shaping the future of biopharmaceutical production and enabling the development of personalized and targeted therapies.
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Affiliation(s)
- Vikas Sharma
- Center for Intelligent Microprocess of Pharmaceutical Synthesis, Department of Chemical Engineering, Pohang University of Science and Technology (POSTECH), Pohang 37673, Republic of Korea.
| | - Amirreza Mottafegh
- Center for Intelligent Microprocess of Pharmaceutical Synthesis, Department of Chemical Engineering, Pohang University of Science and Technology (POSTECH), Pohang 37673, Republic of Korea.
| | - Jeong-Un Joo
- Center for Intelligent Microprocess of Pharmaceutical Synthesis, Department of Chemical Engineering, Pohang University of Science and Technology (POSTECH), Pohang 37673, Republic of Korea.
| | - Ji-Ho Kang
- Center for Intelligent Microprocess of Pharmaceutical Synthesis, Department of Chemical Engineering, Pohang University of Science and Technology (POSTECH), Pohang 37673, Republic of Korea.
| | - Lei Wang
- School of Chemistry and Chemical Engineering, Harbin Institute of Technology, Harbin 150001, Heilongjiang, P. R. China
| | - Dong-Pyo Kim
- Center for Intelligent Microprocess of Pharmaceutical Synthesis, Department of Chemical Engineering, Pohang University of Science and Technology (POSTECH), Pohang 37673, Republic of Korea.
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6
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Drobnjakovic M, Hart R, Kulvatunyou BS, Ivezic N, Srinivasan V. Current challenges and recent advances on the path towards continuous biomanufacturing. Biotechnol Prog 2023; 39:e3378. [PMID: 37493037 DOI: 10.1002/btpr.3378] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/20/2023] [Revised: 05/13/2023] [Accepted: 06/21/2023] [Indexed: 07/27/2023]
Abstract
Continuous biopharmaceutical manufacturing is currently a field of intense research due to its potential to make the entire production process more optimal for the modern, ever-evolving biopharmaceutical market. Compared to traditional batch manufacturing, continuous bioprocessing is more efficient, adjustable, and sustainable and has reduced capital costs. However, despite its clear advantages, continuous bioprocessing is yet to be widely adopted in commercial manufacturing. This article provides an overview of the technological roadblocks for extensive adoptions and points out the recent advances that could help overcome them. In total, three key areas for improvement are identified: Quality by Design (QbD) implementation, integration of upstream and downstream technologies, and data and knowledge management. First, the challenges to QbD implementation are explored. Specifically, process control, process analytical technology (PAT), critical process parameter (CPP) identification, and mathematical models for bioprocess control and design are recognized as crucial for successful QbD realizations. Next, the difficulties of end-to-end process integration are examined, with a particular emphasis on downstream processing. Finally, the problem of data and knowledge management and its potential solutions are outlined where ontologies and data standards are pointed out as key drivers of progress.
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Affiliation(s)
- Milos Drobnjakovic
- Systems Integration Division, National Institute of Standards and Technology, Gaithersburg, Maryland, USA
| | - Roger Hart
- National Institute for Innovation in Manufacturing Biopharmaceuticals, Newark, New Jersey, USA
| | - Boonserm Serm Kulvatunyou
- Systems Integration Division, National Institute of Standards and Technology, Gaithersburg, Maryland, USA
| | - Nenad Ivezic
- Systems Integration Division, National Institute of Standards and Technology, Gaithersburg, Maryland, USA
| | - Vijay Srinivasan
- Systems Integration Division, National Institute of Standards and Technology, Gaithersburg, Maryland, USA
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7
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Worsham RD, Thomas V, Farid SS. Impact of ethanol on continuous inline diafiltration of liposomal drug products. Biotechnol J 2023; 18:e2300194. [PMID: 37531572 DOI: 10.1002/biot.202300194] [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: 05/02/2023] [Revised: 07/14/2023] [Accepted: 07/27/2023] [Indexed: 08/04/2023]
Abstract
Liposomal drug products are playing an increasing role in the field of drug delivery. With this increased demand comes the need to increase the capabilities and capacity of manufacturing options. Continuous manufacturing techniques present a significant opportunity to address these needs for liposomal manufacturing processes. Liposomal formulations have unique considerations that impact translation from batch to continuous process designs. This article examines aspects of converting to a continuous design that were previously viewed as inconsequential in a batch process. The batch process involves the removal of ethanol (EtOH) through tangential flow filtration (TFF). EtOH was found to reduce the permeability of the hollow fibers used for TFF. This effect was determined to have minimal impact on the overall batch process design but considerable influence on the design of continuous TFF such as inline diafiltration (ILDF). Using a pilot scale setup, EtOH was found to decrease permeability in an inverse manner to EtOH concentration. Further assessment found that dilution of the EtOH levels prior to diafiltration can significantly reduce the amount of ILDF stages needed and that a continuous design requires less buffer to the commensurate batch design.
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Affiliation(s)
- Robert D Worsham
- Insmed, Inc., Bridgewater, New Jersey, USA
- Department of Biochemical Engineering, University College London, London, UK
| | - Vaughan Thomas
- Department of Biochemical Engineering, University College London, London, UK
| | - Suzanne S Farid
- Department of Biochemical Engineering, University College London, London, UK
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8
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Rizki Z, Ottens M. Model-based optimization approaches for pressure-driven membrane systems. Sep Purif Technol 2023. [DOI: 10.1016/j.seppur.2023.123682] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 03/30/2023]
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9
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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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10
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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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11
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Ding C, Ardeshna H, Gillespie C, Ierapetritou M. Process Design of a Fully Integrated Continuous Biopharmaceutical Process using Economic and Ecological Impact Assessment. Biotechnol Bioeng 2022; 119:3567-3583. [DOI: 10.1002/bit.28234] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/22/2022] [Revised: 08/31/2022] [Accepted: 09/11/2022] [Indexed: 11/06/2022]
Affiliation(s)
- Chaoying Ding
- Department of Chemical and Biomolecular EngineeringUniversity of DelawareNewarkDE19716US
| | - Hiren Ardeshna
- Manufacturing Science and Technology, Biopharm and Steriles, GlaxoSmithKlinePhiladelphiaPA19112US
| | | | - Marianthi Ierapetritou
- Department of Chemical and Biomolecular EngineeringUniversity of DelawareNewarkDE19716US
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12
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Tan R, Franzreb M. Simulation-based evaluation of single pass continuous diafiltration with alternating permeate flow direction. Sep Purif Technol 2022. [DOI: 10.1016/j.seppur.2021.119987] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/27/2022]
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13
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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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14
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Thakur G, Ghumade P, Rathore AS. Process analytical technology in continuous processing: Model-based real time control of pH between capture chromatography and viral inactivation for monoclonal antibody production. J Chromatogr A 2021; 1658:462614. [PMID: 34656843 DOI: 10.1016/j.chroma.2021.462614] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/02/2021] [Revised: 08/25/2021] [Accepted: 10/05/2021] [Indexed: 11/16/2022]
Abstract
A real time mechanistic model-based control strategy is demonstrated for in-line pH adjustment post-capture chromatography and prior to viral inactivation for continuous processing of monoclonal antibodies. At this point in the process, tight control of pH is essential, as pH fluctuations above 3.5 can result in incomplete viral inactivation, while fluctuations below 3.5 can lead to significant aggregate formation. The present approach predicts the pH profile during the transition phase between chromatography wash and elution steps by modelling the process stream at the column outlet as a mixture of two independent buffer systems. Control of pH in this transition phase is a critical consideration in capture chromatography as a significant amount of mAb material is eluted at this time. The model inputs are buffer concentrations, flow rates, and theoretical pKa values, along with cleaning step conductivity profiles which are readily available from a typical process chromatography equipment. The utilization of the most recent cleaning cycle data as an input to the model allows sensitive calibration to the individual process at hand on a column-to-column basis. The model is able to accurately predict the pH profile throughout the elution, as well as calculate the flow rate of the acid (titrant) required at each time point to maintain the pH consistently at 3.5±0.2. The strategy is demonstrated for various buffers, columns, operating conditions, and process deviations in a three-column continuous process, and is a useful and simple approach for achieving robust control of pH at this critical point in the continuous train.
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Affiliation(s)
- Garima Thakur
- Department of Chemical Engineering, Indian Institute of Technology, 110016, Hauz Khas, India
| | - Pragati Ghumade
- Department of Chemical Engineering, Indian Institute of Technology, 110016, Hauz Khas, India
| | - Anurag S Rathore
- Department of Chemical Engineering, Indian Institute of Technology, 110016, Hauz Khas, India.
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15
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Kilmartin CP, Ouimet JA, Dowling AW, Phillip WA. Staged Diafiltration Cascades Provide Opportunities to Execute Highly Selective Separations. Ind Eng Chem Res 2021. [DOI: 10.1021/acs.iecr.1c02984] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Cara P. Kilmartin
- Department of Chemical and Biomolecular Engineering, University of Notre Dame, Notre Dame, Indiana 46556, United States
| | - Jonathan Aubuchon Ouimet
- Department of Chemical and Biomolecular Engineering, University of Notre Dame, Notre Dame, Indiana 46556, United States
| | - Alexander W. Dowling
- Department of Chemical and Biomolecular Engineering, University of Notre Dame, Notre Dame, Indiana 46556, United States
| | - William A. Phillip
- Department of Chemical and Biomolecular Engineering, University of Notre Dame, Notre Dame, Indiana 46556, United States
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16
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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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17
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Thakur G, Nikita S, Tiwari A, Rathore AS. Control of surge tanks for continuous manufacturing of monoclonal antibodies. Biotechnol Bioeng 2021; 118:1913-1931. [PMID: 33547800 DOI: 10.1002/bit.27706] [Citation(s) in RCA: 12] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/21/2020] [Revised: 01/12/2021] [Accepted: 01/28/2021] [Indexed: 12/14/2022]
Abstract
Surge tanks are critical but often overlooked enablers of continuous bioprocessing. They provide multiple benefits including dampening of concentration gradients and allowing process resumption efforts in case of equipment failure or unexpected deviations, which can occur during a continuous campaign of weeks or months. They are also useful in enabling steady-state operation across a continuous train by facilitating mass balance between unit operations such as chromatography which have periodic loading and elution cycles. In this paper, we propose a design of a system of surge tanks for a monoclonal antibody (mAb) production process consisting of cell culture, clarification, capture chromatography, viral inactivation, polishing chromatography, and single-pass ultrafiltration and diafiltration. A Python controller has been developed for robust control of the continuous train. The controller has four layers, namely data acquisition, process scheduling, deviation handling, and real-time execution. A set of general guidelines for surge tank placement and sizing have been proposed together with process control strategies based on the design space of the individual unit operations, failure modes analysis of the different equipment, and expected variability in the process feed streams for both fed-batch and perfusion bioreactors. The control system has been successfully demonstrated for several continuous runs of up to 36 h in duration and is able to leverage surge tanks for robust control of the continuous train in the face of product variability as well as process errors while maintaining critical quality attributes. The proposed set of strategies for surge tank control are adaptable to most continuous processing setups for mAbs, and together form the first framework that can fully realize the benefits of surge tanks in continuous bioprocessing.
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Affiliation(s)
- Garima Thakur
- Department of Chemical Engineering, Indian Institute of Technology, Hauz Khas, New Delhi, India
| | - Saxena Nikita
- Department of Chemical Engineering, Indian Institute of Technology, Hauz Khas, New Delhi, India
| | - Anamika Tiwari
- Department of Chemical Engineering, Indian Institute of Technology, Hauz Khas, New Delhi, India
| | - Anurag S Rathore
- Department of Chemical Engineering, Indian Institute of Technology, Hauz Khas, New Delhi, India
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18
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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: 29] [Impact Index Per Article: 9.7] [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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19
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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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20
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21
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Li Z, Chen TH, Andini E, Coffman JL, Przybycien T, Zydney AL. Enhanced filtration performance using feed-and-bleed configuration for purification of antibody precipitates. Biotechnol Prog 2020; 37:e3082. [PMID: 32940015 DOI: 10.1002/btpr.3082] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/10/2020] [Revised: 08/24/2020] [Accepted: 09/14/2020] [Indexed: 11/10/2022]
Abstract
Precipitation can be used for the initial purification of monoclonal antibodies (mAbs), with the soluble host cell proteins removed in the permeate by tangential flow microfiltration. The objective of this study was to examine the use of a feed-and-bleed configuration to increase the effective conversion (ratio of permeate to feed flow rates) in the hollow fiber module to enable more effective washing of the precipitate. Experiments were performed using human serum Immunoglobulin G (IgG) precipitates formed with 10 mM zinc chloride and 7 wt% polyethylene glycol. The critical flux was evaluated as a function of the shear rate and IgG concentration, with the resulting correlation used to predict conditions that can achieve 90% conversion in a single pass with minimal fouling. Experimental data for both the start-up and steady-state performance are in good agreement with model calculations. These results were used to analyze the performance of an enhanced continuous precipitation-microfiltration process using the feed-and-bleed configuration for the initial capture / purification of a mAb product.
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Affiliation(s)
- Zhao Li
- Department of Chemical Engineering, The Pennsylvania State University, University Park, Pennsylvania, USA
| | - Ting-Hsi Chen
- Department of Chemical Engineering, The Pennsylvania State University, University Park, Pennsylvania, USA
| | - Erha Andini
- Department of Chemical Engineering, The Pennsylvania State University, University Park, Pennsylvania, USA
| | - Jonathan L Coffman
- BioProcess Technologies and Engineering, AstraZeneca, Gaithersburg, Maryland, USA
| | - Todd Przybycien
- Department of Chemical & Biological Engineering, Rensselaer Polytechnic Institute, Troy, New York, USA
| | - Andrew L Zydney
- Department of Chemical Engineering, The Pennsylvania State University, University Park, Pennsylvania, USA
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22
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Yehl CJ, Zydney AL. Single-use, single-pass tangential flow filtration using low-cost hollow fiber modules. J Memb Sci 2020. [DOI: 10.1016/j.memsci.2019.117517] [Citation(s) in RCA: 12] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/16/2023]
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23
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Tripathi NK, Shrivastava A. Recent Developments in Bioprocessing of Recombinant Proteins: Expression Hosts and Process Development. Front Bioeng Biotechnol 2019; 7:420. [PMID: 31921823 PMCID: PMC6932962 DOI: 10.3389/fbioe.2019.00420] [Citation(s) in RCA: 251] [Impact Index Per Article: 50.2] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/07/2019] [Accepted: 11/29/2019] [Indexed: 12/22/2022] Open
Abstract
Infectious diseases, along with cancers, are among the main causes of death among humans worldwide. The production of therapeutic proteins for treating diseases at large scale for millions of individuals is one of the essential needs of mankind. Recent progress in the area of recombinant DNA technologies has paved the way to producing recombinant proteins that can be used as therapeutics, vaccines, and diagnostic reagents. Recombinant proteins for these applications are mainly produced using prokaryotic and eukaryotic expression host systems such as mammalian cells, bacteria, yeast, insect cells, and transgenic plants at laboratory scale as well as in large-scale settings. The development of efficient bioprocessing strategies is crucial for industrial production of recombinant proteins of therapeutic and prophylactic importance. Recently, advances have been made in the various areas of bioprocessing and are being utilized to develop effective processes for producing recombinant proteins. These include the use of high-throughput devices for effective bioprocess optimization and of disposable systems, continuous upstream processing, continuous chromatography, integrated continuous bioprocessing, Quality by Design, and process analytical technologies to achieve quality product with higher yield. This review summarizes recent developments in the bioprocessing of recombinant proteins, including in various expression systems, bioprocess development, and the upstream and downstream processing of recombinant proteins.
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Affiliation(s)
- Nagesh K. Tripathi
- Bioprocess Scale Up Facility, Defence Research and Development Establishment, Gwalior, India
| | - Ambuj Shrivastava
- Division of Virology, Defence Research and Development Establishment, Gwalior, India
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