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Emerging application of hydrocyclone in biotechnology and food processing. Sep Purif Technol 2022. [DOI: 10.1016/j.seppur.2022.122992] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/24/2022]
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He L, Ji L, He Y, Liu Y, Chen S, Chu K, Kuang S. Experimental and numerical analysis of Chinese hamster ovary cell viability loss in mini-hydrocyclones. Sep Purif Technol 2022. [DOI: 10.1016/j.seppur.2022.121203] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/26/2022]
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3
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Dryden WA, Larsen LM, Britt DW, Smith MT. Technical and economic considerations of cell culture harvest and clarification technologies. Biochem Eng J 2021. [DOI: 10.1016/j.bej.2020.107892] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/16/2022]
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Kundu AM, Hiller GW. Hydrocyclones as cell retention devices for an N-1 perfusion bioreactor linked to a continuous-flow stirred tank production bioreactor. Biotechnol Bioeng 2021; 118:1973-1986. [PMID: 33559888 DOI: 10.1002/bit.27711] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/09/2020] [Revised: 01/06/2021] [Accepted: 02/01/2021] [Indexed: 11/07/2022]
Abstract
A continuous Chinese hamster ovary (CHO) cell culture process comprised of a highly proliferative N-1 perfusion bioreactor utilizing a hydrocyclone as a cell retention device linked to a production continuous-flow stirred tank reactor (CSTR) is presented. The overflow stream from the hydrocyclone, which is only partially depleted of cells, provides a continuous source of high viability cells from the N-1 perfusion bioreactor to the 5-20 times larger CSTR. Under steady-state conditions, this linked-bioreactor system achieved a peak volumetric productivity of 0.96 g/L/day, twofold higher than the optimized fed-batch process. The linked bioreactor system using a hydrocyclone was also shown to be 1.8-3.1 times more productive than a dual, cascading CSTR system without cell retention.
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Affiliation(s)
- Anita M Kundu
- Upstream Process Development, Bioprocess Research and Development, Pfizer, Inc., Andover, Massachusetts, USA
| | - Gregory W Hiller
- Upstream Process Development, Bioprocess Research and Development, Pfizer, Inc., Andover, Massachusetts, USA
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Coronel J, Gränicher G, Sandig V, Noll T, Genzel Y, Reichl U. Application of an Inclined Settler for Cell Culture-Based Influenza A Virus Production in Perfusion Mode. Front Bioeng Biotechnol 2020; 8:672. [PMID: 32714908 PMCID: PMC7343718 DOI: 10.3389/fbioe.2020.00672] [Citation(s) in RCA: 21] [Impact Index Per Article: 5.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/21/2020] [Accepted: 05/29/2020] [Indexed: 12/13/2022] Open
Abstract
Influenza viruses have been successfully propagated using a variety of animal cell lines in batch, fed-batch, and perfusion culture. For suspension cells, most studies reported on membrane-based cell retention devices typically leading to an accumulation of viruses in the bioreactor in perfusion mode. Aiming at continuous virus harvesting for improved productivities, an inclined settler was evaluated for influenza A virus (IAV) production using the avian suspension cell line AGE1.CR.pIX. Inclined settlers present many advantages as they are scalable, robust, and comply with cGMP regulations, e.g., for recombinant protein manufacturing. Perfusion rates up to 3000 L/day have been reported. In our study, successful growth of AGE1.CR.pIX cells up to 50 × 106 cells/mL and a cell retention efficiency exceeding 96% were obtained with the settler cooled to room temperature. No virus retention was observed. A total of 5.4-6.5 × 1013 virions were produced while a control experiment with an ATF system equaled to 1.9 × 1013 virions. For infection at 25 × 106 cells/mL, cell-specific virus yields up to 3474 virions/cell were obtained, about 5-fold higher than for an ATF based cultivation performed as a control (723 virions/cell). Trypsin activity was shown to have a large impact on cell growth dynamics after infection following the cell retention device, especially at a cell concentration of 50 × 106 cells/mL. Further control experiments performed with an acoustic settler showed that virus production was improved with a heat exchanger of the inclined settler operated at 27°C. In summary, cell culture-based production of viruses in perfusion mode with an inclined settler and continuous harvesting can drastically increase IAV yields and possibly the yield of other viruses. To our knowledge, this is the first report to show the potential of this device for viral vaccine production.
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Affiliation(s)
- Juliana Coronel
- Max Planck Institute for Dynamics of Complex Technical Systems, Magdeburg, Germany
| | - Gwendal Gränicher
- Max Planck Institute for Dynamics of Complex Technical Systems, Magdeburg, Germany
| | | | - Thomas Noll
- Institute of Cell Culture Technology, Bielefeld University, Bielefeld, Germany
| | - Yvonne Genzel
- Max Planck Institute for Dynamics of Complex Technical Systems, Magdeburg, Germany
| | - Udo Reichl
- Max Planck Institute for Dynamics of Complex Technical Systems, Magdeburg, Germany.,Bioprocess Engineering, Otto von Guericke University Magdeburg, Magdeburg, Germany
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Bettinardi IW, Castan A, Medronho RA, Castilho LR. Hydrocyclones as cell retention device for CHO perfusion processes in single‐use bioreactors. Biotechnol Bioeng 2020; 117:1915-1928. [DOI: 10.1002/bit.27335] [Citation(s) in RCA: 13] [Impact Index Per Article: 3.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/05/2019] [Revised: 02/11/2020] [Accepted: 03/16/2020] [Indexed: 12/20/2022]
Affiliation(s)
- Ioná W. Bettinardi
- COPPE/PEQ, Cell Culture Engineering Laboratory (LECC)Federal University of Rio de Janeiro (UFRJ) Rio de Janeiro RJ Brazil
| | - Andreas Castan
- BioProcess R&DGE Healthcare Bio‐Sciences AB Uppsala Sweden
| | - Ricardo A. Medronho
- Department of Chemical Engineering, School of ChemistryFederal University of Rio de Janeiro (UFRJ) Rio de Janeiro RJ Brazil
| | - Leda R. Castilho
- COPPE/PEQ, Cell Culture Engineering Laboratory (LECC)Federal University of Rio de Janeiro (UFRJ) Rio de Janeiro RJ Brazil
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Seyfi Mazraeno M, Fazlali A, Hosseini SN. Application of hydrocyclone for separation of Pichia pastoris produced r-HBsAg from fermentation culture: impact of concentration and pressure on hydrocyclone performance. Prep Biochem Biotechnol 2019; 49:813-821. [PMID: 31169457 DOI: 10.1080/10826068.2019.1621891] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.4] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/26/2022]
Abstract
Separation of biomass from culture media by centrifugation and then washing the biomass are mandatory steps in the fermentation process of recombinant Pichia pastoris expressed HBsAg intracellularly. Biomass has to be washed many times to eliminate the culture media residues thoroughly. In this study, we tried to develop the hydrocyclone as an alternative method for separation of biomass from fermentation culture, an attractive replacement for centrifugation processes. The advantages of using hydrocyclone in biomass separation could be summarized in its suitability for continuous separation and its low risk of contamination. To evaluate the performance of hydrocyclone, concentration ratio in underflow to feed stream, capacity, and centrifugal force by considering three parameters of pressure drop, concentration, and the type of hydrocyclone were investigated. Using three level factorial design a concentration ratio equation was developed, with the correlation coefficient R2 = 0.977 ensured the good fitness of the predicted data with the experimental results. In optimal conditions, maximum concentration ratio was 1.246, for flow rate 13.5 LPM and C-force equal to 1276.11 at maximum pressure drop (3 bar) and minimum concentration (0.5% w/w) in hydrocyclone 1. Herein, two different hydrocyclones with the cylindrical diameters of 19 mm and 21 mm were used for separating the yeast cells.
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Affiliation(s)
| | - Alireza Fazlali
- a Department of Chemical Engineering, Arak University , Arak , Iran
| | - Seyed Nezamedin Hosseini
- b Department of Hepatitis B vaccine Production, Production and Research, Complex Pasteur Institute of Iran , Tehran , Iran
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Patil R, Walther J. Continuous Manufacturing of Recombinant Therapeutic Proteins: Upstream and Downstream Technologies. ADVANCES IN BIOCHEMICAL ENGINEERING/BIOTECHNOLOGY 2019; 165:277-322. [PMID: 28265699 DOI: 10.1007/10_2016_58] [Citation(s) in RCA: 14] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 12/16/2022]
Abstract
Continuous biomanufacturing of recombinant therapeutic proteins offers several potential advantages over conventional batch processing, including reduced cost of goods, more flexible and responsive manufacturing facilities, and improved and consistent product quality. Although continuous approaches to various upstream and downstream unit operations have been considered and studied for decades, in recent years interest and application have accelerated. Researchers have achieved increasingly higher levels of process intensification, and have also begun to integrate different continuous unit operations into larger, holistically continuous processes. This review first discusses approaches for continuous cell culture, with a focus on perfusion-enabling cell separation technologies including gravitational, centrifugal, and acoustic settling, as well as filtration-based techniques. We follow with a review of various continuous downstream unit operations, covering categories such as clarification, chromatography, formulation, and viral inactivation and filtration. The review ends by summarizing case studies of integrated and continuous processing as reported in the literature.
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Affiliation(s)
- Rohan Patil
- Bioprocess Development, Sanofi, Framingham, MA, 01701, USA
| | - Jason Walther
- Bioprocess Development, Sanofi, Framingham, MA, 01701, USA.
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Shakeel Syed M, Rafeie M, Henderson R, Vandamme D, Asadnia M, Ebrahimi Warkiani M. A 3D-printed mini-hydrocyclone for high throughput particle separation: application to primary harvesting of microalgae. LAB ON A CHIP 2017; 17:2459-2469. [PMID: 28695927 DOI: 10.1039/c7lc00294g] [Citation(s) in RCA: 37] [Impact Index Per Article: 5.3] [Reference Citation Analysis] [Abstract] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 05/14/2023]
Abstract
The separation of micro-sized particles in a continuous flow is crucial part of many industrial processes, from biopharmaceutical manufacturing to water treatment. Conventional separation techniques such as centrifugation and membrane filtration are largely limited by factors such as clogging, processing time and operation efficiency. Microfluidic based techniques have been gaining great attention in recent years as efficient and powerful approaches for particle-liquid separation. Yet the production of such systems using standard micro-fabrication techniques is proven to be tedious, costly and have cumbersome user interfaces, which all render commercialization difficult. Here, we demonstrate the design, fabrication and evaluation based on CFD simulation as well as experimentation of 3D-printed miniaturized hydrocyclones with smaller cut-size for high-throughput particle/cell sorting. The characteristics of the mini-cyclones were numerically investigated using computational fluid dynamics (CFD) techniques previously revealing that reduction in the size of the cyclone results in smaller cut-size of the particles. To showcase its utility, high-throughput algae harvesting from the medium with low energy input is demonstrated for the marine microalgae Tetraselmis suecica. Final microalgal biomass concentration was increased by 7.13 times in 11 minutes of operation time using our designed hydrocyclone (HC-1). We expect that this elegant approach can surmount the shortcomings of other microfluidic technologies such as clogging, low-throughput, cost and difficulty in operation. By moving away from production of planar microfluidic systems using conventional microfabrication techniques and embracing 3D-printing technology for construction of discrete elements, we envision 3D-printed mini-cyclones can be part of a library of standardized active and passive microfluidic components, suitable for particle-liquid separation.
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Affiliation(s)
- Maira Shakeel Syed
- School of Mechanical and Manufacturing Engineering, University of New South Wales, Sydney, NSW 2052, Australia.
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Meier K, Djeljadini S, Regestein L, Büchs J, Carstensen F, Wessling M, Holland T, Raven N. In situ cell retention of a CHO culture by a reverse-flow diafiltration membrane bioreactor. Biotechnol Prog 2014; 30:1348-55. [PMID: 25202924 DOI: 10.1002/btpr.1988] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/24/2014] [Revised: 08/28/2014] [Indexed: 11/10/2022]
Abstract
Heterogeneities occur in various bioreactor designs including cell retention devices. Whereas in external devices changing environmental conditions cannot be prevented, cells are retained in their optimal environment in internal devices. Conventional reverse-flow diafiltration utilizes an internal membrane device, but pulsed feeding causes temporal heterogeneities. In this study, the influence of conventional reverse-flow diafiltration on the yeast Hansenula polymorpha is investigated. Alternating 180 s of feeding with 360 s of non-feeding at a dilution rate of 0.2 h(-1) results in an oscillating DOT signal with an amplitude of 60%. Thereby, induced short-term oxygen limitations result in the formation of ethanol and a reduced product concentration of 25%. This effect is enforced at increased dilution rate. To overcome this cyclic problem, sequential operation of three membranes is introduced. Thus, quasi-continuous feeding is achieved reducing the oscillation of the DOT signal to an amplitude of 20% and 40% for a dilution rate of 0.2 h(-1) and 0.5 h(-1) , respectively. Fermentation conditions characterized by complete absence of oxygen limitation and without formation of overflow metabolites could be obtained for dilution rates from 0.1 h(-1) - 0.5 h(-1) . Thus, sequential operation of three membranes minimizes oscillations in the DOT signal providing a nearly homogenous culture over time.
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Affiliation(s)
- Kristina Meier
- RWTH Aachen, AVT-Biochemical Engineering, Worringer Weg 1, Aachen, 52074, Germany
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Pinto AA, Bicalho IC, Mognon JL, Duarte CR, Ataíde CH. Separation of Saccharomyces cerevisiae from alcoholic fermentation broth by two commercial hydrocyclones. Sep Purif Technol 2013. [DOI: 10.1016/j.seppur.2013.09.013] [Citation(s) in RCA: 18] [Impact Index Per Article: 1.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/01/2022]
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Bicalho IC, Mognon JL, Shimoyama J, Ataíde CH, Duarte CR. Effects of Operating Variables on the Yeast Separation Process in a Hydrocyclone. SEP SCI TECHNOL 2013. [DOI: 10.1080/01496395.2012.712597] [Citation(s) in RCA: 14] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Submit a Manuscript] [Subscribe] [Scholar Register] [Indexed: 10/27/2022]
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Henzler HJ. Kontinuierliche Fermentation mit tierischen Zellen. Teil 2. Techniken und Methoden der Zellrückhaltung. CHEM-ING-TECH 2012. [DOI: 10.1002/cite.201200003] [Citation(s) in RCA: 12] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/05/2022]
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Bicalho IC, Mognon JL, Shimoyama J, Ataíde CH, Duarte CR. Separation of yeast from alcoholic fermentation in small hydrocyclones. Sep Purif Technol 2012. [DOI: 10.1016/j.seppur.2011.11.023] [Citation(s) in RCA: 38] [Impact Index Per Article: 3.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/17/2022]
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Bai Z, Wang H, Tu ST. Study of Air-Liquid Flow Patterns in Hydrocyclone Enhanced by Air Bubbles. Chem Eng Technol 2009. [DOI: 10.1002/ceat.200800518] [Citation(s) in RCA: 7] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/11/2022]
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Liu PK, Chu LY, Wang J, Yu YF. Enhancement of Hydrocyclone Classification Efficiency for Fine Particles by Introducing a Volute Chamber with a Pre-Sedimentation Function. Chem Eng Technol 2008. [DOI: 10.1002/ceat.200700449] [Citation(s) in RCA: 19] [Impact Index Per Article: 1.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/05/2022]
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