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A comprehensive comparison of mixing and mass transfer in shake flasks and their relationship with MAb productivity of CHO cells. Bioprocess Biosyst Eng 2022; 45:1033-1045. [DOI: 10.1007/s00449-022-02722-y] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/21/2021] [Accepted: 03/14/2022] [Indexed: 11/26/2022]
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YekrangSafakar A, Mehrnezhad A, Wu T, Park K. High-density adherent culture of CHO cells using rolled scaffold bioreactor. Biotechnol Bioeng 2022; 119:1498-1508. [PMID: 35319094 DOI: 10.1002/bit.28079] [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: 09/19/2021] [Revised: 02/21/2022] [Accepted: 02/27/2022] [Indexed: 11/05/2022]
Abstract
Rapid expansion of biopharmaceutical market calls for more efficient and reliable platforms to culture mammalian cells on a large scale. Stirred-tank bioreactors have been widely used for large-scale cell culture. However, it requires months of trials and errors to optimize culture conditions for each cell line. In this article, we extend our earlier studies on rolled scaffold (RS) bioreactors for high-density adherent cell culture and report two new implementations of RSs with greatly enhanced mass-manufacturability, termed as Mesh-RS and Fiber-RS. CHO-K1 cells were successfully expanded in Mesh-RS and Fiber-RS bioreactors with an average growth rate of 1.09 ± 0.04 1/day and 0.95 ± 0.07 1/day, which were higher than those reported in similar studies. Fiber-RS bioreactor exhibited a very high cell density of 72.8 × 106 cells/ml. Besides, a dialyzer was integrated into the RS bioreactor to remove cellular waste and to replenish nutrients without disturbing the cells. By collecting the dialyzed media separately, the dialysis efficiency was significantly improved. In conclusion, the developed RS bioreactor has a strong potential to provide a highly reliable and easily scalable platform for large-scale cell culture in the biopharmaceutical industry.
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Affiliation(s)
- Ashkan YekrangSafakar
- Division of Electrical and Computer Engineering, Louisiana State University, Baton Rouge, Louisiana, USA
| | - Ali Mehrnezhad
- Division of Electrical and Computer Engineering, Louisiana State University, Baton Rouge, Louisiana, USA
| | - Tongyao Wu
- Division of Electrical and Computer Engineering, Louisiana State University, Baton Rouge, Louisiana, USA
| | - Kidong Park
- Division of Electrical and Computer Engineering, Louisiana State University, Baton Rouge, Louisiana, USA
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3
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Sharma R, Harrison STL, Tai SL. Advances in Bioreactor Systems for the Production of Biologicals in Mammalian Cells. CHEMBIOENG REVIEWS 2021. [DOI: 10.1002/cben.202100022] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/07/2022]
Affiliation(s)
- Rajesh Sharma
- University of Cape Town Centre for Bioprocess Engineering Research (CeBER) Department of Chemical Engineering Faculty of Engineering and the Built Environment Private Bag 7701 Rondebosch South Africa
| | - Susan T. L. Harrison
- University of Cape Town Centre for Bioprocess Engineering Research (CeBER) Department of Chemical Engineering Faculty of Engineering and the Built Environment Private Bag 7701 Rondebosch South Africa
| | - Siew Leng Tai
- University of Cape Town Centre for Bioprocess Engineering Research (CeBER) Department of Chemical Engineering Faculty of Engineering and the Built Environment Private Bag 7701 Rondebosch South Africa
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4
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Strobl F, Duerkop M, Palmberger D, Striedner G. High shear resistance of insect cells: the basis for substantial improvements in cell culture process design. Sci Rep 2021; 11:9413. [PMID: 33941799 PMCID: PMC8093278 DOI: 10.1038/s41598-021-88813-4] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/04/2020] [Accepted: 04/13/2021] [Indexed: 11/23/2022] Open
Abstract
Multicellular organisms cultivated in continuous stirred tank reactors (CSTRs) are more sensitive to environmental conditions in the suspension culture than microbial cells. The hypothesis, that stirring induced shear stress is the main problem, persists, although it has been shown that these cells are not so sensitive to shear. As these results are largely based on Chinese Hamster Ovary (CHO) cell experiments the question remains if similar behavior is valid for insect cells with a higher specific oxygen demand. The requirement of higher oxygen transfer rates is associated with higher shear forces in the process. Consequently, we focused on the shear resistance of insect cells, using CHO cells as reference system. We applied a microfluidic device that allowed defined variations in shear rates. Both cell lines displayed high resistance to shear rates up to 8.73 × 105 s−1. Based on these results we used microbial CSTRs, operated at high revolution speeds and low aeration rates and found no negative impact on cell viability. Further, this cultivation approach led to substantially reduced gas flow rates, gas bubble and foam formation, while addition of pure oxygen was no longer necessary. Therefore, this study contributes to the development of more robust insect cell culture processes.
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Affiliation(s)
| | - Mark Duerkop
- Institute of Bioprocess Science and Engineering, University of Natural Resources and Life Sciences, Vienna, Austria.,Novasign GmbH, Vienna, Austria
| | | | - Gerald Striedner
- ACIB GmbH, Vienna, Austria. .,Institute of Bioprocess Science and Engineering, University of Natural Resources and Life Sciences, Vienna, Austria. .,Novasign GmbH, Vienna, Austria.
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Burghardt JP, Fan R, Baas M, Eckhardt D, Gerlach D, Czermak P. Enhancing the Heterologous Fructosyltransferase Activity of Kluyveromyces lactis: Developing a Scaled-Up Process and Abolishing Invertase by CRISPR/Cas9 Genome Editing. Front Bioeng Biotechnol 2020; 8:607507. [PMID: 33324627 PMCID: PMC7724039 DOI: 10.3389/fbioe.2020.607507] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/17/2020] [Accepted: 11/02/2020] [Indexed: 11/13/2022] Open
Abstract
The enzymatic production of prebiotic fructo-oligosaccharides (FOS) from sucrose involves fructosyltransferases (FFTs) and invertases, both of which catalyze forward (transferase) and reverse (hydrolysis) reactions. FOS yields can therefore be increased by favoring the forward reaction. We investigated process conditions that favored transferase activity in the yeast strain Kluyveromyces lactis GG799, which expresses a native invertase and a heterologous FFT from Aspergillus terreus. To maximize transferase activity while minimizing native invertase activity in a scaled-up process, we evaluated two reactor systems in terms of oxygen input capacity in relation to the cell dry weight. In the 0.5-L reactor, we found that galactose was superior to lactose for the induction of the LAC4 promoter, and we optimized the induction time and induction to carbon source ratio using a response surface model. Based on the critical parameter of oxygen supply, we scaled up the process to 7 L using geometric similarity and a higher oxygen transport rate, which boosted the transferase activity by 159%. To favor the forward reaction even more, we deleted the native invertase gene by CRISPR/Cas9 genome editing and compared the ΔInv mutant to the original production strain in batch and fed-batch reactions. In fed-batch mode, we found that the ΔInv mutant increased the transferase activity by a further 66.9%. The enhanced mutant strain therefore provides the basis for a highly efficient and scalable fed-batch process for the production of FOS.
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Affiliation(s)
- Jan Philipp Burghardt
- Institute of Bioprocess Engineering and Pharmaceutical Technology, University of Applied Sciences Mittelhessen, Giessen, Germany
- Faculty of Biology and Chemistry, Justus Liebig University, Giessen, Germany
| | - Rong Fan
- Institute of Bioprocess Engineering and Pharmaceutical Technology, University of Applied Sciences Mittelhessen, Giessen, Germany
- Department of Bioresources, Fraunhofer Institute for Molecular Biology and Applied Ecology IME, Giessen, Germany
| | - Markus Baas
- Institute of Bioprocess Engineering and Pharmaceutical Technology, University of Applied Sciences Mittelhessen, Giessen, Germany
| | - Dustin Eckhardt
- Institute of Bioprocess Engineering and Pharmaceutical Technology, University of Applied Sciences Mittelhessen, Giessen, Germany
| | - Doreen Gerlach
- Department of Bioresources, Fraunhofer Institute for Molecular Biology and Applied Ecology IME, Giessen, Germany
| | - Peter Czermak
- Institute of Bioprocess Engineering and Pharmaceutical Technology, University of Applied Sciences Mittelhessen, Giessen, Germany
- Faculty of Biology and Chemistry, Justus Liebig University, Giessen, Germany
- Department of Bioresources, Fraunhofer Institute for Molecular Biology and Applied Ecology IME, Giessen, Germany
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Weidner T, Druzinec D, Mühlmann M, Buchholz R, Czermak P. The components of shear stress affecting insect cells used with the baculovirus expression vector system. ACTA ACUST UNITED AC 2018; 72:429-439. [PMID: 28822988 DOI: 10.1515/znc-2017-0066] [Citation(s) in RCA: 5] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/18/2017] [Accepted: 07/17/2017] [Indexed: 02/07/2023]
Abstract
Insect-based expression platforms such as the baculovirus expression vector system (BEVS) are widely used for the laboratory- and industrial-scale production of recombinant proteins. Thereby, major drawbacks to gain high-quality proteins are the lytic infection cycle and the shear sensitivity of infected insect cells due to turbulence and aeration. Smaller bubbles were formerly assumed to be more harmful than larger ones, but we found that cell damage is also dependent on the concentration of protective agents such as Pluronic®. At the appropriate concentration, Pluronic forms a layer around air bubbles and hinders the attachment of cells, thus limiting the damage. In this context, we used microaeration to vary bubble sizes and confirmed that size is not the most important factor, but the total gas surface area in the reactor is. If the surface area exceeds a certain threshold, the concentration of Pluronic is no longer sufficient for cell protection. To investigate the significance of shear forces, a second study was carried out in which infected insect cells were cultivated in a hollow fiber module to protect them from shear forces. Both model studies revealed important aspects of the design and scale-up of BEVS processes for the production of recombinant proteins.
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Druzinec D, Salzig D, Kraume M, Czermak P. Micro-bubble aeration in turbulent stirred bioreactors: Coalescence behavior in Pluronic F68 containing cell culture media. Chem Eng Sci 2015. [DOI: 10.1016/j.ces.2014.12.020] [Citation(s) in RCA: 13] [Impact Index Per Article: 1.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/24/2022]
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Druzinec D, Weiss K, Elseberg C, Salzig D, Kraume M, Pörtner R, Czermak P. Process analytical technology (PAT) in insect and mammalian cell culture processes: dielectric spectroscopy and focused beam reflectance measurement (FBRM). Methods Mol Biol 2014; 1104:313-341. [PMID: 24297424 DOI: 10.1007/978-1-62703-733-4_20] [Citation(s) in RCA: 5] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 06/02/2023]
Abstract
Modern bioprocesses demand for a careful definition of the critical process parameters (CPPs) already during the early stages of process development in order to ensure high-quality products and satisfactory yields. In this context, online monitoring tools can be applied to recognize unfavorable changes of CPPs during the production processes and to allow for early interventions in order to prevent losses of production batches due to quality issues. Process analytical technologies such as the dielectric spectroscopy or focused beam reflectance measurement (FBRM) are possible online monitoring tools, which can be applied to monitor cell growth as well as morphological changes. Since the dielectric spectroscopy only captures cells with intact cell membranes, even information about dead cells with ruptured or leaking cell membranes can be derived. The following chapter describes the application of dielectric spectroscopy on various virus-infected and non-infected cell lines with respect to adherent as well as suspension cultures in common stirred tank reactors. The adherent mammalian cell lines Vero (African green monkey kidney cells) and hMSC-TERT (telomerase-immortalized human mesenchymal stem cells) are thereby cultured on microcarrier, which provide the required growth surface and allow the cultivation of these cells even in dynamic culture systems. In turn, the insect-derived cell lines S2 and Sf21 are used as examples for cells typically cultured in suspension. Moreover, the FBRM technology as a further monitoring tool for cell culture applications has been included in this chapter using the example of Drosophila S2 insect cells.
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Affiliation(s)
- Damir Druzinec
- Institute of Bioprocess Engineering and Pharmaceutical Technology, University of Applied Sciences Mittelhessen, Giessen, Germany
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Ayyildiz-Tamis D, Avcı K, Deliloglu-Gurhan SI. Comparative investigation of the use of various commercial microcarriers as a substrate for culturing mammalian cells. In Vitro Cell Dev Biol Anim 2013; 50:221-31. [PMID: 24357035 DOI: 10.1007/s11626-013-9717-y] [Citation(s) in RCA: 11] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/09/2013] [Accepted: 11/27/2013] [Indexed: 11/24/2022]
Abstract
Microcarriers provide large adhesion area allowing high cell densities in bioreactor systems. This study focused on the investigation of cell adhesion and cell growth characteristics of both anchorage-dependent CHO-K1 and anchorage-independent Ag8 myeloma cell lines cultivated on four different microcarriers (Biosilon®, Microhex®, Cytodex 3®, Cytoline 2®) by considering the cell kinetics and physiological data. Experiments were performed in both static and agitated cell culture systems by using 24-well tissue culture plates and then 50-ml spinner flasks. In agitated cultures, the highest specific growth rates (0.026 h for CHO-K1 and 0.061 h for Ag8 cell line) were obtained with Cytodex 3® and Cytoline 2® microcarriers for CHO-K1 and Ag8 cell line, respectively. Metabolic characteristics showed some variation among the cultures with the four microcarriers. The most significant being the higher production of lactate with microcarriers with CHO-K1 cells relative to the Ag8 cells. SEM analyses revealed the differences in the morphology of the cells along with microcarriers. On Cytodex 3® and Cytoline 2®, CHO-K1 cells attached to the substratum through long, slender filopodia, whereas the cells showed a flat morphology by covering the substratum on the Biosilon® and Microhex®. Ag8 cells maintained their spherical shapes throughout the culture for all types of microcarriers. In an attempt to scale-up, productions were carried out in 50-ml spinner flasks. Cytodex 3® (for CHO-K1 cells) and Cytoline 2® (for Ag8 cells) were evaluated. The results demonstrate that high yield of biomass could be achieved through the immobilization of the cells in each culture system. And cell cultures on microcarriers, especially on Cytodex 3® and Cytoline 2®, represented a good potential as microcarriers for larger scale cultures of CHO-K1 and Ag8, respectively. Moreover, owing to the fact that the cell lines and culture media are specific, outcomes will be applicable for other clones derived from the same host cell lines.
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Affiliation(s)
- Duygu Ayyildiz-Tamis
- Engineering Faculty, Department of Bioengineering, Ege University, Izmir, 35100, Bornova, Turkey,
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Platas Barradas O, Jandt U, Minh Phan LD, Villanueva ME, Schaletzky M, Rath A, Freund S, Reichl U, Skerhutt E, Scholz S, Noll T, Sandig V, Pörtner R, Zeng AP. Evaluation of criteria for bioreactor comparison and operation standardization for mammalian cell culture. Eng Life Sci 2012. [DOI: 10.1002/elsc.201100163] [Citation(s) in RCA: 26] [Impact Index Per Article: 2.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/09/2022] Open
Affiliation(s)
- Oscar Platas Barradas
- Institute of Bioprocess and Biosystems Engineering; Hamburg University of Technology; Hamburg; Germany
| | - Uwe Jandt
- Institute of Bioprocess and Biosystems Engineering; Hamburg University of Technology; Hamburg; Germany
| | - Linh Da Minh Phan
- Institute of Bioprocess and Biosystems Engineering; Hamburg University of Technology; Hamburg; Germany
| | - Mario E. Villanueva
- Institute of Bioprocess and Biosystems Engineering; Hamburg University of Technology; Hamburg; Germany
| | - Martin Schaletzky
- Institute of Bioprocess and Biosystems Engineering; Hamburg University of Technology; Hamburg; Germany
| | - Alexander Rath
- Bioprocess Engineering; Max Planck Institute for Dynamics of Complex Technical Systems; Magdeburg; Germany
| | - Susann Freund
- Bioprocess Engineering; Max Planck Institute for Dynamics of Complex Technical Systems; Magdeburg; Germany
| | - Udo Reichl
- Bioprocess Engineering; Max Planck Institute for Dynamics of Complex Technical Systems; Magdeburg; Germany
| | - Eva Skerhutt
- Cell Culture Technology; Bielefeld University; Bielefeld; Germany
| | - Sebastian Scholz
- Cell Culture Technology; Bielefeld University; Bielefeld; Germany
| | - Thomas Noll
- Cell Culture Technology; Bielefeld University; Bielefeld; Germany
| | - Volker Sandig
- Chief Scientific Officer, ProBioGen AG; Berlin; Germany
| | - Ralf Pörtner
- Institute of Bioprocess and Biosystems Engineering; Hamburg University of Technology; Hamburg; Germany
| | - An-Ping Zeng
- Institute of Bioprocess and Biosystems Engineering; Hamburg University of Technology; Hamburg; Germany
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Couet F, Mantovani D. A new bioreactor adapts to materials state and builds a growth model for vascular tissue engineering. Artif Organs 2011; 36:438-45. [PMID: 22187974 DOI: 10.1111/j.1525-1594.2011.01388.x] [Citation(s) in RCA: 10] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Abstract
Bioreactors are a promising enabling technology for vascular tissue engineering. Beyond their value for the scale-up and manufacturing of tissue-engineered blood vessels, bioreactors represent a potential path toward the understanding of the regeneration process of tissues in vitro, toward the development of mathematical models for growth and remodeling in tissue engineering, and toward the study of pathological conditions. To achieve these promises, bioreactors must overcome the paradigm of a black box for the growth of tissues and become a tool for the study of growth in tissue engineering. An advanced control strategy was developed to study and maximize growth in bioreactors. The aim of this paper is to validate experimentally the ability of this controller to build knowledge during the culture of a tissue-engineered blood vessel. During the experiments, the controller proposed linear regression models, therefore making hypotheses on the parameters that influence growth; then, it chose experiments to refine these models, therefore verifying these hypotheses. These results show that tissue maturation in bioreactors can become more efficient by acquiring information about the process, and by dynamically adapting culture conditions according to this information input.
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Affiliation(s)
- Frédéric Couet
- Laboratory for Biomaterials and Bioengineering, Department of Materials Engineering and Research Centre, Quebec University Hospital, Laval University, Quebec City, Quebec, Canada
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