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Ihling N, Berg C, Paul R, Munkler LP, Mäkinen MEL, Chotteau V, Büchs J. Scale-down of CHO cell cultivation from shake flasks based on oxygen mass transfer allows application of parallelized, non-invasive, and time-resolved monitoring of the oxygen transfer rate in 48-well microtiter plates. Biotechnol J 2023; 18:e2300053. [PMID: 37424196 DOI: 10.1002/biot.202300053] [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: 02/02/2023] [Revised: 06/23/2023] [Accepted: 07/06/2023] [Indexed: 07/11/2023]
Abstract
Cultivating Chinese hamster ovary (CHO) cells in microtiter plates (MTPs) with time-resolved monitoring of the oxygen transfer rate (OTR) is highly desirable to provide process insights at increased throughput. However, monitoring of the OTR in MTPs has not been demonstrated for CHO cells, yet. Hence, a CHO cultivation process was transferred from shake flasks to MTPs to enable monitoring of the OTR in each individual well of a 48-well MTP. For this, the cultivation of an industrially relevant, antibody-producing cell line was transferred from shake flask to MTP based on the volumetric oxygen mass transfer coefficient (kL a). Culture behavior was well comparable (deviation of the final IgG titer less than 10%). Monitoring of the OTR in 48-well MTPs was then used to derive the cytotoxicity of dimethyl sulfoxide (DMSO) based on a dose-response curve in a single experiment using a second CHO cell line. Logistic fitting of the dose-response curve determined after 100 h was used to determine the DMSO concentration that resulted in a cytotoxicity of 50% (IC50). A DMSO concentration of 2.70% ± 0.25% was determined, which agrees with the IC50 previously determined in shake flasks (2.39% ± 0.1%). Non-invasive, parallelized, and time-resolved monitoring of the OTR of CHO cells in MTPs was demonstrated and offers excellent potential to speed up process development and assess cytotoxicity.
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Affiliation(s)
- Nina Ihling
- AVT - Biochemical Engineering, RWTH Aachen University, Aachen, Germany
| | - Christoph Berg
- AVT - Biochemical Engineering, RWTH Aachen University, Aachen, Germany
| | - Richard Paul
- AVT - Biochemical Engineering, RWTH Aachen University, Aachen, Germany
| | | | - Meeri E-L Mäkinen
- KTH Royal Institute of Technology, Department of Industrial Biotechnology, School of Engineering Sciences in Chemistry, Biotechnology and Health, Stockholm, Sweden
| | - Veronique Chotteau
- KTH Royal Institute of Technology, Department of Industrial Biotechnology, School of Engineering Sciences in Chemistry, Biotechnology and Health, Stockholm, Sweden
- AdBIOPRO, Competence Centre for Advanced BioProduction by Continuous Processing, KTH, Stockholm, Sweden
| | - Jochen Büchs
- AVT - Biochemical Engineering, RWTH Aachen University, Aachen, Germany
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Tingaud V, Bordes C, Al Mouazen E, Cogné C, Bolzinger MA, Lawton P. Experimental studies from shake flasks to 3 L stirred tank bioreactor of nutrients and oxygen supply conditions to improve the growth of the avian cell line DuckCelt®-T17. J Biol Eng 2023; 17:31. [PMID: 37095522 PMCID: PMC10127095 DOI: 10.1186/s13036-023-00349-5] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/09/2023] [Accepted: 04/04/2023] [Indexed: 04/26/2023] Open
Abstract
BACKGROUND To produce viral vaccines, avian cell lines are interesting alternatives to replace the egg-derived processes for viruses that do not grow well on mammalian cells. The avian suspension cell line DuckCelt®-T17 was previously studied and investigated to produce a live attenuated metapneumovirus (hMPV)/respiratory syncytial virus (RSV) and influenza virus vaccines. However, a better understanding of its culture process is necessary for an efficient production of viral particles in bioreactors. RESULTS The growth and metabolic requirements of the avian cell line DuckCelt®-T17 were investigated to improve its cultivation parameters. Several nutrient supplementation strategies were studied in shake flasks highlighting the interest of (i) replacing L-glutamine by glutamax as main nutrient or (ii) adding these two nutrients in the serum-free growth medium in a fed-batch strategy. The scale-up in a 3 L bioreactor was successful for these types of strategies confirming their efficiencies in improving the cells' growth and viability. Moreover, a perfusion feasibility test allowed to achieve up to ~ 3 times the maximum number of viable cells obtained with the batch or fed-batch strategies. Finally, a strong oxygen supply - 50% dO2 - had a deleterious effect on DuckCelt®-T17 viability, certainly because of the greater hydrodynamic stress imposed. CONCLUSIONS The culture process using glutamax supplementation with a batch or a fed-batch strategy was successfully scaled-up to 3 L bioreactor. In addition, perfusion appeared as a very promising culture process for subsequent continuous virus harvesting.
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Affiliation(s)
- Valentine Tingaud
- LAGEPP, Laboratoire d'Automatique, de Génie des Procédés et de Génie Pharmaceutique, GePharm Team, Université Claude Bernard Lyon 1, CNRS UMR5007, 43 Boulevard du 11 Novembre 1918, Villeurbanne CEDEX, 69622, France
| | - Claire Bordes
- LAGEPP, Laboratoire d'Automatique, de Génie des Procédés et de Génie Pharmaceutique, GePharm Team, Université Claude Bernard Lyon 1, CNRS UMR5007, 43 Boulevard du 11 Novembre 1918, Villeurbanne CEDEX, 69622, France
| | - Eyad Al Mouazen
- LAGEPP, Laboratoire d'Automatique, de Génie des Procédés et de Génie Pharmaceutique, GePharm Team, Université Claude Bernard Lyon 1, CNRS UMR5007, 43 Boulevard du 11 Novembre 1918, Villeurbanne CEDEX, 69622, France
| | - Claudia Cogné
- LAGEPP, Laboratoire d'Automatique, de Génie des Procédés et de Génie Pharmaceutique, GePharm Team, Université Claude Bernard Lyon 1, CNRS UMR5007, 43 Boulevard du 11 Novembre 1918, Villeurbanne CEDEX, 69622, France
| | - Marie-Alexandrine Bolzinger
- LAGEPP, Laboratoire d'Automatique, de Génie des Procédés et de Génie Pharmaceutique, GePharm Team, Université Claude Bernard Lyon 1, CNRS UMR5007, 43 Boulevard du 11 Novembre 1918, Villeurbanne CEDEX, 69622, France
| | - Philippe Lawton
- LAGEPP, Laboratoire d'Automatique, de Génie des Procédés et de Génie Pharmaceutique, GePharm Team, Université Claude Bernard Lyon 1, CNRS UMR5007, 43 Boulevard du 11 Novembre 1918, Villeurbanne CEDEX, 69622, France.
- Laboratoire d'Automatique, de Génie des Procédés et de Génie Pharmaceutique, Université Claude Bernard Lyon 1, ISPB, 8 avenue Rockefeller, Lyon, 69373, CEDEX 08, France.
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Tan Z, Guan Y, Luo Y, Wang L, Zhou H, Yang C, Meng D, Chen Y. Evaluation of the stability of shortcut nitrification-denitrification process based on online specific oxygen uptake rate monitoring. CHINESE CHEM LETT 2022. [DOI: 10.1016/j.cclet.2022.108074] [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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Trout M, Harcum SW, Groff RE. Sensitive real-time on-line estimator for oxygen transfer rates in fermenters. J Biotechnol 2022; 358:92-101. [PMID: 36116734 DOI: 10.1016/j.jbiotec.2022.09.005] [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: 06/03/2022] [Accepted: 09/12/2022] [Indexed: 11/16/2022]
Abstract
Recombinant Escherichia coli grown in large-scale fermenters are used extensively to produce plasmids and biopharmaceuticals. One method commonly used to control culture growth is predefined glucose feeding, often an exponential feeding profile. Predefined feeding profiles cannot adjust automatically to metabolic state changes, such as the metabolic burden associated with recombinant protein expression or high-cell density associated stresses. As the culture oxygen consumption rates indicates a culture's metabolic state, there exist several methods to estimate the oxygen uptake rate (OUR). These common OUR methods have limited application since these approaches either disrupt the oxygen supply, rely on empirical relationships, or are unable to account for latency and filtering effects. In this study, an oxygen transfer rate (OTR) estimator was developed to aid OUR prediction. This non-disruptive OTR estimator uses the dissolved oxygen and the off-gas oxygen concentration, in parallel. This new OTR estimator captures small variations in OTR due to physical and chemical manipulations of the fermenter, such as in stir speed variation, glucose feeding rate change, and recombinant protein expression. Due its sensitivity, this non-disruptive real-time OTR estimator could be integrated with feed control algorithms to maintain the metabolic state of a culture to a desired setpoint.
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Affiliation(s)
- Marshall Trout
- Department of Electrical and Computer Engineering, Clemson University, Clemson, SC 29634, United States
| | - Sarah W Harcum
- Department of Bioengineering, Clemson University, Clemson, SC 29634, United States.
| | - Richard E Groff
- Department of Electrical and Computer Engineering, Clemson University, Clemson, SC 29634, United States
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Martínez-Monge I, Martínez C, Decker M, Udugama IA, Marín de Mas I, Gernaey KV, Nielsen LK. Soft-sensors application for automated feeding control in high-throughput mammalian cell cultures. Biotechnol Bioeng 2022; 119:1077-1090. [PMID: 35005786 DOI: 10.1002/bit.28032] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/18/2021] [Revised: 01/03/2022] [Accepted: 01/04/2022] [Indexed: 11/07/2022]
Abstract
The ever-increasing demand for biopharmaceuticals has created the need for improving the overall productivity of culture processes. One such operational concept that is considered is fed-batch operations as opposed to batch operations. However, optimal fed-batch operations require complete knowledge of the cell culture to optimize the culture conditions and the nutrients feeding. For example, when using high-throughput small-scale bioreactors to test multiple clones that do not behave the same, depletion or overfeeding of some key components can occur if the feeding strategy is not individually optimized. Over the recent years, various solutions for real-time measuring of the main cell culture metabolites have been proposed. Still, the complexity in the implementation of these techniques has limited their use. Soft-sensors present an opportunity to overcome these limitations by indirectly estimate these variables in real-time. This manuscript details the development of a new soft-sensor based fed-batch strategy to maintain substrate concentration (glucose and glutamine) at optimal levels in small-scale multi parallel CHO cultures. Two alternatives to the standard feeding strategy were tested: an OUR soft-sensor-based strategy for glucose and glutamine (Strategy 1) and a dual OUR for glutamine and CO2 /alkali addition for glucose soft-sensor strategy (Strategy 2). The results demonstrated the applicability of the OUR soft-sensor based strategy to optimize glucose and glutamine feedings, which yielded a 21% increase in final viable cell density (VCD) and a 31% in erythropoietin (EPO) titer compared with the reference one. However, CO2/alkali addition soft-sensor suffered from insufficient data to relate alkali addition with glucose consumption. As a result, the culture was overfed with glucose resulting in a 4% increase on final VCD, but a 9% decrease in final titer compared to the Reference Strategy. This article is protected by copyright. All rights reserved.
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Affiliation(s)
- I Martínez-Monge
- The Novo Nordisk Foundation Center for Biosustainability, Technical University of Denmark, DK-2800, Kongens, Lyngby, Denmark
| | - C Martínez
- The Novo Nordisk Foundation Center for Biosustainability, Technical University of Denmark, DK-2800, Kongens, Lyngby, Denmark
| | - M Decker
- The Novo Nordisk Foundation Center for Biosustainability, Technical University of Denmark, DK-2800, Kongens, Lyngby, Denmark
| | - I A Udugama
- Department of Chemical and Biochemical Engineering, Technical University of Denmark, DK-2800, Kongens, Lyngby, Denmark
| | - I Marín de Mas
- The Novo Nordisk Foundation Center for Biosustainability, Technical University of Denmark, DK-2800, Kongens, Lyngby, Denmark
| | - K V Gernaey
- Department of Chemical and Biochemical Engineering, Technical University of Denmark, DK-2800, Kongens, Lyngby, Denmark
| | - L K Nielsen
- The Novo Nordisk Foundation Center for Biosustainability, Technical University of Denmark, DK-2800, Kongens, Lyngby, Denmark
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Ihling N, Munkler LP, Berg C, Reichenbächer B, Wirth J, Lang D, Wagner R, Büchs J. Time-Resolved Monitoring of the Oxygen Transfer Rate of Chinese Hamster Ovary Cells Provides Insights Into Culture Behavior in Shake Flasks. Front Bioeng Biotechnol 2021; 9:725498. [PMID: 34513814 PMCID: PMC8423908 DOI: 10.3389/fbioe.2021.725498] [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: 06/15/2021] [Accepted: 08/12/2021] [Indexed: 11/13/2022] Open
Abstract
Cultivations of mammalian cells are routinely conducted in shake flasks. In contrast to instrumented bioreactors, reliable options for non-invasive, time-resolved monitoring of the culture status in shake flasks are lacking. The Respiration Activity Monitoring Respiration Activity Monitoring System system was used to determine the oxygen transfer rate (OTR) in shake flasks. It was proven that the OTR could be regarded as equal to the oxygen uptake rate as the change of the dissolved oxygen concentration in the liquid phase over time was negligibly small. Thus, monitoring the oxygen transfer rate (OTR) was used to increase the information content from shake flask experiments. The OTR of a Chinese hamster ovary cell line was monitored by applying electrochemical sensors. Glass flasks stoppered with cotton plugs and polycarbonate flasks stoppered with vent-caps were compared in terms of mass transfer characteristics and culture behavior. Similar mass transfer resistances were determined for both sterile closures. The OTR was found to be well reproducible within one experiment (standard deviation <10%). It correlated with changes in cell viability and depletion of carbon sources, thus, giving more profound insights into the cultivation process. Culture behavior in glass and polycarbonate flasks was identical. Monitoring of the OTR was applied to a second culture medium. Media differed in the maximum OTR reached during cultivation and in the time when all carbon sources were depleted. By applying non-invasive, parallelized, time-resolved monitoring of the OTR, the information content and amount of data from shake flask experiments was significantly increased compared to manual sampling and offline analysis. The potential of the technology for early-stage process development was demonstrated.
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Affiliation(s)
- Nina Ihling
- AVT-Biochemical Engineering, RWTH Aachen University, Aachen, Germany
| | | | - Christoph Berg
- AVT-Biochemical Engineering, RWTH Aachen University, Aachen, Germany
| | | | | | | | | | - Jochen Büchs
- AVT-Biochemical Engineering, RWTH Aachen University, Aachen, Germany
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Fung Shek C, Betenbaugh M. Taking the pulse of bioprocesses: at-line and in-line monitoring of mammalian cell cultures. Curr Opin Biotechnol 2021; 71:191-197. [PMID: 34454382 DOI: 10.1016/j.copbio.2021.08.007] [Citation(s) in RCA: 9] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/27/2021] [Revised: 08/01/2021] [Accepted: 08/06/2021] [Indexed: 01/01/2023]
Abstract
Real-time and near real-time monitoring of cell culture processes are critical to the evolving process analytical technology (PAT) paradigm for upstream bioprocessing. The responses measured from these analytical instruments can enable rapid feedback to perturbations that can otherwise lead to batch failures. Historically, real-time monitoring of bioreactor processes has been relegated to parameters such as pH, dissolved oxygen, and temperature. Other analytical results, such as cell growth and metabolites, are provided through manual daily sampling. In order to reduce sample error and increase throughput, real-time and near real-time instruments have been developed. Here we discuss recent advances in these technologies. This article aims to focus on other developing at-line and in-line technologies that enable monitoring of bioreactor processes, including dielectric spectroscopy, NIR, off-gas spectrometry, integrated at-line HPLC, and nanofluidic devices for monitoring cell growth and health, metabolites, titer, and product quality.
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Affiliation(s)
- Coral Fung Shek
- Department of Chemical and Biomolecular Engineering, Johns Hopkins University, 3400 North Charles Street, Baltimore, MD 21218, United States; Pivotal Bioprocess Sciences and Technologies, Amgen, 360 Binney Street, Cambridge, MA 02141, United States.
| | - Michael Betenbaugh
- Department of Chemical and Biomolecular Engineering, Johns Hopkins University, 3400 North Charles Street, Baltimore, MD 21218, United States
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Seidel S, Maschke RW, Werner S, Jossen V, Eibl D. Oxygen Mass Transfer in Biopharmaceutical Processes: Numerical and Experimental Approaches. CHEM-ING-TECH 2020. [DOI: 10.1002/cite.202000179] [Citation(s) in RCA: 14] [Impact Index Per Article: 3.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/11/2022]
Affiliation(s)
- Stefan Seidel
- Zurich University of Applied Sciences School of Life Sciences and Facility Management Institute of Chemistry and Biotechnology Grüentalstrasse 14 8820 Wädenswil Switzerland
| | - Rüdiger W. Maschke
- Zurich University of Applied Sciences School of Life Sciences and Facility Management Institute of Chemistry and Biotechnology Grüentalstrasse 14 8820 Wädenswil Switzerland
| | - Sören Werner
- Zurich University of Applied Sciences School of Life Sciences and Facility Management Institute of Chemistry and Biotechnology Grüentalstrasse 14 8820 Wädenswil Switzerland
| | - Valentin Jossen
- Zurich University of Applied Sciences School of Life Sciences and Facility Management Institute of Chemistry and Biotechnology Grüentalstrasse 14 8820 Wädenswil Switzerland
| | - Dieter Eibl
- Zurich University of Applied Sciences School of Life Sciences and Facility Management Institute of Chemistry and Biotechnology Grüentalstrasse 14 8820 Wädenswil Switzerland
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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: 237] [Impact Index Per Article: 47.4] [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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