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Arduino Soft Sensor for Monitoring Schizochytrium sp. Fermentation, a Proof of Concept for the Industrial Application of Genome-Scale Metabolic Models in the Context of Pharma 4.0. Processes (Basel) 2022. [DOI: 10.3390/pr10112226] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022] Open
Abstract
Schizochytrium sp. is a microorganism cultured for producing docosahexaenoic acid (DHA). Genome-scale metabolic modeling (GEM) is a promising technique for describing gen-protein-reactions in cells, but with still limited industrial application due to its complexity and high computation requirements. In this work, we simplified GEM results regarding the relationship between the specific oxygen uptake rate (−rO2), the specific growth rate (µ), and the rate of lipid synthesis (rL) using an evolutionary algorithm for developing a model that can be used by a soft sensor for fermentation monitoring. The soft sensor estimated the concentration of active biomass (X), glutamate (N), lipids (L), and DHA in a Schizochytrium sp. fermentation using the dissolved oxygen tension (DO) and the oxygen mass transfer coefficient (kLa) as online input variables. The soft sensor model described the biomass concentration response of four reported experiments characterized by different kLa values. The average range normalized root-mean-square error for X, N, L, and DHA were equal to 1.1, 1.3, 1.1, and 3.2%, respectively, suggesting an acceptable generalization capacity. The feasibility of implementing the soft sensor over a low-cost electronic board was successfully tested using an Arduino UNO, showing a novel path for applying GEM-based soft sensors in the context of Pharma 4.0.
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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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Abstract
In recent years process modelling has become an established method which generates digital twins of manufacturing plant operation with the aid of numerically solved process models. This article discusses the benefits of establishing process modelling, in-house or by cooperation, in order to support the workflow from process development, piloting and engineering up to manufacturing. The examples are chosen from the variety of botanicals and biologics manufacturing thus proving the broad applicability from variable feedstock of natural plant extracts of secondary metabolites to fermentation of complex molecules like mAbs, fragments, proteins and peptides.Consistent models and methods to simulate whole processes are available. To determine the physical properties used as model parameters, efficient laboratory-scale experiments are implemented. These parameters are case specific since there is no database for complex molecules of biologics and botanicals in pharmaceutical industry, yet.Moreover, Quality-by-Design approaches, demanded by regulatory authorities, are integrated within those predictive modelling procedures. The models could be proven to be valid and predictive under regulatory aspects. Process modelling does earn its money from the first day of application. Process modelling is a key-enabling tool towards cost-efficient digitalization in chemical-pharmaceutical industries.
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Floris P, Dorival-García N, Lewis G, Josland G, Merriman D, Bones J. Real-time characterization of mammalian cell culture bioprocesses by magnetic sector MS. ANALYTICAL METHODS : ADVANCING METHODS AND APPLICATIONS 2020; 12:5601-5612. [PMID: 33179638 DOI: 10.1039/d0ay01563f] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 06/11/2023]
Abstract
Mammalian cell culture processes were characterized upon the analysis of the exhaust-gas composition achieved through the on-line integration of a magnetic sector MS analyser with benchtop bioreactors. The non-invasive configuration of the magnetic sector MS provided continuous evaluation of the bioreactor's exhaust gas filter integrity and facilitated the accurate quantification of O2 and CO2 levels in the off-gas stream which ensured preserved bioreactor sterility prior to cell inoculation and provided evidence of the ongoing cellular respiratory activity throughout the cultures. Real-time determination of process parameters such as the Respiratory Quotient (RQ) allowed for precise pin-pointing of the occurrence of shifts in cellular metabolism which were correlated to depletion of key nutrients in the growth medium, demonstrating the suitability of this technology for tracking cell culture process performance.
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Affiliation(s)
- Patrick Floris
- Characterisation and Comparability Laboratory, NIBRT-The National Institute for Bioprocessing Research and Training, Fosters avenue, Mount Merrion, Blackrock, Co. Dublin A94 X099, Ireland.
| | - Noemí Dorival-García
- Characterisation and Comparability Laboratory, NIBRT-The National Institute for Bioprocessing Research and Training, Fosters avenue, Mount Merrion, Blackrock, Co. Dublin A94 X099, Ireland.
| | - Graham Lewis
- Thermo Fisher Scientific, Ion Path, Road Three, Winsford, CW7 3GA, UK
| | - Graham Josland
- Thermo Fisher Scientific, Ion Path, Road Three, Winsford, CW7 3GA, UK
| | - Daniel Merriman
- Thermo Fisher Scientific, Ion Path, Road Three, Winsford, CW7 3GA, UK
| | - Jonathan Bones
- Characterisation and Comparability Laboratory, NIBRT-The National Institute for Bioprocessing Research and Training, Fosters avenue, Mount Merrion, Blackrock, Co. Dublin A94 X099, Ireland. and School of Chemical and Bioprocess Engineering, University College Dublin, Dublin 4, Belfield, D04 V1W8, Ireland
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Goh HY, Sulu M, Alosert H, Lewis GL, Josland GD, Merriman DE. Applications of off-gas mass spectrometry in fed-batch mammalian cell culture. Bioprocess Biosyst Eng 2019; 43:483-493. [PMID: 31709471 PMCID: PMC7007916 DOI: 10.1007/s00449-019-02242-2] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/13/2019] [Accepted: 10/28/2019] [Indexed: 11/30/2022]
Abstract
Off-gas analysis using a magnetic sector mass spectrometer was performed in mammalian cell cultures in the fed-batch mode at the 5 L bench and 50 L pilot scales. Factors affecting the MS gas traces were identified during the duration of the fed-batch cultures. Correlation between viable cell concentration (VCC) and oxygen concentration of the inlet gas into the bioreactor (O2-in) resulted in R2 ≈ 0.9; O2-in could be used as a proxy for VCC. Oxygen mass transfer (kLa) was also quantified throughout the culture period with antifoam addition at different time points which is shown to lower the kLa. Real-time specific oxygen consumption rate (qO2) of 2–20 pmol/cell/day throughout the bioreactor runs were within the range of values reported in literature for mammalian cell cultures. We also report, to our knowledge, the first instance of a distinct correlation between respiration quotient (RQ) and the metabolic state of the cell culture with regard to lactate production phase (average RQ > 1) and consumption phase (average RQ < 1).
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Affiliation(s)
- Hai-Yuan Goh
- The Advanced Centre for Biochemical Engineering, Department of Biochemical Engineering, University College London, Bernard Katz Building, Gordon Street, London, WC1H 0AH, UK
| | - Michael Sulu
- The Advanced Centre for Biochemical Engineering, Department of Biochemical Engineering, University College London, Bernard Katz Building, Gordon Street, London, WC1H 0AH, UK.
| | - Haneen Alosert
- The Advanced Centre for Biochemical Engineering, Department of Biochemical Engineering, University College London, Bernard Katz Building, Gordon Street, London, WC1H 0AH, UK
| | - Graham L Lewis
- Thermo Fisher Scientific, Ion Path, Road 3, Winsford, CW7 3GA, Cheshire, UK
| | - Graham D Josland
- Thermo Fisher Scientific, Ion Path, Road 3, Winsford, CW7 3GA, Cheshire, UK
| | - Daniel E Merriman
- Thermo Fisher Scientific, Ion Path, Road 3, Winsford, CW7 3GA, Cheshire, UK
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Goldrick S, Lee K, Spencer C, Holmes W, Kuiper M, Turner R, Farid SS. On-Line Control of Glucose Concentration in High-Yielding Mammalian Cell Cultures Enabled Through Oxygen Transfer Rate Measurements. Biotechnol J 2018; 13:e1700607. [DOI: 10.1002/biot.201700607] [Citation(s) in RCA: 26] [Impact Index Per Article: 4.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/20/2017] [Revised: 11/27/2017] [Indexed: 12/25/2022]
Affiliation(s)
- Stephen Goldrick
- The Advanced Centre of Biochemical Engineering, Department of Biochemical Engineering; University College London; Gower Street, WC1E 6BT London United Kingdom
- MedImmune; Milstein Building, Granta Park Cambridge, CB21 6GH United Kingdom
| | - Kenneth Lee
- MedImmune LLC; Gaithersburg Headquarters Gaithersburg MD 20878 USA
| | - Christopher Spencer
- MedImmune; Milstein Building, Granta Park Cambridge, CB21 6GH United Kingdom
| | - William Holmes
- MedImmune; Milstein Building, Granta Park Cambridge, CB21 6GH United Kingdom
| | - Marcel Kuiper
- MedImmune; Milstein Building, Granta Park Cambridge, CB21 6GH United Kingdom
| | - Richard Turner
- MedImmune; Milstein Building, Granta Park Cambridge, CB21 6GH United Kingdom
| | - Suzanne S. Farid
- The Advanced Centre of Biochemical Engineering, Department of Biochemical Engineering; University College London; Gower Street, WC1E 6BT London United Kingdom
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