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Zhang K, Barbieri E, LeBarre J, Rameez S, Mostafa S, Menegatti S. Peptonics: A new family of cell-protecting surfactants for the recombinant expression of therapeutic proteins in mammalian cell cultures. Biotechnol J 2024; 19:e2300261. [PMID: 37844203 DOI: 10.1002/biot.202300261] [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: 06/02/2023] [Revised: 08/08/2023] [Accepted: 10/05/2023] [Indexed: 10/18/2023]
Abstract
Polymer surfactants are key components of cell culture media as they prevent mechanical damage during fermentation in stirred bioreactors. Among cell-protecting surfactants, Pluronics are widely utilized in biomanufacturing to ensure high cell viability and productivity. Monodispersity of monomer sequence and length is critical for the effectiveness of Pluronics-since minor deviations can damage the cells-but is challenging to achieve due to the stochastic nature of polymerization. Responding to this challenge, this study introduces Peptonics, a novel family of peptide and peptoid surfactants whose monomer composition and sequence are designed to achieve high cell viability and productivity at a fraction of chain length and cost of Pluronics. A designed ensemble of Peptonics was initially characterized via light scattering and tensiometry to select sequences whose phase behavior and tensioactivity align with those of Pluronics. Selected sequences were evaluated as cell-protecting surfactants using Chinese hamster ovary (CHO) cells expressing therapeutic monoclonal antibodies (mAb). Peptonics IH-T1010, ih-T1010, and ih-T1020 afforded high cell density (up to 3 × 107 cells mL-1 ) and viability (up to 95% within 10 days of culture), while reducing the accumulation of ammonia (a toxic metabolite) by ≈10% compared to Pluronic F-68. Improved cell viability afforded high mAb titer (up to 5.5 mg mL-1 ) and extended the production window beyond 14 days; notably, Peptonic IH-T1020 decreased mAb fragmentation and aggregation ≈5%, and lowered the titer of host cell proteins by 16% compared to Pluronic F-68. These features can improve significantly the purification of mAbs, thus increasing their availability at a lower cost to patients.
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Affiliation(s)
- Ka Zhang
- Department of Chemical and Biomolecular Engineering, North Carolina State University, Raleigh, North Carolina, USA
- KBI Biopharma, Durham, North Carolina, USA
| | - Eduardo Barbieri
- Department of Chemical and Biomolecular Engineering, North Carolina State University, Raleigh, North Carolina, USA
- LigaTrap Technologies LLC, Raleigh, North Carolina, USA
| | - Jacob LeBarre
- Department of Chemical and Biomolecular Engineering, North Carolina State University, Raleigh, North Carolina, USA
| | | | | | - Stefano Menegatti
- Department of Chemical and Biomolecular Engineering, North Carolina State University, Raleigh, North Carolina, USA
- LigaTrap Technologies LLC, Raleigh, North Carolina, USA
- Biomanufacturing Training and Education Center (BTEC), North Carolina State University, Raleigh, North Carolina, USA
- North Carolina Viral Vector Initiative in Research and Learning (NC-VVIRAL), North Carolina State University, Raleigh, North Carolina, USA
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Wei Z, Xia Y, Su Y, Quan Y, Sun L, Wang S, Zhu F, Chen Z, Tian J, Wang WC, Zhou W, Yu H. Modulating and optimizing Pluronic F-68 concentrations and feeding for intensified perfusion Chinese hamster ovary cell cultures. Biotechnol Prog 2023; 39:e3340. [PMID: 36970759 DOI: 10.1002/btpr.3340] [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: 10/16/2022] [Revised: 02/21/2023] [Accepted: 03/10/2023] [Indexed: 03/29/2023]
Abstract
Perfusion culture is often performed with micro-sparger to fulfill the high oxygen demand from the densified cells. Protective additive Pluronic F-68 (PF-68) is widely used to mitigate the adverse effect in cell viability from micro-sparging. In this study, different PF-68 retention ratio in alternating tangential filtration (ATF) columns was found to be crucial for cell performance of different perfusion culture modes. The PF-68 in the perfusion medium was found retained inside the bioreactor when exchanged through ATF hollow fibers with a small pore size (50 kD). The accumulated PF-68 could provide sufficient protection for cells under micro-sparging. On the other hand, with large-pore-size (0.2 μm) hollow fibers, PF-68 could pass through the ATF filtration membranes with little retention, and consequently led to compromised cell growth. To overcome the defect, a PF-68 feeding strategy was designed and successfully verified on promoting cell growth with different Chinese hamster ovary (CHO) cell lines. With PF-68 feeding, enhancements were observed in both viable cell densities (20%-30%) and productivity (~30%). A threshold PF-68 concentration of 5 g/L for high-density cell culture (up to 100 × 106 cells/mL) was also proposed and verified. The additional PF-68 feeding was not observed to affect product qualities. By designing the PF-68 concentration of perfusion medium to or higher than the threshold level, a similar cell growth enhancement was also achieved. This study systematically investigated the protecting role of PF-68 in intensified CHO cell cultures, shedding a light on the optimization of perfusion cultures through the control of protective additives.
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Affiliation(s)
- Zhaohui Wei
- Process Development, WuXi Biologics, 108 Meiliang Road, Wuxi, 214092, China
| | - Yang Xia
- Process Development, WuXi Biologics, 108 Meiliang Road, Wuxi, 214092, China
| | - Yuning Su
- Process Development, WuXi Biologics, 108 Meiliang Road, Wuxi, 214092, China
| | - Yufen Quan
- Process Development, WuXi Biologics, 108 Meiliang Road, Wuxi, 214092, China
| | - Liuliu Sun
- Process Development, WuXi Biologics, 108 Meiliang Road, Wuxi, 214092, China
| | - Shanshan Wang
- Process Development, WuXi Biologics, 108 Meiliang Road, Wuxi, 214092, China
| | - Fangjian Zhu
- Process Development, WuXi Biologics, 108 Meiliang Road, Wuxi, 214092, China
| | - Zhenzhen Chen
- Process Development, WuXi Biologics, 108 Meiliang Road, Wuxi, 214092, China
| | - Jun Tian
- Process Development, WuXi Biologics, 108 Meiliang Road, Wuxi, 214092, China
| | - Wei-Chun Wang
- Process Development, WuXi Biologics, 108 Meiliang Road, Wuxi, 214092, China
| | - Weichang Zhou
- WuXi Biologics, 299 Fute Zhong Road, Waigaoqiao Free Trade Zone, Shanghai, 200131, China
| | - Haiyang Yu
- Process Development, WuXi Biologics, 108 Meiliang Road, Wuxi, 214092, China
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Šrom O, Trávníková V, Bláha L, Ciofalo M, Šoóš M. Investigation of poloxamer cell protective ability via shear sensitive aggregates in stirred aerated bioreactor. Biochem Eng J 2022. [DOI: 10.1016/j.bej.2022.108549] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/02/2022]
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Grilo AL, Mantalaris A. Apoptosis: A mammalian cell bioprocessing perspective. Biotechnol Adv 2019; 37:459-475. [PMID: 30797096 DOI: 10.1016/j.biotechadv.2019.02.012] [Citation(s) in RCA: 98] [Impact Index Per Article: 19.6] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/16/2018] [Revised: 02/08/2019] [Accepted: 02/19/2019] [Indexed: 02/07/2023]
Abstract
Apoptosis is a form of programmed and controlled cell death that accounts for the majority of cellular death in bioprocesses. Cell death affects culture longevity and product quality; it is instigated by several stresses experienced by the cells within a bioreactor. Understanding the factors that cause apoptosis as well as developing strategies that can protect cells is crucial for robust bioprocess development. This review aims to a) address apoptosis from a bioprocess perspective; b) describe the significant apoptotic mechanisms linking them to the most relevant stresses encountered in bioreactors; c) discuss the design of operating conditions in order to avoid cell death; d) focus on industrially relevant cell lines; and e) present anti-apoptosis strategies including cell engineering and model-based optimization of bioprocesses. In addition, the importance of apoptosis in quality-by-design bioprocess development from clone screening to production scale are highlighted.
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Affiliation(s)
- Antonio L Grilo
- Biological Systems Engineering Laboratory, Centre for Process Systems Engineering, Department of Chemical Engineering, Imperial College London, Exhibition Road, London SW7 2AZ, United Kingdom.
| | - Athanasios Mantalaris
- Biological Systems Engineering Laboratory, Centre for Process Systems Engineering, Department of Chemical Engineering, Imperial College London, Exhibition Road, London SW7 2AZ, United Kingdom.
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Bareford L, Peng H, Ali A, Kolwyck D, Dickens J. Development of a rapid and reliable analytical method for screening poloxamer 188 for use in cell culture process. Biotechnol Prog 2019; 35:e2792. [PMID: 30816019 DOI: 10.1002/btpr.2792] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.6] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/10/2018] [Revised: 01/15/2019] [Accepted: 02/25/2019] [Indexed: 11/12/2022]
Abstract
Poloxamer P188 is a common nonionic surfactant additive used in cell culture media as a cellular protectant from the hydrodynamic forces and shear stress during bioprocessing. Presence of a hydrophobic high molecular weight impurity contaminant has been shown to compromise its protective properties and lead to batch failure. In this work we present, a reliable, sensitive, and rapid analytical method to detect and quantify the contaminant impurity in poloxamer 188. This method replaces a laborious and time-consuming functional test in the form of a shake flask assay. The method is based upon reversed-phase liquid chromatography with charged aerosol detection, simple mobile phase compositions, and a three-step gradient. The method was optimized to resolve the impurity from the main P188 fraction in less than 10 min. Analytical method qualification and functional test comparison demonstrate equivalent or better high throughput impurity screening performance. Attempts to identify the impurity and establish suitable method positive control standards are also discussed.
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Affiliation(s)
| | - Haofan Peng
- Manufacturing Sciences, Biogen, Davis, North Carolina
| | - Amr Ali
- Analytical Development, Biogen, Cambridge, Massachusetts
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Dickens J, Khattak S, Matthews TE, Kolwyck D, Wiltberger K. Biopharmaceutical raw material variation and control. Curr Opin Chem Eng 2018. [DOI: 10.1016/j.coche.2018.10.007] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/10/2023]
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Chang D, Fox R, Hicks E, Ferguson R, Chang K, Osborne D, Hu W, Velev OD. Investigation of interfacial properties of pure and mixed poloxamers for surfactant-mediated shear protection of mammalian cells. Colloids Surf B Biointerfaces 2017; 156:358-365. [DOI: 10.1016/j.colsurfb.2017.05.040] [Citation(s) in RCA: 11] [Impact Index Per Article: 1.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/30/2017] [Revised: 05/10/2017] [Accepted: 05/13/2017] [Indexed: 11/27/2022]
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Poellmann MJ, Lee RC. Repair and Regeneration of the Wounded Cell Membrane. REGENERATIVE ENGINEERING AND TRANSLATIONAL MEDICINE 2017. [DOI: 10.1007/s40883-017-0031-1] [Citation(s) in RCA: 10] [Impact Index Per Article: 1.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/28/2022]
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Impact of Pluronic ® F68 on hollow fiber filter-based perfusion culture performance. Bioprocess Biosyst Eng 2017; 40:1317-1326. [PMID: 28577048 DOI: 10.1007/s00449-017-1790-2] [Citation(s) in RCA: 16] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/19/2017] [Accepted: 05/24/2017] [Indexed: 10/19/2022]
Abstract
High cell density is an important factor in achieving high bioreactor productivity. To meet the oxygen demand with density at >100 × 106 cells/mL, a frit sparger is often used. In this study, the impact of Pluronic® F68 on a perfusion process using a frit sparger was studied. The perfusion process was developed using an alternating tangential flow device with a 0.2 µm PES hollow fiber filter. Pluronic® F68 at 2 g/L was sufficient in preventing cell damage at gas flow rate of ~0.20 vvm from a drilled hole sparger (0.5 mm) but inadequate at ~0.025 vvm from a frit sparger (20 µm). Increase of Pluronic® F68 concentration to 5 g/L prevented cell death at up to ~0.10 vvm from the frit sparger and was able to maintain high cell density at high viability in the range of 60-80 × 106 cells/mL. Such positive effect was demonstrated in both 3- and 200-L bioreactors. Supplementing additional Pluronic® F68 was also effective in restoring cell growth/viability from low viability cultures. Increased Pluronic® F68 concentration had no adverse impact on target antibody, HCP, and Pluronic® F68 transmissions.
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Kroll P, Eilers K, Fricke J, Herwig C. Impact of cell lysis on the description of cell growth and death in cell culture. Eng Life Sci 2016; 17:440-447. [PMID: 32624789 DOI: 10.1002/elsc.201600088] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/31/2016] [Revised: 07/18/2016] [Accepted: 09/23/2016] [Indexed: 11/08/2022] Open
Abstract
The primary task of process development is a process design that guarantees product quality and maximizes product quantity. One part of the process development is the identification of critical process parameters. Especially in cell culture processes, unwanted cell damage as critical process parameter is still challenging in stirred tank reactors and needs therefore to be considered. Nevertheless, this topic and its effects on process performance are currently not well discussed and not verified in literature until now. The process of cell damage or lysis can be defined as the loss of integrity of the cells. For the investigation of this phenomenon, a model-based designed fed-batch cultivation with Chinese hamster ovary cells was performed. Besides measurements of viable and dead cell concentration, lysed cell count was determined by DNA measurements. Based on these analytics, different hypotheses, characterizing the cell death, were compared. From this, four main statements could be derived: (i) consideration of lysis in cell culture processes is of great importance for the description of the living biomass population in terms of growth and dying; (ii) a higher effort in process monitoring facilitates significantly model development; (iii) in contradiction to existing models from literature, our verification approach demonstrated a direct correlation of lysis with viable cell concentration and therefore with productivity; and (iv) lysis could be effectively described by only one model parameter, the specific lysis rate from viable cells to lysed cells. All these statements could be accurately proven by statistical methods. Our results enable future detailed investigations of the causes of cell damage and the influences of cell lysis on product quality and quantity. Potential application fields are scale-up issues, process optimization, and impurity screening.
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Affiliation(s)
- Paul Kroll
- Institute of Biochemical Engineering Vienna University of Technology Vienna Austria.,CD Laboratory on Mechanistic and Physiological Methods for Improved Bioprocesses Vienna University of Technology Vienna Austria
| | - Kay Eilers
- CD Laboratory on Mechanistic and Physiological Methods for Improved Bioprocesses Vienna University of Technology Vienna Austria
| | - Jens Fricke
- Institute of Biochemical Engineering Vienna University of Technology Vienna Austria.,CD Laboratory on Mechanistic and Physiological Methods for Improved Bioprocesses Vienna University of Technology Vienna Austria
| | - Christoph Herwig
- Institute of Biochemical Engineering Vienna University of Technology Vienna Austria.,CD Laboratory on Mechanistic and Physiological Methods for Improved Bioprocesses Vienna University of Technology Vienna Austria
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