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Fang S, Sinanan DJ, Perez MH, Cruz-Quintero RG, Jadhav SR. Development of a high-throughput scale-down model in Ambr® 250 HT for plasmid DNA fermentation processes. Biotechnol Prog 2024; 40:e3458. [PMID: 38494959 DOI: 10.1002/btpr.3458] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/02/2024] [Revised: 02/28/2024] [Accepted: 03/06/2024] [Indexed: 03/19/2024]
Abstract
Recent advances in messenger ribonucleic acid (mRNA) vaccines and gene therapy vectors have increased the need for rapid plasmid DNA (pDNA) screening and production within the biopharmaceutical industry. High-throughput (HT) fermentor systems, such as the Ambr® 250 HT, can significantly accelerate process development timelines of pDNA upstream processes compared to traditional bench-scale glass fermentors or small-scale steam-in-place (SIP) fermentors. However, such scale-down models must be qualified to ensure that they are representative of the larger scale process similar to traditional small-scale models. In the current study, we developed a representative scale-down model of a Biostat® D-DCU 30 L pDNA fermentation process in Ambr® 250 HT fermentors using three cell lines producing three different constructs. The Ambr scale-down model provided comparable process performance and pDNA quality as the 30 L SIP fermentation process. In addition, we demonstrated the predictive value of the Ambr model by two-way qualification, first by accurately reproducing the prior trends observed in a 30 L process, followed by predicting new process trends that were then successfully reproduced in the 30 L process. The representative and predictive scale-down Ambr model developed in this study would enable a faster and more efficient approach to strain/clone/host-cell screening, pDNA process development and characterization studies, process scale-up studies, and manufacturing support.
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Affiliation(s)
- Shu Fang
- BioProcess Research & Development, Pfizer Inc., Chesterfield, Missouri, USA
| | - Dillon J Sinanan
- BioProcess Research & Development, Pfizer Inc., Chesterfield, Missouri, USA
| | - Marc H Perez
- BioProcess Research & Development, Pfizer Inc., Chesterfield, Missouri, USA
| | | | - Sachin R Jadhav
- BioProcess Research & Development, Pfizer Inc., Chesterfield, Missouri, USA
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2
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Karimi Alavijeh M, Lee YY, Gras SL. A perspective-driven and technical evaluation of machine learning in bioreactor scale-up: A case-study for potential model developments. Eng Life Sci 2024; 24:e2400023. [PMID: 38975020 PMCID: PMC11223373 DOI: 10.1002/elsc.202400023] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/29/2024] [Accepted: 03/01/2024] [Indexed: 07/09/2024] Open
Abstract
Bioreactor scale-up and scale-down have always been a topical issue for the biopharmaceutical industry and despite considerable effort, the identification of a fail-safe strategy for bioprocess development across scales remains a challenge. With the ubiquitous growth of digital transformation technologies, new scaling methods based on computer models may enable more effective scaling. This study aimed to evaluate the potential application of machine learning (ML) algorithms for bioreactor scale-up, with a specific focus on the prediction of scaling parameters. Factors critical to the development of such models were identified and data for bioreactor scale-up studies involving CHO cell-generated mAb products collated from the literature and public sources for the development of unsupervised and supervised ML models. Comparison of bioreactor performance across scales identified similarities between the different processes and primary differences between small- and large-scale bioreactors. A series of three case studies were developed to assess the relationship between cell growth and scale-sensitive bioreactor features. An embedding layer improved the capability of artificial neural network models to predict cell growth at a large-scale, as this approach captured similarities between the processes. Further models constructed to predict scaling parameters demonstrated how ML models may be applied to assist the scaling process. The development of data sets that include more characterization data with greater variability under different gassing and agitation regimes will also assist the future development of ML tools for bioreactor scaling.
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Affiliation(s)
- Masih Karimi Alavijeh
- Department of Chemical EngineeringThe University of MelbourneParkvilleVictoriaAustralia
- The Bio21 Molecular Science and Biotechnology InstituteThe University of MelbourneParkvilleVictoriaAustralia
| | | | - Sally L. Gras
- Department of Chemical EngineeringThe University of MelbourneParkvilleVictoriaAustralia
- The Bio21 Molecular Science and Biotechnology InstituteThe University of MelbourneParkvilleVictoriaAustralia
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3
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Anand A, McCahill M, Thomas J, Sood A, Kinross J, Dasgupta A, Rajendran A. An in-silico analysis of hydrodynamics and gas mass transfer characteristics in scale-down models for mammalian cell cultures. J Biotechnol 2024; 388:96-106. [PMID: 38642816 DOI: 10.1016/j.jbiotec.2024.04.013] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/06/2023] [Revised: 03/01/2024] [Accepted: 04/17/2024] [Indexed: 04/22/2024]
Abstract
Bioprocess scale-up and technology transfer can be challenging due to multiple variables that need to be optimized during process development from laboratory scale to commercial manufacturing. Cell cultures are highly sensitive to key factors during process transfer across scales, including geometric variability in bioreactors, shear stress from impeller and sparging activity, and nutrient gradients that occur due to increasing blend times. To improve the scale-up and scale-down of these processes, it is important to fully characterize bioreactors to better understand the differences that will occur within the culture environment, especially the hydrodynamic profiles that will vary in vessel designs across scales. In this study, a comprehensive hydrodynamic characterization of the Ambr® 250 mammalian single-use bioreactor was performed using time-accurate computational fluid dynamics simulations conducted with M-Star computational fluid dynamics software, which employs lattice-Boltzmann techniques to solve the Navier-Stokes transport equations at a mesoscopic scale. The single-phase and two-phase fluid properties within this small-scale vessel were analyzed in the context of agitation hydrodynamics and mass transfer (both within the bulk fluid and the free surface) to effectively characterize and understand the differences that scale-down models possess when compared to their large-scale counterparts. The model results validate the use of computational fluid dynamics as an in-silico tool to characterize bioreactor hydrodynamics and additionally identify important free-surface transfer mechanics that need to be considered during the qualification of a scale-down model in the development of mammalian bioprocesses.
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Affiliation(s)
- Alaina Anand
- Bioprocess Research and Development, Pfizer, Andover, MA 01810, USA
| | - Madelynn McCahill
- Manufacturing Sciences and Technology, Global Technology and Engineering, Pfizer, Andover, MA 01810, USA; Manufacturing Intelligence, Global Technology and Engineering, Pfizer, Andover, MA, USA
| | - John Thomas
- M-Star Simulations, 11000 Baltimore National Pike, Ellicott City, MD 21042, USA
| | - Aishwarya Sood
- Manufacturing Sciences and Technology, Global Technology and Engineering, Pfizer, Andover, MA 01810, USA
| | - Jonathan Kinross
- Manufacturing Sciences and Technology, Global Technology and Engineering, Pfizer, Andover, MA 01810, USA
| | - Aparajita Dasgupta
- Manufacturing Sciences and Technology, Global Technology and Engineering, Pfizer, Andover, MA 01810, USA.
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4
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Tamminen A, Turunen R, Barth D, Vidgren V, Wiebe MG. Use of ambr ®250 to assess mucic acid production in fed-batch cultures of a marine Trichoderma sp. D-221704. AMB Express 2022; 12:90. [PMID: 35831483 PMCID: PMC9279543 DOI: 10.1186/s13568-022-01436-4] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/01/2022] [Accepted: 07/06/2022] [Indexed: 11/10/2022] Open
Abstract
Mucic acid, a diacid with potential use in the food, cosmetic, chemical and pharmaceutical industries, can be produced by microbial conversion of D-galacturonic acid, which is abundant in pectin. Using the ambr®250 bioreactor system, we found that a recently generated transformant (D-221704, formerly referred to as T2) of a marine Trichoderma species produced up to 53 g L-1 mucic acid in glucose-limited fed-batch culture with D-galacturonic acid in the feed at pH 4, with a yield of 0.99 g mucic acid per g D-galacturonic acid consumed. Yeast extract was not essential for high production, but increased the initial production rate. Reducing the amount of glucose as the co-substrate reduced the amount of mucic acid produced to 31 g L-1. Mucic acid could also be produced at pH values less than 4.0 (3.5 and 3.0), but the amount produced was less than at pH 4.0. Furthermore, the yield of mucic acid on D-galacturonic acid at the end of the cultivations (0.5 to 0.7 g g-1) at these low pH levels suggested that recovery may be more difficult at lower pH on account of the high level of crystal formation. Another strain engineered to produce mucic acid, Trichoderma reesei D-161646, produced only 31 g L-1 mucic acid under the conditions used with D-221704.
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Affiliation(s)
- Anu Tamminen
- VTT Technical Research Centre of Finland Ltd, Tietotie 2, P.O. Box 1000, 02044, Espoo, Finland
| | - Rosaliina Turunen
- VTT Technical Research Centre of Finland Ltd, Tietotie 2, P.O. Box 1000, 02044, Espoo, Finland
| | - Dorothee Barth
- VTT Technical Research Centre of Finland Ltd, Tietotie 2, P.O. Box 1000, 02044, Espoo, Finland
| | - Virve Vidgren
- VTT Technical Research Centre of Finland Ltd, Tietotie 2, P.O. Box 1000, 02044, Espoo, Finland
| | - Marilyn G Wiebe
- VTT Technical Research Centre of Finland Ltd, Tietotie 2, P.O. Box 1000, 02044, Espoo, Finland.
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Rowland-Jones RC, Graf A, Woodhams A, Diaz-Fernandez P, Warr S, Soeldner R, Finka G, Hoehse M. Spectroscopy integration to miniature bioreactors and large scale production bioreactors-Increasing current capabilities and model transfer. Biotechnol Prog 2020; 37:e3074. [PMID: 32865874 DOI: 10.1002/btpr.3074] [Citation(s) in RCA: 14] [Impact Index Per Article: 3.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/27/2020] [Revised: 08/26/2020] [Accepted: 08/28/2020] [Indexed: 11/10/2022]
Abstract
Spectroscopy techniques are being implemented within the biopharmaceutical industry due to their non-destructive ability to measure multiple analytes simultaneously, however, minimal work has been applied focussing on their application at small scale. Miniature bioreactor systems are being applied across the industry for cell line development as they offer a high-throughput solution for screening and process optimization. The application of small volume, high-throughput, automated analyses to miniature bioreactors has the potential to significantly augment the type and quality of data from these systems and enhance alignment with large-scale bioreactors. Here, we present an evaluation of 1. a prototype that fully integrates spectroscopy to a miniature bioreactor system (ambr®15, Sartorius Stedim Biotech) enabling automated Raman spectra acquisition, 2. In 50 L single-use bioreactor bag (SUB) prototype with an integrated spectral window. OPLS models were developed demonstrating good accuracy for multiple analytes at both scales. Furthermore, the 50 L SUB prototype enabled on-line monitoring without the need for sterilization of the probe prior to use and minimal light interference was observed. We also demonstrate the ability to build robust models due to induced changes that are hard and costly to perform at large scale and the potential of transferring these models across the scales. The implementation of this technology enables integration of spectroscopy at the small scale for better process understanding and generation of robust models over a large design space while facilitating model transfer throughout the scales enabling continuity throughout process development and utilization and transfer of ever-increasing data generation from development to manufacturing.
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Affiliation(s)
- Ruth C Rowland-Jones
- Biopharm Process Research, Biopharm Product Development and Supply, GlaxoSmithKline R&D, Stevenage, UK
| | - Alexander Graf
- Product Development, PAT Corporate Research, Bioprocessing, Sartorius Stedim Biotech GmbH, Goettingen, Germany
| | - Angus Woodhams
- Hardware Development, The Automation Partnership (Cambridge) Limited, Hertfordshire, UK
| | - Paloma Diaz-Fernandez
- Biopharm Process Research, Biopharm Product Development and Supply, GlaxoSmithKline R&D, Stevenage, UK
| | - Steve Warr
- Biopharm Process Research, Biopharm Product Development and Supply, GlaxoSmithKline R&D, Stevenage, UK
| | - Robert Soeldner
- Product Development, PAT Corporate Research, Bioprocessing, Sartorius Stedim Biotech GmbH, Goettingen, Germany
| | - Gary Finka
- Biopharm Process Research, Biopharm Product Development and Supply, GlaxoSmithKline R&D, Stevenage, UK
| | - Marek Hoehse
- Product Development, PAT Corporate Research, Bioprocessing, Sartorius Stedim Biotech GmbH, Goettingen, Germany
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Xu S, Borys M, Khetan A, Pla I. Osmolality as a lever to modulate the N-glycolylneuraminicacid (Neu5Gc) level of a recombinant glycoprotein produced in Chinese hamster ovary cells. Biotechnol Prog 2020; 36:e3038. [PMID: 32542945 DOI: 10.1002/btpr.3038] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/12/2020] [Revised: 06/11/2020] [Accepted: 06/12/2020] [Indexed: 12/19/2022]
Abstract
Glycoproteins could be highly sialylated, and controlling the sialic acid levels for some therapeutic proteins is critical to ensure product consistency and efficacy. N-acetylneuraminic acid (Neu5Ac, or NANA) and N-glycolylneuraminic acid (Neu5Gc, or NGNA) are the two most common forms of sialic acids produced in mammalian cells. As Neu5Gc is not produced in humans and can elicit immune responses, minimizing Neu5Gc formation is important in controlling this quality attribute for complex glycoproteins. In this study, a sialylated glycoprotein was used as the model molecule to study the effect of culture osmolality on Neu5Gc. A 14-day fed-batch process with osmolality maintained at physiological levels produced high levels of Neu5Gc. Increase of culture osmolality reduced the Neu5Gc level up to 70-80%, and the effect was proportional to the osmolality level. Through evaluating different osmolality conditions (300-450 mOsm/kg) under low or high pCO2 , we demonstrated that osmolality could be an effective process lever to modulate the Neu5Gc level. Potential mechanism of osmolality impact on Neu5Gc is discussed and is hypothesized to be cytosol NADH availability related. Compared with cell line engineering efforts, this simple process lever provides the opportunity to readily modulate the Neu5Gc level in a cell culture environment.
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Affiliation(s)
- Sen Xu
- Biologics Development, Bristol Myers Squibb Co, New Brunswick, New Jersey, USA
| | - Michael Borys
- Biologics Development, Bristol Myers Squibb Co., Devens, Massachusetts, USA
| | - Anurag Khetan
- Biologics Development, Bristol Myers Squibb Co, New Brunswick, New Jersey, USA
| | - Itzcoatl Pla
- Manufacturing Science and Technology, Bristol Myers Squibb Co, Devens, Massachusetts, USA
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7
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Doi T, Kajihara H, Chuman Y, Kuwae S, Kaminagayoshi T, Omasa T. Development of a scale-up strategy for Chinese hamster ovary cell culture processes using the k L a ratio as a direct indicator of gas stripping conditions. Biotechnol Prog 2020; 36:e3000. [PMID: 32298540 DOI: 10.1002/btpr.3000] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/08/2020] [Revised: 03/31/2020] [Accepted: 04/03/2020] [Indexed: 01/18/2023]
Abstract
Herein, we described a scale-up strategy focused on the dissolved carbon dioxide concentration (dCO2 ) during fed-batch cultivation of Chinese hamster ovary cells. A fed-batch culture process for a 2000-L scale stainless steel (SS) bioreactor was scaled-up from similarly shaped 200-L scale bioreactors based on power input per unit volume (P/V). However, during the 2000-L fed-batch culture, the dCO2 was higher compared with the 200-L scale bioreactor. Therefore, we developed an alternative approach by evaluating the kL a values of O2 (kL a[O2 ]) and CO2 [kL a(CO2 )] in the SS bioreactors as a scale-up factor for dCO2 reduction. The kL a ratios [kL a(CO2 )/kL a(O2 )] were different between the 200-L and 2000-L bioreactors under the same P/V condition. When the agitation conditions were changed, the kL a ratio of the 2000-L scale bioreactor became similar and the P/V value become smaller compared with those of the 200-L SS bioreactor. The dCO2 trends in fed-batch cultures performed in 2000-L scale bioreactors under the modified agitation conditions were similar to the control. This kL a ratio method was used for process development in single-use bioreactors (SUBs) with shapes different from those of the SS bioreactor. The kL a ratios for the SUBs were evaluated and conditions that provided kL a ratios similar to the 200-L scale SS bioreactors were determined. The cell culture performance and product quality at the end of the cultivation process were comparable for all tested SUBs. Therefore, we concluded that the kL a ratio is a powerful scale-up factor useful to control dCO2 during fed-batch cultures.
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Affiliation(s)
- Tomohiro Doi
- Takeda Pharmaceutical Company Limited, Yamaguchi, Japan
| | | | - Yasuo Chuman
- Takeda Pharmaceutical Company Limited, Yamaguchi, Japan
| | - Shinobu Kuwae
- Takeda Pharmaceutical Company Limited, Yamaguchi, Japan.,Takeda Pharmaceutical Company Limited, Kanagawa, Japan
| | | | - Takeshi Omasa
- Institute of Bioscience and Bioindustry, Tokushima University, Tokushima, Japan.,Graduate School of Engineering, Osaka University, Osaka, Japan
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Zhang X, Jiang R, Lin H, Xu S. Feeding tricarboxylic acid cycle intermediates improves lactate consumption and antibody production in Chinese hamster ovary cell cultures. Biotechnol Prog 2020; 36:e2975. [PMID: 32012447 DOI: 10.1002/btpr.2975] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/29/2019] [Revised: 12/11/2019] [Accepted: 01/26/2020] [Indexed: 12/12/2022]
Abstract
Media components play an important role in modulating cell metabolism and improving product titer in mammalian cell cultures. To sustain cell productivity, highly active oxidative metabolism is desired. Here we explored the effect of tricarboxylic acid (TCA) cycle intermediates supplementation on lactate metabolism and productivity in Chinese hamster ovary fed-batch cultures. Direct addition of 5 mM alpha-ketoglutarate (α-KG), malic acid, or succinic acid in the basal medium did not have any significant impact on culture performance. On the other hand, feeding α-KG, malic acid, and succinic acid in the stationary phase, either as a single solution or as a mixture, significantly improved lactate consumption, reduced ammonium accumulation, and led to higher cell specific productivity and antibody titer (~35% increase for the best condition). Delivering those intermediates as an acidic solution for pH control eliminated CO2 sparging and accumulation. Feeding TCA cycle intermediates was also demonstrated to be superior to feeding lactic acid or pyruvic acid in titer improvement. Taken together, feeding TCA cycle intermediates was effective in improving lactate consumption and increasing product titer, which is likely due to enhanced oxidative metabolism in an extended duration.
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Affiliation(s)
- Xiaolin Zhang
- Biologics Process Research & Development, Process Research & Development, Merck & Co., Inc., Kenilworth, New Jersey
| | - Rubin Jiang
- Biologics Process Research & Development, Process Research & Development, Merck & Co., Inc., Kenilworth, New Jersey
| | - Henry Lin
- Biologics Process Research & Development, Process Research & Development, Merck & Co., Inc., Kenilworth, New Jersey
| | - Sen Xu
- Biologics Process Research & Development, Process Research & Development, Merck & Co., Inc., Kenilworth, New Jersey.,Biologics Development, Bristol-Myers Squibb Co., Pennington 08534, NJ
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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: 242] [Impact Index Per Article: 48.4] [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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