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Vitharana S, Stillahn JM, Katayama DS, Henry CS, Manning MC. Application of Formulation Principles to Stability Issues Encountered During Processing, Manufacturing, and Storage of Drug Substance and Drug Product Protein Therapeutics. J Pharm Sci 2023; 112:2724-2751. [PMID: 37572779 DOI: 10.1016/j.xphs.2023.08.003] [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: 10/14/2022] [Revised: 07/24/2023] [Accepted: 08/07/2023] [Indexed: 08/14/2023]
Abstract
The field of formulation and stabilization of protein therapeutics has become rather extensive. However, most of the focus has been on stabilization of the final drug product. Yet, proteins experience stress and degradation through the manufacturing process, starting with fermentaition. This review describes how formulation principles can be applied to stabilize biopharmaceutical proteins during bioprocessing and manufacturing, considering each unit operation involved in prepration of the drug substance. In addition, the impact of the container on stabilty is discussed as well.
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Affiliation(s)
| | - Joshua M Stillahn
- Legacy BioDesign LLC, Johnstown, CO 80534, USA; Department of Chemistry, Colorado State University, Fort Collins, CO 80523, USA
| | | | - Charles S Henry
- Department of Chemistry, Colorado State University, Fort Collins, CO 80523, USA
| | - Mark Cornell Manning
- Legacy BioDesign LLC, Johnstown, CO 80534, USA; Department of Chemistry, Colorado State University, Fort Collins, CO 80523, USA.
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Suh D, Kim M, Lee C, Baek Y. Virus filtration in biopharmaceutical downstream processes: key factors and current limitations. SEPARATION & PURIFICATION REVIEWS 2022. [DOI: 10.1080/15422119.2022.2143379] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/16/2022]
Affiliation(s)
- Dongwoo Suh
- School of Chemical and Biological Engineering, College of Engineering, Institute of Chemical Process (ICP), Seoul National University (SNU), Gwanak-gu, Republic of Korea
| | - Mina Kim
- Department of Biotechnology, Institute of Basic Science, Sungshin Women’s University, Seoul, Republic of Korea
| | - Changha Lee
- School of Chemical and Biological Engineering, College of Engineering, Institute of Chemical Process (ICP), Seoul National University (SNU), Gwanak-gu, Republic of Korea
| | - Youngbin Baek
- Department of Biological Engineering, Inha University, Incheon, Republic of Korea
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Busto M, Tarifa EE, Cristaldi M, Badano JM, Vera CR. Simulation of thermal sanitization of air with heat recovery as applied to airborne pathogen deactivation. INTERNATIONAL JOURNAL OF ENVIRONMENTAL SCIENCE AND TECHNOLOGY : IJEST 2022; 19:11685-11698. [PMID: 35126566 PMCID: PMC8801388 DOI: 10.1007/s13762-022-03948-9] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 06/06/2021] [Revised: 11/28/2021] [Accepted: 01/10/2022] [Indexed: 05/02/2023]
Abstract
The technique of air sterilization by thermal effect was revisited in this work. The impact of incorporating a high efficiency heat recovery exchanger to a sterilizing cell was especially assessed. A mathematical model was developed to study the dynamics and the steady state of the sterilizer. Computer simulation and reported data of thermal inactivation of pathogens permitted obtaining results for a proof-of-concept. The simulation results confirmed that the incorporation of a heat recovery exchanger permits saving more than 90% of the energy needed to heat the air to the temperature necessary for sterilization, i.e., sterilization without heat recovery consumes 10-20 times the energy of the same sterilization device with heat recovery. Sanitization temperature is the main process variable for sanitization, a fact related to the activated nature of the thermal inactivation of viruses and bacteria. Heat recovery efficiency was a strong function of the heat transfer parameters but also rather insensitive to the cell temperature. The heat transfer area determined the maximum capacity of the sterilizer (maximum air flowrate) given the restrictions of minimum sanitization efficiency and maximum power consumption. The proposed thermal sterilization device has important advantages of robustness and simplicity over other commercial sterilization devices, needing practically no maintenance and eliminating a big variety of microorganisms to any desired degree. For most pathogens, the inactivation can be total. This result is not affected by the uncertainties in thermal inactivation data, due to the Arrhenius-like dependence of inactivation. Temperature can be adjusted to achieve any removal degree.
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Affiliation(s)
- M. Busto
- Institute of Research On Catalysis and Petrochemistry, INCAPE, FIQ-UNL, CONICET, Collecting Ring, National Road 168 km 0, El Pozo, 3000 Santa Fe, Argentina
| | - E. E. Tarifa
- Faculty of Engineering, Universidad Nacional de Jujuy, CONICET, Ítalo Palanca No. 10, 4600 San Salvador de Jujuy, Argentina
| | - M. Cristaldi
- Av. Gob. Gregores & Piloto Rivera, Universidad Nacional de La Patagonia Austral, 9400 Río Gallegos, Argentina
| | - J. M. Badano
- Institute of Research On Catalysis and Petrochemistry, INCAPE, FIQ-UNL, CONICET, Collecting Ring, National Road 168 km 0, El Pozo, 3000 Santa Fe, Argentina
| | - C. R. Vera
- Institute of Research On Catalysis and Petrochemistry, INCAPE, FIQ-UNL, CONICET, Collecting Ring, National Road 168 km 0, El Pozo, 3000 Santa Fe, Argentina
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Manukyan L, Mantas A, Razumikhin M, Katalevsky A, Golubev E, Mihranyan A. Two-Step Size-Exclusion Nanofiltration of Prothrombin Complex Concentrate Using Nanocellulose-Based Filter Paper. Biomedicines 2020; 8:E69. [PMID: 32224972 PMCID: PMC7235758 DOI: 10.3390/biomedicines8040069] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/29/2020] [Revised: 03/16/2020] [Accepted: 03/21/2020] [Indexed: 02/06/2023] Open
Abstract
Coagulation Factor IX-rich protrhombin complex concentrate (FIX-PCC) is a therapeutic biologic product that consists of a mixture of several human plasma-derived proteins, useful for treating hemophilia B. Due to its complex composition, FIX-PCC is very challenging to bioprocess through virus removing nanofilters in order to ensure its biosafety. This article describes a two-step filtration process of FIX-PCC using a nanocellulose-based filter paper with tailored porosity. The filters were characterized with scanning electron microscopy (SEM), cryoporometry with differential scanning calorimetry, and nitrogen gas sorption. Furthermore, in order to probe the filter's cut-off size rejection threshold, removal of small- and large-size model viruses, i.e., ΦX174 (28 nm) and PR772 (70 nm), was evaluated. The feed, pre-filtrate, and permeate solutions were characterized with mass-spectrometric proteomic analysis, dynamic light scattering (DLS), sodium dodecyl sulfate-polyacrylamide gel electrophoresis (SDS-PAGE), and analytical size-exclusion high-performance liquid chromatography (SEHPLC). By sequential filtration through 11 μm pre-filter and 33 μm virus removal filter paper, it was possible to achieve high product throughput and high virus removal capacity. The presented approach could potentially be applied for bioprocessing other protein-based drugs.
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Affiliation(s)
- Levon Manukyan
- Nanotechnology and Functional Materials, Department of Materials Science and Engineering, Uppsala University, Box 534, 751 21 Uppsala, Sweden; (L.M.); (A.M.)
| | - Athanasios Mantas
- Nanotechnology and Functional Materials, Department of Materials Science and Engineering, Uppsala University, Box 534, 751 21 Uppsala, Sweden; (L.M.); (A.M.)
| | | | | | - Eugen Golubev
- National Research Center for Hematology, Novyi Zykovskiy proezd 4, 125167 Moscow, Russia;
| | - Albert Mihranyan
- Nanotechnology and Functional Materials, Department of Materials Science and Engineering, Uppsala University, Box 534, 751 21 Uppsala, Sweden; (L.M.); (A.M.)
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Pazouki M, Noelle Wilton A, Latulippe DR. An experimental study on sterile filtration of fluorescently labeled nanoparticles – the importance of surfactant concentration. Sep Purif Technol 2019. [DOI: 10.1016/j.seppur.2019.02.038] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/15/2022]
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Ma S, Pang GL, Shao YJ, Hongo-Hirasaki T, Shang MX, Inouye M, Jian CY, Zhu MZ, Yang HH, Gao JF, Xi ZY, Song DW. Validation and implementation of Planova™ BioEX virus filters in the manufacture of a new liquid intravenous immunoglobulin in China. Biologicals 2018; 52:37-43. [DOI: 10.1016/j.biologicals.2018.01.004] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/20/2017] [Revised: 01/17/2018] [Accepted: 01/21/2018] [Indexed: 11/30/2022] Open
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Kosiol P, Hansmann B, Ulbricht M, Thom V. Determination of pore size distributions of virus filtration membranes using gold nanoparticles and their correlation with virus retention. J Memb Sci 2017. [DOI: 10.1016/j.memsci.2017.03.043] [Citation(s) in RCA: 20] [Impact Index Per Article: 2.9] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/19/2022]
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Junter GA, Lebrun L. Cellulose-based virus-retentive filters: a review. RE/VIEWS IN ENVIRONMENTAL SCIENCE AND BIO/TECHNOLOGY 2017; 16:455-489. [PMID: 32214924 PMCID: PMC7088658 DOI: 10.1007/s11157-017-9434-1] [Citation(s) in RCA: 24] [Impact Index Per Article: 3.4] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 04/20/2023]
Abstract
Viral filtration is a critical step in the purification of biologics and in the monitoring of microbiological water quality. Viral filters are also essential protection elements against airborne viral particles. The present review first focuses on cellulose-based filter media currently used for size-exclusion and/or adsorptive filtration of viruses from biopharmaceutical and environmental water samples. Data from spiking studies quantifying the viral filtration performance of cellulosic filters are detailed, i.e., first, the virus reduction capacity of regenerated cellulose hollow fiber filters in the manufacturing process of blood products and, second, the efficiency of virus recovery/concentration from water samples by the viradel (virus adsorption-elution) method using charge modified, electropositive cellulosic filters or conventional electronegative cellulose ester microfilters. Viral analysis of field water samples by the viradel technique is also surveyed. This review then describes cellulose-based filter media used in individual protection equipment against airborne viral pathogens, presenting innovative filtration media with virucidal properties. Some pros and cons of cellulosic viral filters and perspectives for cellulose-based materials in viral filtration are underlined in the review.
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Affiliation(s)
- Guy-Alain Junter
- Normandie Univ, UNIROUEN Normandie, INSA Rouen, CNRS, PBS, 76000 Rouen, France
| | - Laurent Lebrun
- Normandie Univ, UNIROUEN Normandie, INSA Rouen, CNRS, PBS, 76000 Rouen, France
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Sekine S, Komuro M, Sohka T, Sato T. Integrity testing of Planova™ BioEX virus removal filters used in the manufacture of biological products. Biologicals 2015; 43:186-94. [DOI: 10.1016/j.biologicals.2015.02.003] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/25/2014] [Revised: 02/07/2015] [Accepted: 02/09/2015] [Indexed: 10/23/2022] Open
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Urayama T, Cameron R, Sato T, Yunoki M, Ikuta K. Misinterpretation in virus clearance studies of biological products due to an uncommon discrepancy between cytopathic effects and infectivity of human immunodeficiency virus (HIV). Biologicals 2012; 41:125-7. [PMID: 23131459 DOI: 10.1016/j.biologicals.2012.10.004] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/22/2012] [Revised: 10/16/2012] [Accepted: 10/19/2012] [Indexed: 10/27/2022] Open
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Koenderman AHL, ter Hart HGJ, Prins-de Nijs IMM, Bloem J, Stoffers S, Kempers A, Derksen GJ, Al B, Dekker L, Over J. Virus safety of plasma products using 20 nm instead of 15 nm filtration as virus removing step. Biologicals 2012; 40:473-81. [PMID: 22901944 DOI: 10.1016/j.biologicals.2012.07.010] [Citation(s) in RCA: 8] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/02/2012] [Revised: 07/06/2012] [Accepted: 07/23/2012] [Indexed: 10/28/2022] Open
Abstract
During the manufacture of human plasma derivatives, a series of complementary measures are undertaken to prevent transmission of blood-borne viruses. Virus filtration using 15 nm (Planova15N) filters has successfully been implemented in manufacturing processes for various plasma derivatives primarily because virus filtration is a technique, mild for proteins, that can effectively remove even small non-lipid-enveloped viruses, such as HAV and parvovirus B19. However, the use of 15 nm filters has limitations with regard to protein capacity of the filters and the process flow, resulting in an expensive manufacturing step. Therefore, studies were performed to test whether the use of 20 nm (Planova20N) filters, having different characteristics compared to 15 nm filters, can be an alternative for the use of 15 nm filters. It is shown that 20 nm filtration can be an alternative for 15 nm filtration. However, the virus removal capacity of the 20 nm filters depends on the plasma product that is filtered. Therefore, an optimisation study must be performed with regard to process parameters such as pressure, pH and protein concentration for each plasma product. In this study, using optimised conditions, the virus removal capacity of 20 nm filters appears to be comparable or even better when compared to that of 15 nm filters.
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Affiliation(s)
- A H L Koenderman
- Sanquin Blood Supply, Division of Plasma Products, Product Development, PO Box 9190, 1006 AD Amsterdam, The Netherlands.
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Abstract
Manufacturing of cell culture-derived virus particles for vaccination and gene therapy is a rapidly growing field in the biopharmaceutical industry. The process involves a number of complex tasks and unit operations ranging from selection of host cells and virus strains for the cultivation in bioreactors to the purification and formulation of the final product. For the majority of cell culture-derived products, efforts focused on maximization of bioreactor yields, whereas design and optimization of downstream processes were often neglected. Owing to this biased focus, downstream procedures today often constitute a bottleneck in various manufacturing processes and account for the majority of the overall production costs. For efficient production methods, particularly in sight of constantly increasing economic pressure within human healthcare systems, highly productive downstream schemes have to be developed. Here, we discuss unit operations and downstream trains to purify virus particles for use as vaccines and vectors for gene therapy.
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Affiliation(s)
- Michael W Wolf
- Bioprocess Engineering, Max Planck Institute for Dynamics of Complex Technical Systems, Sandtorstrasse 1, 39106 Magdeburg, Germany.
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Jeong EK, Sung HM, Kim IS. Inactivation and removal of influenza A virus H1N1 during the manufacture of plasma derivatives. Biologicals 2010; 38:652-7. [DOI: 10.1016/j.biologicals.2010.07.007] [Citation(s) in RCA: 9] [Impact Index Per Article: 0.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/12/2010] [Revised: 07/23/2010] [Accepted: 07/27/2010] [Indexed: 12/01/2022] Open
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