Effects of resin ligand density on yield and impurity clearance in preparative cation exchange chromatography. II. Process characterization

Influence of ligand density variations on the two peak elution behavior of a monoclonal antibody in cation exchange chromatography

Cation exchange chromatography, as part of the monoclonal antibody purification train, is known as a mild polishing technique. However, in the last couple of years, more and more publications have shown unusual elution behavior, resulting from e.g. on-column (reversible) unfolding and aggregation of the predominantly mAb molecules. The stability of the investigated protein seems to play a significant role in this phenomenon. We have used a glycosylated IgG1 antibody as a model protein and investigated several influencing factors, including pH value and ligand density variations of three prototype Fractogel® cation exchange resins. Ligand density, pH and salt concentration are the main contributing factors in the Donnan effect, i.e. distribution of ions, between resin pore volume and bulk volume. This leads to a significantly lower pH value the protein is subjected to during the on-column hold time and therefore influences the conformational stability of our protein. Nano-DSF and kinetic SEC measurements show that the protein is destabilized at low pH values, but also, that the binding to the CEX resin and the elution with increasing salt concentration is responsible for the resulting two-peak elution behavior and partially reversible unfolding and aggregation.

Optimization and troubleshooting of preparative liquid chromatography using statistical design of experiments: Four small-molecule case studies

Statistical design of experiments (DoE) is used to aid in the development and execution of preparative liquid chromatography (LC) for large-scale purification of active pharmaceutical ingredients (API) and pharmaceutical intermediates. Four purification case studies were undertaken. In case study 1, a normal phase preparative silica method is developed and modeled. After initial method screening, DoE results were used to set mobile phase composition, flowrate, and sample diluent. Of the three particle sizes studied (10 µm, 20 µm, 50 µm) only 10 µm silica resin was able to produce purified API at the yield (>96%) and productivity (> 1 kg/kg-resin/day) necessitated by the project. The second case study uses DoE studies to identify critical process parameters of column load, mobile phase solvent ratio and basic modifier level for a low-resolution, preparative, chiral separation. Trade-offs between purity, yield and productivity are quantified in a tight separation which made compromising on process outcomes a necessity. The third case study troubleshoots a loss of yield experienced during operation of a process-scale reverse-phase LC purification. DoE is used to identify a critical interaction between levels of acetonitrile and phosphoric acid in the mobile phase. An operating region which increased yield from around 85% to 97% was defined and implemented. The fourth case study was initially designed as a preparative chromatography purification of API. DoE was used to screen mobile phase solubility. These experiments uncovered conditions where API is soluble, and impurities are not. The solubility model in acetonitrile/water mixtures is further defined via a response surface DoE. The resulting targeted solvent mixture allows bulk purification via dissolution of API while three less-polar impurities remain in the solid phase and are removed by filtration. These four case studies demonstrate the efficiency of DoE and response surface modeling as tools for process development and optimization.

Cross-scale quality assessment of a mechanistic cation exchange chromatography model

Cation exchange chromatography (CEX) is an essential part of most monoclonal antibody (mAb) purification platforms. Process characterization and root cause investigation of chromatographic unit operations are performed using scale down models (SDM). SDM chromatography columns typically have the identical bed height as the respective manufacturing-scale, but a significantly reduced inner diameter. While SDMs enable process development demanding less material and time, their comparability to manufacturing-scale can be affected by variability in feed composition, mobile phase and resin properties, or dispersion effects depending on the chromatography system at hand. Mechanistic models can help to close gaps between scales and reduce experimental efforts compared to experimental SDM applications. In this study, a multicomponent steric mass-action (SMA) adsorption model was applied to the scale-up of a CEX polishing step. Based on chromatograms and elution pool data ranging from laboratory- to manufacturing-scale, the proposed modeling workflow enabled early identification of differences between scales, for example, system dispersion effects or ionic capacity variability. A multistage model qualification approach was introduced to measure the model quality and to understand the model's limitations across scales. The experimental SDM and the in silico model were qualified against large-scale data using the identical state of the art equivalence testing procedure. The mechanistic chromatography model avoided limitations of the SDM by capturing effects of bed height, loading density, feed composition, and mobile phase properties. The results demonstrate the applicability of mechanistic chromatography models as a possible alternative to conventional SDM approaches.

Bridging size and charge variants of a therapeutic monoclonal antibody by two-dimensional liquid chromatography

Monoclonal antibodies are heterogeneous in nature and may contain numerous variants with differences in size, charge, and hydrophobicity, which may impact clinical efficacy, immunogenicity, and safety. Characterization of antibody variants is necessary to build structure-function correlation and establish a proper control strategy. Isolation and enrichment of variants by conventional chromatographic peak fractionation is labor-intensive and time-consuming. The instability of fractions during isolation and subsequent characterization may also be a concern. Hence, it is desirable to analyze antibody variants in an online and real-time manner. Here we demonstrate a 2D-LC methodology - multiple heart-cutting IEC-SEC- as an investigational tool to facilitate a charge variant characterization study. Both IEC modes - anion exchange (AEX) and cation exchange (CEX) chromatography are discussed. Using this approach, direct bridging of size and charge variants of an antibody molecule was achieved without offline peak fractionation. It was observed that antibody aggregates elute late on both the AEX and CEX columns, presumably due to secondary hydrophobic interactions. Additionally, we overcame the solvent mismatch issue and developed a 2D SEC-IEC method to confirm the bridging results. This is the first reported SEC-IEC 2D-LC application for the characterization of antibody size and charge variants.

In situ analysis and imaging of aromatic amidine at varying ligand densities in solid phase

We report the development of a fast and accurate fluorescence-based assay for amidine linked to cellulose membranes and Sepharose gel. The assay is founded on the glyoxal reaction, which involves reaction of an amidine group with glyoxal and an aromatic aldehyde, leading to the formation of a fluorophore that can be analyzed and quantified by fluorescence spectroscopy and imaging. While the assay has been reported previously for aromatic amidine estimation in solution phase, here we describe its adaptation and application to amidine linked to diverse forms of solid matrices, particularly benzamidine Sepharose and benzamidine-linked cellulose membranes. These functionalized porous matrices find important application in purification of serine proteases. The efficacy of a protein separation device is determined by, among other factors, the ligand (amidine) density. Hence, a sensitive and reproducible method for amidine quantitation in solid phase is needed. The glyoxal reaction was carried out on microbead-sized Sepharose gel and cellulose membranes. Calibration curves were developed for each phase, which established linearity in the range of 0-0.45 μmol per mL amidine for free amidine in solution, 0-0.45 μmol amidine per mL Sepharose gel, and 0-0.48 μmol per mL cellulose membrane. The assay showed high accuracy (~ 3.4% error), precision (RSD < 2%), and reproducibility. Finally, we show how this fluorescent labeling (glyoxal) method can provide a tool for imaging membranes and ligand distribution through confocal laser scanning microscopy. Graphical abstract.

Synthesis of Cellulose-graft-Polypropionic Acid Nanofiber Cation-Exchange Membrane Adsorbers for High-Efficiency Separations

Fabrication of membrane adsorbers with elevated binding capacity and high throughput is highly desired for simplifying and improving purification efficiencies of bioproducts (biotherapeutics, vaccines, etc.) in the biotechnological and biopharmaceutical industries. Here we demonstrate the preparation of a novel class of self-supported, cellulose-graft-polypropionic acid (CL-g-PPA) cation-exchange nanofiber membrane adsorbers under mild reaction conditions for the purification of positively charged therapeutic proteins. In our fabrication method, acrylonitrile was first polymerized and surface grafted onto cellulose nanofibers using cerium ammonium nitrate as a redox initiator to form cellulose-g-polyacrylonitrile (CL-g-PAN). CL-g-PAN was then submitted to a hydrolyzation reaction to form CL-g-PPA cationic membrane adsorbers. Morphology and structural characterization illustrated the formation of CL-g-PPA membranes with uniform coating of polyacid nanolayers along the individual nanofibers without disturbing the nanofiber structure. Benefiting from these numerous cationic polyacid binding sites and inherent large surface area and open porous structure, CL-g-PPA nanofiber membrane adsorbers showed a lysozyme static adsorption capacity of 1664 mg/g of nanofibers. These membranes showed a lysozyme dynamic binding capacity of 508 mg/g of nanofibers at 10% breakthrough (equivalent to 206 g/L capacity), with a residence time of less than 6 s. Moreover, CL-g-PPA self-supported nanofibers displayed excellent structural stability and reversibility after several cycles of protein binding studies. This dynamic binding capacity of the CL-g-PPA nanofiber membranes was 3.2 times higher than that of macroporous cellulose membranes and 8.5 times higher than that of the Sartobind S commercial membrane adsorber. Considering the simple fabrication method employed, excellent protein adsorption capacity, remarkable structural stability, and reusability, CL-g-PPA nanofiber membranes provided a versatile platform for the chromatographic separations of biomolecules (e.g., proteins, nucleic acids, and viral vaccines) as well as water purification and similar ion-exchange applications.

Ionic strength-dependent changes in tentacular ion exchangers with variable ligand density. I. Structural properties

The ligand density critically affects the performance of ion-exchange resins in such measures as the adsorption capacity and transport characteristics. However, for tentacular and other polymer-modified exchangers, the mechanistic basis of the effect of ligand density on performance is not yet fully understood. In this study we map the ionic strength-dependent structural changes in tentacular cation exchangers with variable ligand densities as the basis for subsequent investigation of effects on functional properties. Inverse size-exclusion chromatography (ISEC), scanning electron microscopy (SEM) and small-angle x-ray scattering (SAXS) were used to assess the effect of ionic strength on the pore size and intraparticle architecture of resin variants with different ligand densities. Comparison of ISEC and cryo-SEM results shows a considerable reduction in average pore size with increasing ligand density; these methods also confirm an increase of average pore size at higher ionic strengths. SAXS analysis of ionic strength-dependent conformational changes in the grafted polyelectrolyte layer shows a characteristic ionomer peak at values of the scattering vector q (0.1-0.2Å(-1)) that depend on the ligand density and the ionic strength of the solution. This peak attribution reflects nanoscale changes in the structure of the grafted polyelectrolyte chains that can in turn be responsible for observed pore-size changes in the resins. Finally, salt breakthrough experiments confirm a stronger Donnan exclusion effect on pore accessibility for small ions in the high ligand density variant.

Downstream process development strategies for effective bioprocesses: Trends, progress, and combinatorial approaches

The biopharmaceutical industry is at a turning point moving toward a more customized and patient-oriented medicine (precision medicine). Straightforward routines such as the antibody platform process are extended to production processes for a new portfolio of molecules. As a consequence, individual and tailored productions require generic approaches for a fast and dedicated purification process development. In this article, different effective strategies in biopharmaceutical purification process development are reviewed that can analogously be used for the new generation of antibodies. Conventional approaches based on heuristics and high-throughput process development are discussed and compared to modern technologies such as multivariate calibration and mechanistic modeling tools. Such approaches constitute a good foundation for fast and effective process development for new products and processes, but their full potential becomes obvious in a correlated combination. Thus, different combinatorial approaches are presented, which might become future directions in the biopharmaceutical industry.

Custom-tailored adsorbers: A molecular dynamics study on optimal design of ion exchange chromatography material

The performance of functionalized materials, e.g., ion exchange resins, depends on multiple resin characteristics, such as type of ligand, ligand density, the pore accessibility for a molecule, and backbone characteristics. Therefore, the screening and identification process for optimal resin characteristics for separation is very time and material consuming. Previous studies on the influence of resin characteristics have focused on an experimental approach and to a lesser extent on the mechanistic understanding of the adsorption mechanism. In this in silico study, a previously developed molecular dynamics (MD) tool is used, which simulates any given biomolecule on resins with varying ligand densities. We describe a set of simulations and experiments with four proteins and six resins varying in ligand density, and show that simulations and experiments correlate well in a wide range of ligand density. With this new approach simulations can be used as pre-experimental screening for optimal adsorber characteristics, reducing the actual number of screening experiments, which results in a faster and more knowledge-based development of custom-tailored adsorbers.

Light extinction and scattering by agarose based resin beads and applications in high-throughput screening

Optimization of chromatographic processes by high-throughput screening (HTS) methodologies have become a critical part of downstream process development. Nevertheless there are still no non-invasive optical methods to characterize resin as well as protein-resin interaction on liquid-handling platforms available. Several approaches to automated resin screening in microplates are described in literature, yet all those methods involve indirect measurements by removal of, and sample quantification within, supernatant volumes. In this work, we introduce light extinction by light scattering to directly assess resin volume and bead density within microplates. Methods for this novel resin characterization are described for 96 and 384-well microplates. An example application demonstrates ligand concentration measurement in microplates with four commercial SP Sepharose™ Fast Flow batches. Further, direct quantification of adsorbent bound biomolecules is shown in an example with kinetic protein-resin interaction measurement in a batch screening process. This new approach is expected to promote batch-based resin characterization and monitoring on HTS platforms and further miniaturization and increase in throughput of chromatographic HTS processes.