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Keulen D, Hagen EVD, Geldhof G, Le Bussy O, Pabst M, Ottens M. Using artificial neural networks to accelerate flowsheet optimization for downstream process development. Biotechnol Bioeng 2024; 121:2318-2331. [PMID: 37256724 DOI: 10.1002/bit.28454] [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: 02/27/2023] [Revised: 05/11/2023] [Accepted: 05/17/2023] [Indexed: 06/02/2023]
Abstract
An optimal purification process for biopharmaceutical products is important to meet strict safety regulations, and for economic benefits. To find the global optimum, it is desirable to screen the overall design space. Advanced model-based approaches enable to screen a broad range of the design-space, in contrast to traditional statistical or heuristic-based approaches. Though, chromatographic mechanistic modeling (MM), one of the advanced model-based approaches, can be speed-limiting for flowsheet optimization, which evaluates every purification possibility (e.g., type and order of purification techniques, and their operating conditions). Therefore, we propose to use artificial neural networks (ANNs) during global optimization to select the most optimal flowsheets. So, the number of flowsheets for final local optimization is reduced and consequently the overall optimization time. Employing ANNs during global optimization proved to reduce the number of flowsheets from 15 to only 3. From these three, one flowsheet was optimized locally and similar final results were found when using the global outcome of either the ANN or MM as starting condition. Moreover, the overall flowsheet optimization time was reduced by 50% when using ANNs during global optimization. This approach accelerates the early purification process design; moreover, it is generic, flexible, and regardless of sample material's type.
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Affiliation(s)
- Daphne Keulen
- Department of Biotechnology, Delft University of Technology, Delft, The Netherlands
| | - Erik van der Hagen
- Department of Biotechnology, Delft University of Technology, Delft, The Netherlands
| | - Geoffroy Geldhof
- GSK, Technical Research & Development-Microbial Drug Substance, Rixensart, Belgium
| | - Olivier Le Bussy
- GSK, Technical Research & Development-Microbial Drug Substance, Rixensart, Belgium
| | - Martin Pabst
- Department of Biotechnology, Delft University of Technology, Delft, The Netherlands
| | - Marcel Ottens
- Department of Biotechnology, Delft University of Technology, Delft, The Netherlands
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2
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Jiang Z, Dalby PA. Challenges in scaling up AAV-based gene therapy manufacturing. Trends Biotechnol 2023; 41:1268-1281. [PMID: 37127491 DOI: 10.1016/j.tibtech.2023.04.002] [Citation(s) in RCA: 3] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/04/2023] [Revised: 04/05/2023] [Accepted: 04/06/2023] [Indexed: 05/03/2023]
Abstract
Accelerating the scale up of adeno-associated virus (AAV) manufacture is highly desirable to meet the increased demand for gene therapies. However, the development of bioprocesses for AAV gene therapies remains time-consuming and challenging. The quality by design (QbD) approach ensures bioprocess designs that meet the desired product quality and safety profile. Rapid stress tests, developability screens, and scale-down technologies have the potential to streamline AAV product and manufacturing bioprocess development within the QbD framework. Here we review how their successful use for antibody manufacture development is translating to AAV, but also how this will depend critically on improved analytical methods and adaptation of the tools as more understanding is gained on the critical attributes of AAV required for successful therapy.
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Affiliation(s)
- Ziyu Jiang
- Department of Biochemical Engineering, University College London, Gower Street, London WC1E 6BT, UK.
| | - Paul A Dalby
- Department of Biochemical Engineering, University College London, Gower Street, London WC1E 6BT, UK.
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3
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Liang X, He Q, Qin G, Li G, Li Q, Tan H, Wang Z, Fan M, Xu D. Effectively removing the homodimer in bispecific antibodies by weak partitioning mode of anion exchange chromatography. J Chromatogr B Analyt Technol Biomed Life Sci 2023; 1225:123767. [PMID: 37270861 DOI: 10.1016/j.jchromb.2023.123767] [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: 04/17/2023] [Revised: 05/21/2023] [Accepted: 05/26/2023] [Indexed: 06/06/2023]
Abstract
Small amounts of by-products are nevertheless created during the recombinant production of IgG-like bispecific antibodies due to imbalanced chain expression and improper chain pairing, despite the employment of molecular strategy techniques to promote accurate pairing. Among them, homodimers represent the species that are more difficult to remove due to their physical and chemical properties being similar to the target antibody. Homodimer by-products are always produced even though various technologies can significantly increase the expression of heterodimers, so a robust purification process to recover high-purity heterodimers is required. Most of the chromatography methods commonly adopt the bind-and-elute mode or two-step to separate homodimers, which has numerous drawbacks such as prolonged process times and limited dynamic binding capacity. Flow-through mode of anion exchange is a frequently-used polishing step for antibodies, but it is typically regarded as being more effective for host-cell protein or host-cell DNA removal rather than other product-related impurities such as homodimers and aggregates. This paper demonstrated that single-step anion exchange chromatography allows high capacity and effective clearance of the homodimer byproduct to be simultaneously achieved, suggesting that weak partitioning was a better polishing strategy for achieving a high level of heterodimer purity. And robust operation range of anion exchange chromatography steps for homodimer removal was also developed by leveraging the design of experiments.
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Affiliation(s)
- Xiaoying Liang
- Nanjing Chia-Tai Tianqing Pharmaceutical Co.Ltd, Fanghua Pharmaceutical Research Institute, Department of Biology, Nanjing 210046, China
| | - Qingquan He
- Nanjing Chia-Tai Tianqing Pharmaceutical Co.Ltd, Fanghua Pharmaceutical Research Institute, Department of Biology, Nanjing 210046, China
| | - Guohong Qin
- Nanjing Chia-Tai Tianqing Pharmaceutical Co.Ltd, Fanghua Pharmaceutical Research Institute, Department of Biology, Nanjing 210046, China
| | - Guozhu Li
- Nanjing Chia-Tai Tianqing Pharmaceutical Co.Ltd, Fanghua Pharmaceutical Research Institute, Department of Biology, Nanjing 210046, China
| | - Qian Li
- Nanjing Chia-Tai Tianqing Pharmaceutical Co.Ltd, Fanghua Pharmaceutical Research Institute, Department of Biology, Nanjing 210046, China
| | - Huanghong Tan
- Nanjing Chia-Tai Tianqing Pharmaceutical Co.Ltd, Fanghua Pharmaceutical Research Institute, Department of Biology, Nanjing 210046, China
| | - Zichen Wang
- Nanjing Chia-Tai Tianqing Pharmaceutical Co.Ltd, Fanghua Pharmaceutical Research Institute, Department of Biology, Nanjing 210046, China
| | - Mengni Fan
- Nanjing Chia-Tai Tianqing Pharmaceutical Co.Ltd, Fanghua Pharmaceutical Research Institute, Department of Biology, Nanjing 210046, China
| | - Dan Xu
- Nanjing Chia-Tai Tianqing Pharmaceutical Co.Ltd, Fanghua Pharmaceutical Research Institute, Department of Biology, Nanjing 210046, China.
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4
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Furcht C, VanSeveren M, Holstein M, Feroz H, Ghose S. Use of Monte Carlo simulations for improved facility fit planning in downstream biomanufacturing and technology transfer. Biotechnol Prog 2023; 39:e3306. [PMID: 36264017 DOI: 10.1002/btpr.3306] [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: 08/09/2022] [Revised: 10/05/2022] [Accepted: 10/17/2022] [Indexed: 11/10/2022]
Abstract
Biologics manufacturing is capital and consumable intensive with need for advanced inventory planning to account for supply chain constraints. Early-stage process design and technology transfer are often challenging due to limited information on process variability regarding bioreactor titer, process yield, and product quality. Monte Carlo (MC) methods offer a stochastic modeling approach for process optimization where probabilities of occurrence for process inputs are incorporated into a deterministic model to simulate more likely scenarios for process outputs. In this study, we explore MC simulation-based design of a monoclonal antibody downstream manufacturing process. We demonstrate that this probabilistic approach offers more representative outcomes over the conventional worst-case approach where the theoretical minimum and maximum values of each process parameter are used without consideration for their probability of occurrence. Our work demonstrates case studies on more practically sizing unit operations to improve consumable utilization, thereby reducing manufacturing costs. We also used MC simulations to minimize process cadence by constraining the number of cycles per unit operation to fit facility preferences. By factoring in process uncertainty, we have implemented MC simulation-based facility fit analyses to efficiently plan for inventory when accounting for process constraints during technology transfer from lab-scale to clinical or commercial manufacturing.
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Affiliation(s)
- Christopher Furcht
- Biologics Process Development, Bristol Myers Squibb Company, Summit, New Jersey, USA
| | - Michael VanSeveren
- Biologics Process Development, Bristol Myers Squibb Company, Devens, Massachusetts, USA
| | - Melissa Holstein
- Biologics Process Development, Bristol Myers Squibb Company, Devens, Massachusetts, USA
| | - Hasin Feroz
- Biologics Process Development, Bristol Myers Squibb Company, Devens, Massachusetts, USA
| | - Sanchayita Ghose
- Biologics Process Development, Bristol Myers Squibb Company, Devens, Massachusetts, USA
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Xie Z, Li J, Hao X, Xu L. Purification and Analysis of the CREPT Antibody from Mouse Ascites. Appl Bionics Biomech 2022; 2022:8776565. [PMID: 36106137 PMCID: PMC9467789 DOI: 10.1155/2022/8776565] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/28/2022] [Revised: 07/29/2022] [Accepted: 08/03/2022] [Indexed: 11/18/2022] Open
Abstract
Methods Cells were cultivated properly to obtain 3E10 CREPT monoclonal antibody cells in the logarithmic growth stage. Monoclonal antibody cells were injected into the abdominal cavity of sensitized mice. The flowing ascites were observed for 7-15 days. The antibody protein was obtained by collection, filtration, dilution, loading, and chromatography. Furthermore, its binding force was detected by SDS-PAGE and Western blot techniques. Results The antibody protein was successfully obtained with a purity of 1895 μg/mL with high liveness. Conclusion This study establishes a one-step purification method for obtaining monoclonal antibody with high liveness and purity for CREPT ascites antibody. This method is simple to perform and lays a foundation for the preparation and purification of humanized monoclonal antibodies in the future. In addition, it provides a basis for further research to investigate how CREPT affects the occurrence and development of different tumors.
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Affiliation(s)
- Zhihao Xie
- Department of Hematology, The First Affiliated Hospital of Hainan Medical University, Haikou 570102, Hainan, China
| | - Jun Li
- State Key Laboratory of Membrane Biology, School of Medicine, Tsinghua University, Beijing 100091, China
| | - Xinbao Hao
- Department of Hematology, The First Affiliated Hospital of Hainan Medical University, Haikou 570102, Hainan, China
| | - Lu Xu
- Department of Hematology, The First Affiliated Hospital of Hainan Medical University, Haikou 570102, Hainan, China
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Keulen D, Geldhof G, Bussy OL, Pabst M, Ottens M. Recent advances to accelerate purification process development: a review with a focus on vaccines. J Chromatogr A 2022; 1676:463195. [DOI: 10.1016/j.chroma.2022.463195] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/07/2022] [Revised: 05/24/2022] [Accepted: 06/01/2022] [Indexed: 10/18/2022]
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7
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Schreiber M, Schembecker G. Development of an Automated Adsorbent Selection Strategy for Liquid–Phase Adsorption. Chem Eng Technol 2022. [DOI: 10.1002/ceat.202200152] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/11/2022]
Affiliation(s)
- Mareike Schreiber
- TU Dortmund University Department of Biochemical and Chemical Engineering Laboratory of Plant and Process Design Emil-Figge-Str. 70 44227 Dortmund Germany
| | - Gerhard Schembecker
- TU Dortmund University Department of Biochemical and Chemical Engineering Laboratory of Plant and Process Design Emil-Figge-Str. 70 44227 Dortmund Germany
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8
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Javidanbardan A, Chu V, Conde JP, Azevedo AM. Microchromatography integrated with impedance sensor for bioprocess optimization: Experimental and numerical study of column efficiency for evaluation of scalability. J Chromatogr A 2021; 1661:462678. [PMID: 34879308 DOI: 10.1016/j.chroma.2021.462678] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/14/2021] [Revised: 11/03/2021] [Accepted: 11/05/2021] [Indexed: 10/19/2022]
Abstract
In the last decade, there has been a growing interest in developing microfluidic systems as new scale-down models for accelerated and cost-effective biopharmaceutical process development. Nonetheless, the research in this field is still in its infancy and requires further investigation to simplify and accelerate the microfabrication process. In addition, integration of different label-free sensors into the microcolumn systems has utmost importance to minimize result discrepancies during the scale-up process. In this study, we developed a simple, low-cost integrated microcolumn (26 µl). Micromilling technology was employed to define the geometry and shape of microfluidic structures using poly(methylmethacrylate) (PMMA). The design of PMMA microstructure was transferred to polydimethylsiloxane (PDMS), and interdigitated planar microelectrodes (IDE) were integrated into the system. To evaluate the scalability of the developed microcolumn column, column performance was assessed and compared with a conventional 1-ml prepacked column. Computational Fluid Dynamics (CFD) studies were performed for both columns to understand the differences between theoretical and experimental results regarding retention time and peak broadening. Despite obtaining an acceptable asymmetric factor for the microcolumn (1.03 ± 0.02), the reduced plate height value was still higher than the recommended range with the value of 4.14 ± 0.18. Nevertheless, the consistency and significant improvement of microcolumn efficiency compared to previous studies provide the possibility of developing robust simulation tools for transferring acquired experimental data for larger-scale units.
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Affiliation(s)
- Amin Javidanbardan
- IBB - Institute for Bioengineering and Biosciences, Instituto Superior Técnico, Universidade de Lisboa, Lisbon, Portugal; Department of Bioengineering, Instituto Superior Técnico, Universidade de Lisboa, Lisbon, Portugal
| | - Virginia Chu
- Instituto de Engenharia de Sistemas e Computadores - Microsistemas e Nanotecnologias (INESC MN), Lisbon, Portugal
| | - João P Conde
- Department of Bioengineering, Instituto Superior Técnico, Universidade de Lisboa, Lisbon, Portugal; Instituto de Engenharia de Sistemas e Computadores - Microsistemas e Nanotecnologias (INESC MN), Lisbon, Portugal.
| | - Ana M Azevedo
- IBB - Institute for Bioengineering and Biosciences, Instituto Superior Técnico, Universidade de Lisboa, Lisbon, Portugal; Department of Bioengineering, Instituto Superior Técnico, Universidade de Lisboa, Lisbon, Portugal.
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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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Traustason B, Cheeks M, Dikicioglu D. Computer-Aided Strategies for Determining the Amino Acid Composition of Medium for Chinese Hamster Ovary Cell-Based Biomanufacturing Platforms. Int J Mol Sci 2019; 20:E5464. [PMID: 31684012 PMCID: PMC6862603 DOI: 10.3390/ijms20215464] [Citation(s) in RCA: 10] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/08/2019] [Revised: 10/30/2019] [Accepted: 10/31/2019] [Indexed: 01/07/2023] Open
Abstract
Chinese hamster ovary (CHO) cells are used for the production of the majority of biopharmaceutical drugs, and thus have remained the standard industry host for the past three decades. The amino acid composition of the medium plays a key role in commercial scale biologics manufacturing, as amino acids constitute the building blocks of both endogenous and heterologous proteins, are involved in metabolic and non-metabolic pathways, and can act as main sources of nitrogen and carbon under certain conditions. As biomanufactured proteins become increasingly complex, the adoption of model-based approaches become ever more popular in complementing the challenging task of medium development. The extensively studied amino acid metabolism is exceptionally suitable for such model-driven analyses, and although still limited in practice, the development of these strategies is gaining attention, particularly in this domain. This paper provides a review of recent efforts. We first provide an overview of the widely adopted practice, and move on to describe the model-driven approaches employed for the improvement and optimization of the external amino acid supply in light of cellular amino acid demand. We conclude by proposing the likely prevalent direction the field is heading towards, providing a critical evaluation of the current state and the future challenges and considerations.
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Affiliation(s)
- Bergthor Traustason
- Department of Chemical Engineering and Biotechnology, University of Cambridge, Cambridge CB3 0AS, UK.
| | - Matthew Cheeks
- Cell Sciences, Biopharmaceutical Development, AstraZeneca, Cambridge CB21 6GH, UK.
| | - Duygu Dikicioglu
- Department of Chemical Engineering and Biotechnology, University of Cambridge, Cambridge CB3 0AS, UK.
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