Dispersion effects in preparative polymethacrylate monoliths operated in radial-flow columns

Improved mRNA affinity chromatography binding capacity and throughput using an oligo-dT immobilized electrospun polymer nanofiber adsorbent

Increased demand for mRNA-based therapeutics and improved in vitro transcription (IVT) yields have challenged the mRNA purification platform. Hybridization-affinity chromatography with an immobilized oligo-deoxythymidilic acid (oligodT) ligand is often used to capture mRNA through base pairing with the polyadenylated tail. Commercially available oligodT matrices include perfusive cross-linked poly(styrene-divinylbenzene) 50 µm POROS™ chromatography resin beads and convective polymethacrylate CIMmultus® monolithic columns consisting of 2 µm interconnected channels. POROS™ columns may be limited by poor mass transfer for larger mRNAs and slow flowrates, while monoliths can operate at higher flowrates but are limited by modest binding capacity. To enable both high flowrates and binding capacity for mRNA of all lengths, prototype chromatography media was developed by Cytiva using oligodT immobilized electrospun cellulose nanofibers (Fibro™) with a 0.3-0.4 µm pore size. In this work, four polyadenylated mRNAs ranging from ∼1900-4300 nucleotides were used to compare the dynamic binding capacity (DBC) of Fibro™, POROS® and CIMmultus® columns as a function of residence time and binding buffer compositions. Fibro™ improved the DBC ∼2-4-fold higher than CIMmultus® and ∼2-13-fold higher than POROS™ across all residence times, mRNA length, and binding matrix compositions tested. CIMmultus® DBC was least dependent on residence time and mRNA size, while both Fibro™ and POROS™ DBC increased at slower flowrates and with shorter mRNA. Surprisingly, inverse size exclusion (ISE) experiments showed that POROS™ was not limited by diffusion and POROS™ along with CIMmultus® demonstrate higher mRNA permeation however the Fibro™ prototype is not in the final configuration. Lastly, IVT reaction products were subjected to purification and oligodT elution product yield, quality, and purity were consistent across the three matrices investigated. These results highlight the benefits of high DBC and equivalent product profiles offered by the oligodT Fibro™ prototype compared to commercially available oligodT media.

Modeling of dispersion in a polymeric chromatographic monolith

Dispersion in a commercial polymeric monolith was simulated on a sample geometry obtained by direct imaging using high-resolution electron microscopy. A parallelized random walk algorithm, implemented using a velocity field obtained previously by the lattice-Boltzmann method, was used to model mass transfer. Both point particles and probes of finite size were studied. Dispersion simulations with point particles using periodic boundaries resulted in plate heights that varied almost linearly with flow rate, at odds with the weaker dependence suggested by experimental observations and predicted by theory. This discrepancy resulted from the combined effect of the artificial symmetry in the velocity field and the periodic boundaries implemented to emulate macroscopic column lengths. Eliminating periodicity and simulating a single block length instead resulted in a functional dependence of plate heights on flow rate more in accord with experimental trends and theoretical predictions for random media. The lower values of the simulated plate heights than experimental ones are attributed in part to the presence of walls in real systems, an effect not modeled by the algorithm. On the other hand, analysis of transient dispersion coefficients and comparison of lateral particle positions at the entry and exit hinted at non-asymptotic behavior and a strong degree of correlation that was presumably a consequence of preferential high-velocity pathways in the raw sample block. Simulations with finite-sized probes resulted in particle trajectories that frequently terminated at narrow constrictions of the geometry. The amount of entrapment was predicted to increase monotonically with flow rate, evidently due to the relative contributions to transport by convection that carries particles to choke-points and diffusion that dislodges these entrapped particles. The overall effect is very similar to a flow-dependent entrapment phenomenon previously observed experimentally for adenovirus.

Downstream processing of cell culture-derived virus particles

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.

Modeling of flow in a polymeric chromatographic monolith

The flow behavior of a commercial polymeric monolith was investigated by direct numerical simulations employing the lattice-Boltzmann (LB) methodology. An explicit structural representation of the monolith was obtained by serial sectioning of a portion of the monolith and imaging by scanning electron microscopy. After image processing, the three-dimensional structure of a sample block with dimensions of 17.8 μm × 17.8 μm × 14.1 μm was obtained, with uniform 18.5 nm voxel size. Flow was simulated on this reconstructed block using the LB method to obtain the velocity distribution, and in turn macroscopic flow properties such as the permeability and the average velocity. The computed axial velocity distribution exhibits a sharp peak with an exponentially decaying tail. Analysis of the local components of the flow field suggests that flow is not evenly distributed throughout the sample geometry, as is also seen in geometries that exhibit preferential flow paths, such as sphere pack arrays with defects. A significant fraction of negative axial velocities are observed; the largest of these are due to flow along horizontal pores that are also slightly oriented in the negative axial direction. Possible implications for mass transfer are discussed.

Relation of structure to performance characteristics of monolithic and perfusive stationary phases

Commercially available polymer-based monolithic and perfusive stationary phases were evaluated for their applicability in chromatography of biologics. Information on bed geometry, including that from electron microscopy (EM), was used to interpret and predict accessible volumes, binding capacities, and pressure drops. For preparative purification of biologics up to at least 7 nm in diameter, monoliths and perfusive resins are inferior to conventional stationary phases due to their low binding capacities (20-30 g/L for BSA). For larger biologics, up to several hundred nanometers in diameter, calculations from EM images predict a potential increase in binding capacity to nearly 100 g/L. The accessible volume for adenovirus calculated from the EM images matched the experimental value. While the pores of perfusive resins are essentially inaccessible to adenovirus under binding conditions, under non-adsorbing conditions the accessible intrabead porosity is almost as large as the interbead porosity. Modeling of breakthrough curves showed that the experimentally observed slow approach to full saturation can be explained by the distribution of pore sizes.

Methacrylate-based short monolithic columns: enabling tools for rapid and efficient analyses of biomolecules and nanoparticles

This review describes the novel chromatography stationary phase--a porous monolithic methacrylate-based polymer--in terms of the design of the columns and some of the features that make these columns attractive for the purification of large biomolecules. We first start with a brief summary of the characteristics of these large molecules (more precisely large proteins like immunoglobulins G and M, plasmid deoxyribonucleic acid (DNA), and viral particles), and a list of some of the problems that were encountered during the development of efficient purification processes. We then briefly describe the structure of the methacrylate-based monolith and emphasize the features which make them more than suitable for dealing with large entities. The highly efficient structure on a small scale can be transferred to a large scale without the need of making column modifications, and the various approaches of how this is accomplished are briefly presented in this paper. This is followed by presenting some of the examples from the bioprocess development schemes, where the implementation of the methacrylate-based monolithic columns has resulted in a very efficient and productive process. Following this, we move back to the analytical scale and demonstrate the efficiency of the monolithic column--where the mass transfer between the stationary and mobile phase is greatly enhanced--for the in-process and final control of the new therapeutics. The combination of an efficient structure and the appropriate hardware results in separations of proteins with residence time less than 0.1 s.