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Šrom O, Trávníková V, Wutz J, Kuschel M, Unsoeld A, Wucherpfennig T, Šoóš M. Characterization of hydrodynamic stress in ambr250® bioreactor system and its impact on mammalian cell culture. Biochem Eng J 2022. [DOI: 10.1016/j.bej.2021.108240] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/15/2022]
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Schmitz J, Hertel O, Yermakov B, Noll T, Grünberger A. Growth and eGFP Production of CHO-K1 Suspension Cells Cultivated From Single Cell to Laboratory Scale. Front Bioeng Biotechnol 2021; 9:716343. [PMID: 34722476 PMCID: PMC8554123 DOI: 10.3389/fbioe.2021.716343] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/28/2021] [Accepted: 09/13/2021] [Indexed: 11/23/2022] Open
Abstract
Scaling down bioproduction processes has become a major driving force for more accelerated and efficient process development over the last decades. Especially expensive and time-consuming processes like the production of biopharmaceuticals with mammalian cell lines benefit clearly from miniaturization, due to higher parallelization and increased insights while at the same time decreasing experimental time and costs. Lately, novel microfluidic methods have been developed, especially microfluidic single-cell cultivation (MSCC) devices have been proved to be valuable to miniaturize the cultivation of mammalian cells. So far, growth characteristics of microfluidic cultivated cell lines were not systematically compared to larger cultivation scales; however, validation of a miniaturization tool against initial cultivation scales is mandatory to prove its applicability for bioprocess development. Here, we systematically investigate growth, morphology, and eGFP production of CHO-K1 cells in different cultivation scales ranging from a microfluidic chip (230 nl) to a shake flask (125 ml) and laboratory-scale stirred tank bioreactor (2.0 L). Our study shows a high comparability regarding specific growth rates, cellular diameters, and eGFP production, which proves the feasibility of MSCC as a miniaturized cultivation tool for mammalian cell culture. In addition, we demonstrate that MSCC provides insights into cellular heterogeneity and single-cell dynamics concerning growth and production behavior which, when occurring in bioproduction processes, might severely affect process robustness.
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Affiliation(s)
- Julian Schmitz
- Multiscale Bioengineering, Faculty of Technology, Bielefeld University, Bielefeld, Germany.,Center for Biotechnology (CeBiTec), Bielefeld University, Bielefeld, Germany
| | - Oliver Hertel
- Center for Biotechnology (CeBiTec), Bielefeld University, Bielefeld, Germany.,Cell Culture Technology, Faculty of Technology, Bielefeld University, Bielefeld, Germany
| | - Boris Yermakov
- Multiscale Bioengineering, Faculty of Technology, Bielefeld University, Bielefeld, Germany
| | - Thomas Noll
- Center for Biotechnology (CeBiTec), Bielefeld University, Bielefeld, Germany.,Cell Culture Technology, Faculty of Technology, Bielefeld University, Bielefeld, Germany
| | - Alexander Grünberger
- Multiscale Bioengineering, Faculty of Technology, Bielefeld University, Bielefeld, Germany.,Center for Biotechnology (CeBiTec), Bielefeld University, Bielefeld, Germany
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Maruthamuthu MK, Rudge SR, Ardekani AM, Ladisch MR, Verma MS. Process Analytical Technologies and Data Analytics for the Manufacture of Monoclonal Antibodies. Trends Biotechnol 2020; 38:1169-1186. [PMID: 32839030 PMCID: PMC7442002 DOI: 10.1016/j.tibtech.2020.07.004] [Citation(s) in RCA: 39] [Impact Index Per Article: 9.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/08/2020] [Revised: 07/10/2020] [Accepted: 07/13/2020] [Indexed: 12/17/2022]
Abstract
Process analytical technology (PAT) for the manufacture of monoclonal antibodies (mAbs) is defined by an integrated set of advanced and automated methods that analyze the compositions and biophysical properties of cell culture fluids, cell-free product streams, and biotherapeutic molecules that are ultimately formulated into concentrated products. In-line or near-line probes and systems are remarkably well developed, although challenges remain in the determination of the absence of viral loads, detecting microbial or mycoplasma contamination, and applying data-driven deep learning to process monitoring and soft sensors. In this review, we address the current status of PAT for both batch and continuous processing steps and discuss its potential impact on facilitating the continuous manufacture of biotherapeutics.
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Affiliation(s)
- Murali K. Maruthamuthu
- Birck Nanotechnology Center, Purdue University, West Lafayette, IN 47907, USA,Department of Agricultural and Biological Engineering, Purdue University, West Lafayette, IN 47907, USA
| | - Scott R. Rudge
- RMC Pharmaceutical Solutions, Inc., Longmont, CO 80501, USA
| | - Arezoo M. Ardekani
- School of Mechanical Engineering, Purdue University, West Lafayette, IN 47907, USA
| | - Michael R. Ladisch
- Department of Agricultural and Biological Engineering, Purdue University, West Lafayette, IN 47907, USA,Weldon School of Biomedical Engineering, Purdue University, West Lafayette, IN 47907, USA,Laboratory of Renewable Resources Engineering, Purdue University, West Lafayette, IN 47907, USA,Correspondence:
| | - Mohit S. Verma
- Birck Nanotechnology Center, Purdue University, West Lafayette, IN 47907, USA,Department of Agricultural and Biological Engineering, Purdue University, West Lafayette, IN 47907, USA,Weldon School of Biomedical Engineering, Purdue University, West Lafayette, IN 47907, USA,Correspondence:
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4
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Paul K, Hartmann T, Posch C, Behrens D, Herwig C. Investigation of cell line specific responses to pH inhomogeneity and consequences for process design. Eng Life Sci 2020; 20:412-421. [PMID: 32944016 PMCID: PMC7481767 DOI: 10.1002/elsc.202000034] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/02/2020] [Revised: 06/15/2020] [Accepted: 06/25/2020] [Indexed: 12/13/2022] Open
Abstract
With increasing bioreactor volumes, the mixing time of the reactor increases as well, which creates an inhomogeneous environment for the cells. This can result in impaired process performance in large-scale production reactors. Particularly the addition of base through the reactor headspace can be problematic, since it creates an area, where cells are repeatedly exposed to an increased pH. The aim of this study is to simulate this large-scale phenomenon at lab-scale and investigate its impact. Two different cell lines were exposed to pH amplitudes of a maximal magnitude of 0.05 units (pH of 6.95). Both cell lines showed similar responses, like decreased viable cell counts, but unaffected lactate levels. However, cell line B showed an initially increased specific productivity in response to the introduced amplitudes, whereas cell line A showed a consistently lower specific productivity. Furthermore, the time point at which base addition is started influences the impact, which pH amplitudes have on process performance. When pH control was started earlier in the process, maximal viable cell counts decreased and the lactate metabolic shift was less pronounced. These results show that the potential negative impact of pH amplitudes can be minimized by strategic process design.
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Affiliation(s)
- Katrin Paul
- Institute of ChemicalEnvironmental and Bioscience EngineeringTU WienViennaAustria
- Christian Doppler Laboratory for Mechanistic and Physiological Methods for Improved BioprocessesTU WienViennaAustria
| | - Thomas Hartmann
- Institute of ChemicalEnvironmental and Bioscience EngineeringTU WienViennaAustria
- Christian Doppler Laboratory for Mechanistic and Physiological Methods for Improved BioprocessesTU WienViennaAustria
| | | | | | - Christoph Herwig
- Institute of ChemicalEnvironmental and Bioscience EngineeringTU WienViennaAustria
- Christian Doppler Laboratory for Mechanistic and Physiological Methods for Improved BioprocessesTU WienViennaAustria
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5
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Paul K, Herwig C. Scale-down simulators for mammalian cell culture as tools to access the impact of inhomogeneities occurring in large-scale bioreactors. Eng Life Sci 2020; 20:197-204. [PMID: 32874183 PMCID: PMC7447876 DOI: 10.1002/elsc.201900162] [Citation(s) in RCA: 18] [Impact Index Per Article: 4.5] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/08/2019] [Revised: 12/23/2019] [Accepted: 12/27/2019] [Indexed: 12/19/2022] Open
Abstract
During the scale-up of a bioprocess, not all characteristics of the process can be kept constant throughout the different scales. This typically results in increased mixing times with increasing reactor volumes. The poor mixing leads in turn to the formation of concentration gradients throughout the reactor and exposes cells to varying external conditions based on their location in the bioreactor. This can affect process performance and complicate process scale-up. Scale-down simulators, which aim at replicating the large-scale environment, expose the cells to changing environmental conditions. This has the potential to reveal adaptation mechanisms, which cells are using to adjust to rapidly fluctuating environmental conditions and can identify possible root causes for difficulties maintaining similar process performance at different scales. This understanding is of utmost importance in process validation. Additionally, these simulators also have the potential to be used for selecting cells, which are most robust when encountering changing extracellular conditions. The aim of this review is to summarize recent work in this interesting and promising area with the focus on mammalian bioprocesses, since microbial processes have been extensively reviewed.
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Affiliation(s)
- Katrin Paul
- Institute of Chemical, Environmental and Bioscience EngineeringViennaAustria
- Christian Doppler Laboratory for Mechanistic and Physiological Methods for Improved BioprocessesViennaAustria
| | - Christoph Herwig
- Institute of Chemical, Environmental and Bioscience EngineeringViennaAustria
- Christian Doppler Laboratory for Mechanistic and Physiological Methods for Improved BioprocessesViennaAustria
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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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Narayanan H, Luna MF, Stosch M, Cruz Bournazou MN, Polotti G, Morbidelli M, Butté A, Sokolov M. Bioprocessing in the Digital Age: The Role of Process Models. Biotechnol J 2019; 15:e1900172. [DOI: 10.1002/biot.201900172] [Citation(s) in RCA: 90] [Impact Index Per Article: 18.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/01/2019] [Revised: 07/15/2019] [Indexed: 12/20/2022]
Affiliation(s)
- Harini Narayanan
- Institute for Chemical and Bioengineering ETHZ Zurich Switzerland
| | - Martin F. Luna
- Institute for Chemical and Bioengineering ETHZ Zurich Switzerland
| | | | - Mariano Nicolas Cruz Bournazou
- Institute for Chemical and Bioengineering ETHZ Zurich Switzerland
- DataHow AGc/o ETH ZurichHCI, F137Vladimir‐Prelog‐Weg 1 8093 Zurich Switzerland
| | - Gianmarco Polotti
- DataHow AGc/o ETH ZurichHCI, F137Vladimir‐Prelog‐Weg 1 8093 Zurich Switzerland
| | - Massimo Morbidelli
- Institute for Chemical and Bioengineering ETHZ Zurich Switzerland
- DataHow AGc/o ETH ZurichHCI, F137Vladimir‐Prelog‐Weg 1 8093 Zurich Switzerland
| | - Alessandro Butté
- Institute for Chemical and Bioengineering ETHZ Zurich Switzerland
- DataHow AGc/o ETH ZurichHCI, F137Vladimir‐Prelog‐Weg 1 8093 Zurich Switzerland
| | - Michael Sokolov
- Institute for Chemical and Bioengineering ETHZ Zurich Switzerland
- DataHow AGc/o ETH ZurichHCI, F137Vladimir‐Prelog‐Weg 1 8093 Zurich Switzerland
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Qin J, Wu X, Xia Z, Huang Z, Zhang Y, Wang Y, Fu Q, Zheng C. The effect of hyperosmolality application time on production, quality, and biopotency of monoclonal antibodies produced in CHO cell fed-batch and perfusion cultures. Appl Microbiol Biotechnol 2018; 103:1217-1229. [PMID: 30554388 DOI: 10.1007/s00253-018-9555-7] [Citation(s) in RCA: 12] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/22/2018] [Revised: 11/28/2018] [Accepted: 12/01/2018] [Indexed: 12/19/2022]
Abstract
Hyperosmolality has been commonly investigated due to its effects on the production and quality characteristics of monoclonal antibodies (mAbs) produced in CHO cell fed-batch cultures. However, the application of hyperosmolality at different times and its effect on biopotency have seldom been researched, especially in perfusion culture. In our study, different degrees of hyperosmolality induced by sodium chloride were investigated in anti-IgE rCHO cell fed-batch cultures and anti-CD52 rCHO cell perfusion cultures during the initial and stable phases. The results showed that the initial hyperosmolality group (IHG) in fed-batch and early phase of perfusion cultures exhibited significant suppression of the viable cell density yet an enhancement in specific productivity, whereas the stable hyperosmolality group (SHG) achieved higher mAb production in both fed-batch and perfusion cultures. Additionally, the SHG produced less aggregates and acidic charge variants than IHG in fed-batch culture, which differed from perfusion cultures. However, the contents of non-glycosylation heavy chain (NGHC) and man5 were higher in SHG than in IHG in fed-batch cultures at plus 60 and 120 mOsm/kg, which was similar to perfusion cultures. Furthermore, the biopotency in the IHG was higher than in the SHG at plus 60 and 120 mOsm/kg in fed-batch cultures, which is similar to complement-dependent cytotoxicity (CDC) efficacy in perfusion cultures. The biopotency of all group was acceptable, except FI3. Thus, the study shows that hyperosmolality at a certain level could be beneficial for both mAb production, quality and biopotency, which could play an important role in process development for commercial production.
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Affiliation(s)
- Jinyan Qin
- School of Pharmacy, Wuhan University, East Lake Road 185, Wuchang District, Wuhan, 430071, Hubei Province, China.,Shanghai Taiyin Biotech Co., Ltd., Shanghai, 201203, China
| | - Xiang Wu
- Shanghai Taiyin Biotech Co., Ltd., Shanghai, 201203, China
| | - Zhigang Xia
- Shanghai Taiyin Biotech Co., Ltd., Shanghai, 201203, China
| | - Zheng Huang
- School of Pharmacy, Wuhan University, East Lake Road 185, Wuchang District, Wuhan, 430071, Hubei Province, China.,Shanghai Taiyin Biotech Co., Ltd., Shanghai, 201203, China
| | - Ying Zhang
- Shanghai Taiyin Biotech Co., Ltd., Shanghai, 201203, China.,School of Pharmacy, Shanghai Jiao Tong University, Shanghai, 200240, China
| | - Yanchao Wang
- Shanghai Taiyin Biotech Co., Ltd., Shanghai, 201203, China.,School of Pharmacy, Shanghai Jiao Tong University, Shanghai, 200240, China
| | - Qiang Fu
- Shanghai Taiyin Biotech Co., Ltd., Shanghai, 201203, China
| | - Chen Zheng
- Shanghai Taiyin Biotech Co., Ltd., Shanghai, 201203, China.
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