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Ito T, Lutz H, Tan L, Wang B, Tan J, Patel M, Chen L, Tsunakawa Y, Park B, Banerjee S. Host cell proteins in monoclonal antibody processing: Control, detection, and removal. Biotechnol Prog 2024:e3448. [PMID: 38477405 DOI: 10.1002/btpr.3448] [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: 10/30/2023] [Revised: 02/13/2024] [Accepted: 02/14/2024] [Indexed: 03/14/2024]
Abstract
Host cell proteins (HCPs) are process-related impurities in a therapeutic protein expressed using cell culture technology. This review presents biopharmaceutical industry trends in terms of both HCPs in the bioprocessing of monoclonal antibodies (mAbs) and the capabilities for HCP clearance by downstream unit operations. A comprehensive assessment of currently implemented and emerging technologies in the manufacturing processes with extensive references was performed. Meta-analyses of published downstream data were conducted to identify trends. Improved analytical methods and understanding of "high-risk" HCPs lead to more robust manufacturing processes and higher-quality therapeutics. The trend of higher cell density cultures leads to both higher mAb expression and higher HCP levels. However, HCP levels can be significantly reduced with improvements in operations, resulting in similar concentrations of approx. 10 ppm HCPs. There are no differences in the performance of HCP clearance between recent enhanced downstream operations and traditional batch processing. This review includes best practices for developing improved processes.
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Affiliation(s)
- Takao Ito
- Life Science, Process Solutions, Merck Ltd. (An Affiliate of Merck KGaA, Darmstadt, Germany), Tokyo, Japan
| | - Herb Lutz
- Independent Consultant, Sudbury, Massachusetts, USA
| | - Lihan Tan
- Life Science Services, Sigma-Aldrich Pte Ltd, Singapore, Singapore
| | - Bin Wang
- Life Science, Process Solutions, Merck Chemicals (Shanghai) Co. Ltd. (An Affiliate of Merck KGaA Darmstadt, Germany), Shanghai, China
| | - Janice Tan
- Life Science, Process Solutions, Merck Pte Ltd. (An Affiliate of Merck KGaA, Darmstadt, Germany), Singapore
| | - Masum Patel
- Life Science, Process Solutions, Merck Life Sciences Pvt. Ltd. (An Affiliate of Merck KGaA, Darmstadt, Germany), Bangalore, India
| | - Lance Chen
- Life Science, Process Solutions, Merck Pte Ltd. (An Affiliate of Merck KGaA, Darmstadt, Germany), Singapore
| | - Yuki Tsunakawa
- Life Science, Process Solutions, Merck Ltd. (An Affiliate of Merck KGaA, Darmstadt, Germany), Tokyo, Japan
| | - Byunghyun Park
- Life Science, Process Solutions, Merck Ltd. (An Affiliate of Merck KGaA, Darmstadt, Germany), Seoul, South Korea
| | - Subhasis Banerjee
- Life Science, Process Solutions, Merck Life Sciences Pvt. Ltd. (An Affiliate of Merck KGaA, Darmstadt, Germany), Bangalore, India
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Crowley L, Cashen P, Noverraz M, Lobedann M, Nestola P. Reviewing the process intensification landscape through the introduction of a novel, multitiered classification for downstream processing. Biotechnol Bioeng 2024; 121:877-893. [PMID: 38214109 DOI: 10.1002/bit.28641] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/25/2023] [Revised: 12/06/2023] [Accepted: 12/12/2023] [Indexed: 01/13/2024]
Abstract
A demand for process intensification in biomanufacturing has increased over the past decade due to the ever-expanding market for biopharmaceuticals. This is largely driven by factors such as a surge in biosimilars as patents expire, an aging population, and a rise in chronic diseases. With these market demands, pressure upon biomanufacturers to produce quality products with rapid turnaround escalates proportionally. Process intensification in biomanufacturing has been well received and accepted across industry based on the demonstration of its benefits of improved productivity and efficiency, while also reducing the cost of goods. However, while these benefits have been shown empirically, the challenges of adopting process intensification into industry remain, from smaller independent start-up to big pharma. Traditionally, moving from batch to a process intensification scheme has been viewed as an "all or nothing" approach involving continuous bioprocessing, in which the factors of complexity and significant capital costs hinder its adoption. In addition, the literature is crowded with a variety of terms used to describe process intensification (continuous, periodic counter-current, connected, intensified, steady-state, etc.). Often, these terms are used inappropriately or as synonyms, which generates confusion in the field. Through a detailed review of current state-of-the-art systems, consumables, and process intensification case studies, we herein propose a defined approach in the implementation of downstream process intensification through a standardized nomenclature and viewing it as distinct independent levels. These can function separately as intensified single-unit operations or be built upon by integration with other process steps allowing for simple, incremental, cost-effective implementation of process intensification in the manufacturing of biopharmaceuticals.
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Affiliation(s)
- Louis Crowley
- Sartorius Stedim North America Inc, Bohemia, New York, USA
| | - Paul Cashen
- Sartorius Stedim Biotech GmbH, Goettingen, Germany
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Tuameh A, Harding SE, Darton NJ. Methods for addressing host cell protein impurities in biopharmaceutical product development. Biotechnol J 2023; 18:e2200115. [PMID: 36427352 DOI: 10.1002/biot.202200115] [Citation(s) in RCA: 5] [Impact Index Per Article: 5.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/07/2022] [Revised: 11/18/2022] [Accepted: 11/22/2022] [Indexed: 11/27/2022]
Abstract
The high demand for monoclonal antibody (mAb) therapeutics in recent years has resulted in significant efforts to improve their costly manufacturing process. The high cost of manufacturing mAbs derives mainly from the purification process, which contributes to 50%-80% of the total manufacturing cost. One of the main challenges facing industry at the purification stage is the clearance of host cell proteins (HCPs) that are produced and often co-purified with the desired mAb product. One of the issues HCPs can cause is the degradation of the final mAb protein product. In this review, techniques are considered that can be used at different stages (upstream and downstream) of mAb manufacture to improve HCP clearance. In addition to established techniques, many new approaches for HCP removal are discussed that have the potential to replace current methods for improving HCP reduction and thereby the quality and stability of the final mAb product.
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Affiliation(s)
- Abdulrahman Tuameh
- National Centre for Macromolecular Hydrodynamics, School of Biosciences, University of Nottingham, Sutton Bonington, UK
| | - Stephen E Harding
- National Centre for Macromolecular Hydrodynamics, School of Biosciences, University of Nottingham, Sutton Bonington, UK
| | - Nicholas J Darton
- Dosage Form Design and Development, BioPharmaceuticals R&D, AstraZeneca, Cambridge, UK
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Schmitz F, Kruse T, Minceva M, Kampmann M. Integrated double flow-through purification of monoclonal antibodies using membrane adsorbers and single-pass tangential flow filtration. Biochem Eng J 2023. [DOI: 10.1016/j.bej.2023.108913] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 03/29/2023]
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Arakawa T, Tomioka Y, Nakagawa M, Sakuma C, Kurosawa Y, Ejima D, Tsumoto K, Akuta T. Non-Affinity Purification of Antibodies. Antibodies (Basel) 2023; 12:antib12010015. [PMID: 36810520 PMCID: PMC9944463 DOI: 10.3390/antib12010015] [Citation(s) in RCA: 4] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/12/2023] [Revised: 02/01/2023] [Accepted: 02/09/2023] [Indexed: 02/16/2023] Open
Abstract
Currently, purification of antibodies is mainly carried out using a platform technology composed primarily of Protein A chromatography as a capture step, regardless of the scale. However, Protein A chromatography has a number of drawbacks, which are summarized in this review. As an alternative, we propose a simple small-scale purification protocol without Protein A that uses novel agarose native gel electrophoresis and protein extraction. For large-scale antibody purification, we suggest mixed-mode chromatography that can in part mimic the properties of Protein A resin, focusing on 4-Mercapto-ethyl-pyridine (MEP) column chromatography.
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Affiliation(s)
- Tsutomu Arakawa
- Alliance Protein Laboratories, San Diego, CA 92130, USA
- Correspondence:
| | - Yui Tomioka
- Research and Development Division, Kyokuto Pharmaceutical Industrial Co., Ltd., Tahahagi 318-0004, Japan
| | - Masataka Nakagawa
- Research and Development Division, Kyokuto Pharmaceutical Industrial Co., Ltd., Tahahagi 318-0004, Japan
| | - Chiaki Sakuma
- Research and Development Division, Kyokuto Pharmaceutical Industrial Co., Ltd., Tahahagi 318-0004, Japan
| | - Yasunori Kurosawa
- Research and Development Division, Kyokuto Pharmaceutical Industrial Co., Ltd., Tahahagi 318-0004, Japan
| | - Daisuke Ejima
- Bio-Diagnostic Reagent Technology Center, Sysmex Corporation, Sayama 350-1332, Japan
| | - Kouhei Tsumoto
- Department of Bioengineering, School of Engineering, The University of Tokyo, Tokyo 113-8656, Japan
| | - Teruo Akuta
- Research and Development Division, Kyokuto Pharmaceutical Industrial Co., Ltd., Tahahagi 318-0004, Japan
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Samaras JJ, Micheletti M, Ding W. Transformation of Biopharmaceutical Manufacturing Through Single-Use Technologies: Current State, Remaining Challenges, and Future Development. Annu Rev Chem Biomol Eng 2022; 13:73-97. [PMID: 35700527 DOI: 10.1146/annurev-chembioeng-092220-030223] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/09/2022]
Abstract
Single-use technologies have transformed conventional biopharmaceutical manufacturing, and their adoption is increasing rapidly for emerging applications like antibody-drug conjugates and cell and gene therapy products. These disruptive technologies have also had a significant impact during the coronavirus disease 2019 pandemic, helping to advance process development to enable the manufacturing of new monoclonal antibody therapies and vaccines. Single-use systems provide closed plug-and-play solutions and enable process intensification and continuous processing. Several challenges remain, providing opportunities to advance single-use sensors and their integration with single-use systems, to develop novel plastic materials, and to standardize design for interchangeability. Because the industry is changing rapidly, a holistic analysis of the current single-use technologies is required, with a summary of the latest advancements in materials science and the implementation of these technologies in end-to-end bioprocesses.
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Affiliation(s)
- Jasmin J Samaras
- Advanced Centre for Biochemical Engineering, University College London, London, United Kingdom
| | - Martina Micheletti
- Advanced Centre for Biochemical Engineering, University College London, London, United Kingdom
| | - Weibing Ding
- Manufacturing Science & Technology, GSK, King of Prussia, Pennsylvania, USA;
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Kikuchi S, Ishihara Surpervision T, Yamamoto K, Hosono M. Virus clearance by activated carbon for therapeutic monoclonal antibody purification. J Chromatogr B Analyt Technol Biomed Life Sci 2022; 1195:123163. [DOI: 10.1016/j.jchromb.2022.123163] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/19/2021] [Revised: 01/15/2022] [Accepted: 02/05/2022] [Indexed: 11/27/2022]
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Slocum A, Santora S, Ly M, Zhang J, Castano J, Becerra-Arteaga A. Development of an activated carbon filtration step and high throughput screening method to remove host cell proteins from a recombinant enzyme process. Biotechnol Prog 2021; 37:e3151. [PMID: 33764696 DOI: 10.1002/btpr.3151] [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: 11/25/2020] [Revised: 03/19/2021] [Accepted: 03/24/2021] [Indexed: 11/07/2022]
Abstract
An increasing number of non-mAb recombinant proteins are being developed today. These biotherapeutics provide greater purification challenges where multiple polishing steps may be required to meet final purity specifications or the process steps may require extensive optimization. Recent studies have shown that activated carbon can be employed in downstream purification processes to selectively separate host cell proteins (HCPs) from monoclonal antibodies (mAb). However, the use of activated carbon as a unit operation in a cGMP purification process is relatively new. As such, the goal of this work is to provide guidance on development approaches, insight into operating parameters and solution conditions that can impact HCP removal, as well as further investigate the mechanism of removal by using mass spectrometry. In this work, activated carbon was evaluated to remove HCPs in the downstream purification process of a recombinant enzyme. Impact of process placement, flux (or residence time), and mass loading on HCP removal was investigated. Feasibility of high throughput screening (HTS) using loose activated carbon was assessed to reduce the amount of therapeutic protein needed and enable testing of a larger number of solution conditions. Finally, mass spectrometry was used to determine the population of HCPs removed by activated carbon. Our work demonstrates that activated carbon can be used effectively in downstream processes of biopharmaceuticals to remove HCPs (up to a 3 log10 reduction) and that an HTS format can be implemented to reduce material demands by up to 23x and allow for process optimization of this adsorbent for purification purposes.
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Affiliation(s)
- Ashley Slocum
- Downstream Process Development, BioTherapeutics Pharmaceutical Sciences, Pfizer, Andover, Massachusetts, USA
| | - Steven Santora
- Downstream Process Development, BioTherapeutics Pharmaceutical Sciences, Pfizer, Andover, Massachusetts, USA
| | - Mellisa Ly
- Analytical Research and Development, BioTherapeutics Pharmaceutical Sciences, Pfizer, Andover, Massachusetts, USA
| | - Junyan Zhang
- Downstream Process Development, BioTherapeutics Pharmaceutical Sciences, Pfizer, Andover, Massachusetts, USA
| | - Juan Castano
- Manufacturing Sciences and Technology, MilliporeSigma, Burlington, Massachusetts, USA
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Nadar S, Shooter G, Somasundaram B, Shave E, Baker K, Lua LHL. Intensified Downstream Processing of Monoclonal Antibodies Using Membrane Technology. Biotechnol J 2020; 16:e2000309. [PMID: 33006254 DOI: 10.1002/biot.202000309] [Citation(s) in RCA: 13] [Impact Index Per Article: 3.3] [Reference Citation Analysis] [Abstract] [Key Words] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/07/2022]
Abstract
The need to intensify downstream processing of monoclonal antibodies to complement the advances in upstream productivity has led to increased attention toward implementing membrane technologies. With the industry moving toward continuous operations and single use processes, membrane technologies show promise in fulfilling the industry needs due to their operational flexibility and ease of implementation. Recently, the applicability of membrane-based unit operations in integrating the downstream process has been explored. In this article, the major developments in the application of membrane-based technologies in the bioprocessing of monoclonal antibodies are reviewed. The recent progress toward developing intensified end-to-end bioprocesses and the critical role membrane technology will play in achieving this goal are focused upon.
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Affiliation(s)
- Sathish Nadar
- Australian Research Council Training Centre for Biopharmaceutical Innovation, Australian Institute for Bioengineering and Nanotechnology, The University of Queensland, Corner College and Cooper Roads, Brisbane, Queensland, 4072, Australia
| | - Gary Shooter
- Australian Research Council Training Centre for Biopharmaceutical Innovation, Australian Institute for Bioengineering and Nanotechnology, The University of Queensland, Corner College and Cooper Roads, Brisbane, Queensland, 4072, Australia
| | - Balaji Somasundaram
- Protein Expression Facility, The University of Queensland, Corner College and Cooper Roads, Brisbane, Queensland, 4072, Australia
| | - Evan Shave
- Australian Research Council Training Centre for Biopharmaceutical Innovation, Australian Institute for Bioengineering and Nanotechnology, The University of Queensland, Corner College and Cooper Roads, Brisbane, Queensland, 4072, Australia.,Pharma services group, Thermo Fisher Scientific, 37 Kent St, Woolloongabba, Brisbane, Queensland, 4102, Australia
| | - Kym Baker
- Pharma services group, Thermo Fisher Scientific, 37 Kent St, Woolloongabba, Brisbane, Queensland, 4102, Australia
| | - Linda H L Lua
- Australian Research Council Training Centre for Biopharmaceutical Innovation, Australian Institute for Bioengineering and Nanotechnology, The University of Queensland, Corner College and Cooper Roads, Brisbane, Queensland, 4072, Australia.,Protein Expression Facility, The University of Queensland, Corner College and Cooper Roads, Brisbane, Queensland, 4072, Australia
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Roque ACA, Pina AS, Azevedo AM, Aires‐Barros R, Jungbauer A, Di Profio G, Heng JYY, Haigh J, Ottens M. Anything but Conventional Chromatography Approaches in Bioseparation. Biotechnol J 2020; 15:e1900274. [DOI: 10.1002/biot.201900274] [Citation(s) in RCA: 23] [Impact Index Per Article: 5.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/28/2020] [Revised: 04/03/2020] [Indexed: 12/28/2022]
Affiliation(s)
| | - Ana Sofia Pina
- UCIBIOChemistry DepartmentNOVA School of Science and Technology Caparica 2829‐516 Portugal
| | - Ana Margarida Azevedo
- IBB – Institute for Bioengineering and BiosciencesDepartment of BioengineeringInstituto Superior TécnicoUniversidade de Lisboa Av. Rovisco Pais Lisbon 1049‐001 Portugal
| | - Raquel Aires‐Barros
- IBB – Institute for Bioengineering and BiosciencesDepartment of BioengineeringInstituto Superior TécnicoUniversidade de Lisboa Av. Rovisco Pais Lisbon 1049‐001 Portugal
| | - Alois Jungbauer
- Department of BiotechnologyUniversity of Natural Resources and Life Sciences Muthgasse 18 Vienna Muthgasse 1190 Austria
| | - Gianluca Di Profio
- National Research Council of Italy (CNR) – Institute on Membrane Technology (ITM) via P. Bucci Cubo 17/C Rende (CS) 87036 Italy
| | - Jerry Y. Y. Heng
- Department of Chemical EngineeringImperial College London South Kensington Campus London SW7 2AZ UK
| | - Jonathan Haigh
- FUJIFILM Diosynth Biotechnologies UK Limited Belasis Avenue Billingham TS23 1LH UK
| | - Marcel Ottens
- Department of BiotechnologyDelft University of Technology Van der Maasweg 9 Delft 2629 HZ The Netherlands
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