Use of confocal scanning laser microscopy to study virus retention during virus filtration

Adapting virus filtration to continuous processing: Effects of product and process variability on filtration performance

Virus filtration (VF) is an important unit operation in the manufacture of biotherapeutics that provides robust removal of potential virus contaminants. Small virus removal can be impacted by the low operating pressures and potential depressurization events that are often associated with continuous operations where increased operational flexibility for higher loading at low flux and low pressure is required. In this study, we evaluated the impact of low flux (7 LMH) and pressure interruptions on minute virus of mice (MVM) removal. We used long-term filtrations conducted to a target throughput of 1000 L/m2 with four different monoclonal antibodies on small-scale hollow fiber virus filters with a hydrophilic modified polyvinylidene fluoride membrane. These conditions are certainly challenging for any VF operation and ensuring robust viral clearance under such conditions is critical to the design and implementation of continuous VF. Planova BioEX filters effectively removed MVM at 4 log or greater when run continuously for up to 6 days. Interestingly, pressure increases associated with filter fouling over the duration of long-term filtrations were shown to be reflective of load material variability and could be remediated by implementation of an inline prefilter. Pressure interruptions had minimal impact on overall MVM logarithmic reduction value. Effective virus removal was achieved with pressure increases being largely product-specific, which demonstrates the capability of the virus filter to remove virus independent of pressure increases that are expected to occur with increased protein load.

Effect of protein fouling on filtrate flux and virus breakthrough behaviors during virus filtration process

Virus filtration process is used to ensure viral safety in the biopharmaceutical downstream processes with high virus removal capacity (i.e., >4 log₁₀ ). However, it is still constrained by protein fouling, which results in reduced filtration capacity and possible virus breakthrough. This study investigated the effects of protein fouling on filtrate flux and virus breakthrough using commercial membranes that had different symmetricity, nominal pore size, and pore size gradients. Flux decay tendency due to protein fouling was influenced by hydrodynamic drag force and protein concentration. As the results of prediction with the classical fouling model, standard blocking was suitable for most virus filters. Undesired virus breakthrough was observed in the membranes having relatively a large pore diameter of the retentive region. The study found that elevated levels of protein solution reduced virus removal performance. However, the impact of prefouled membranes was minimal. These findings shed light on the factors that influence protein fouling during the virus filtration process of biopharmaceutical production.

Analysis of fouling and breakthrough of process related impurities during depth filtration using confocal microscopy

Titer improvement has driven process intensification in mAb manufacture. However, this has come with the drawback of high cell densities and associated process related impurities such as cell debris, host cell protein (HCP), and DNA. This affects the capacity of depth filters and can lead to carryover of impurities to protein A chromatography leading to early resin fouling. New depth filter materials provide the opportunity to remove more process related impurities at this early stage in the process. Hence, there is a need to understand the mechanism of impurity removal within these filters. In this work, the secondary depth filter Millistak+ X0HC (cellulose and diatomaceous earth) is compared with the X0SP (synthetic), by examining the breakthrough of DNA and HCP. Additionally, a novel method was developed to image the location of key impurities within the depth filter structure under a confocal microscope. Flux, tested at 75, 100, and 250 LMH was found to affect the maximal throughput based on the max pressure of 30 psi, but no significant changes were seen in the HCP and DNA breakthrough. However, a drop in cell culture viability, from 87% to 37%, lead to the DNA breakthrough at 10% decreasing from 81 to 55 L/m² for X0HC and from 105 to 47 L/m² for X0SP. The HCP breakthrough was not affected by cell culture viability or filter type. The X0SP filter has a 30%-50% higher max throughput depending on viability, which can be explained by the confocal imaging where the debris and DNA are distributed differently in the layers of the filter pods, with more of the second tighter layer being utilized in the X0SP.

Virus filtration: A Review of Current and Future Practices in Bioprocessing

For drug products manufactured in mammalian cells, safety assurance practices are needed during production to assure that the final medicinal product is safe from the potential risk of viral contamination. Virus filters provide viral retention for a range of viruses through robust, largely size-based retention mechanism. Therefore, a virus filtration step is commonly utilized in a well-designed recombinant therapeutic protein purification process and is a key component in an overall strategy to minimize the risks of adventitious and endogenous viral particles during the manufacturing of biotechnology products. This review summarizes the history of virus filtration, currently available virus filters and prefilters, and virus filtration integrity test methods and study models. There is also discussion of current understanding and gaps with an eye toward future trends and emerging filtration technologies. This article is protected by copyright. All rights reserved.

A review on recent trends of antiviral nanoparticles and airborne filters: special insight on COVID-19 virus

Novel corona virus (COVID-19) pandemic in the last 4 months stimulates the international scientific community to search for vaccine of antiviral agents suitable for in activating the virus inside and outside the human body. More than 4 million people globally are infected by the virus and about 300,000 dead cases until this moment. The ventilation and airborne filters are also investigated aiming to develop an efficient antiviral filtration technology. Human secretion of the infected person as nasal or saliva droplets goes as airborne and distributes the virus everywhere around the person. N95 and N98 filters are the must use filters for capturing particles of sizes around 300 nm. The average size of the novel corona virus (COVID-19) is 100 nm and there is no standard or special filter suitable for this virus. The nanoparticle-coated airborne filter is a suitable technique in this regard. While the efficiency of this type of filters still needs to be enhanced, new developed nanofiber filters are proposed. Most recently, the charged nanofiber filters of sizes below 100 nm are developed and provide an efficient viral filtration and inactivation. The efficiency of filter must be kept at accepted level without increasing the pressure drop. The present review outlines the most efficient antiviral nanoparticles including the recent functional nanoparticles. The filtration theory, filtration modeling, filter testing, and different types of filter with special concentration on the charged nanofiber filter were discussed. The charged nanofiber filter able to capture novel corona virus (COVID-19) with 94% efficiency and a pressure drop less than 20 MPa.

Encapsulation in alginate-polymers improves stability and allows controlled release of the UFV-AREG1 bacteriophage

The bacteriophage UFV-AREG1 was used as a model organism to evaluate the encapsulation via extrusion using different hydrocolloids. Pure alginate [0.75%, 1.0%, 1.5% and 2.0% (m/v)] and mixtures of alginate [0.75% or 1.0% (m/v)] with carrageenan [1.25% (m/v)], chitosan [0.5% (m/v)], or whey protein [1.5% (m/v)] were used to produce bacteriophage-loaded beads. The encapsulating solutions presented flow behavior of non-Newtonian pseudoplastic fluids and the concentration of hydrocolloid did not influence (p > 0.05) the morphology of the beads, except for alginate-chitosan solutions, which presented the higher flow consistency index (K) and the lower flow behavior index (n). The encapsulation efficiency was about 99% and the confocal photomicrography of the encapsulated bacteriophages labeled with fluorescein isothiocyanate showed homogenous distribution of the viral particles within the beads. The phages remained viable in the beads of alginate-whey protein even when submitted to pH 2.5 for 2 h. Beads incubated directly in simulated intestinal fluid (pH 6.8) resulted in a minimal of 50% release of the UFV-AREG1 phages after 5 min, even when previously submitted to the simulated gastric fluid (pH 2.5). Encapsulation enabled phages to remain viable under refrigeration for five months. Encapsulated UFV-AREG1 phages were sensitive to dehydration, suggesting the need for protective agents. In this study, for the first-time bacteriophages were encapsulated in alginate-carrageenan beads, as well as alginate-chitosan as a bead-forming hydrocolloid. In addition, a novel procedure for encapsulating bacteriophages in alginate-whey protein was proposed. The assembled system showed efficiency in the encapsulation of UFV-AREG1 bacteriophages using different hydrocolloids and has potential to be used for the entrapment of a variety of bioactive compounds.

Microscopic visualization of virus removal by dedicated filters used in biopharmaceutical processing: Impact of membrane structure and localization of captured virus particles

Virus filtration with nanometer size exclusion membranes (“nanofiltration”) is effective for removing infectious agents from biopharmaceuticals. While the virus removal capability of virus removal filters is typically evaluated based on calculation of logarithmic reduction value (LRV) of virus infectivity, knowledge of the exact mechanism(s) of virus retention remains limited. Here, human parvovirus B19 (B19V), a small virus (18–26 nm), was spiked into therapeutic plasma protein solutions and filtered through Planova™ 15N and 20N filters in scaled‐down manufacturing processes. Observation of the gross structure of the Planova hollow fiber membranes by transmission electron microscopy (TEM) revealed Planova filter microporous membranes to have a rough inner, a dense middle and a rough outer layer. Of these three layers, the dense middle layer was clearly identified as the most functionally critical for effective capture of B19V. Planova filtration of protein solution containing B19V resulted in a distribution peak in the dense middle layer with an LRV >4, demonstrating effectiveness of the filtration step. This is the first report to simultaneously analyze the gross structure of a virus removal filter and visualize virus entrapment during a filtration process conducted under actual manufacturing conditions. The methodologies developed in this study demonstrate that the virus removal capability of the filtration process can be linked to the gross physical filter structure, contributing to better understanding of virus trapping mechanisms and helping the development of more reliable and robust virus filtration processes in the manufacture of biologicals.

Free Diffusivity of Icosahedral and Tailed Bacteriophages: Experiments, Modeling, and Implications for Virus Behavior in Media Filtration and Flocculation

The aqueous bulk diffusivities of several near-spherical (icosahedral) and nonspherical (tailed) bacterial viruses were experimentally determined by measuring their flux across large pore membranes and using dynamic light scattering, with excellent agreement between values measured using the two techniques. For the icosahedral viruses, good agreement was also found between measured diffusivity values and values predicted with the Stokes-Einstein equation. However, when the tailed viruses were approximated as spheres, poor agreement was found between measured values and Stokes-Einstein predictions. The shape of the tailed organisms was incorporated into two modeling approaches used to predict diffusivity. Model predictions were found to be in good agreement with measured values, demonstrating the importance of the tail in the diffusive transport of these viruses. Our calculations also show that inaccurate estimates of virus diffusion can lead to significant errors when predicting diffusive contributions to flocculation and to single collector efficiency in media filtration.

Sweep flocculation and adsorption of viruses on aluminum flocs during electrochemical treatment prior to surface water microfiltration

Bench-scale experiments were performed to evaluate virus control by an integrated electrochemical-microfiltration (MF) process from turbid (15 NTU) surface water containing moderate amounts of dissolved organic carbon (DOC, 5 mg C/L) and calcium hardness (50 mg/L as CaCO3). Higher reductions in MS2 bacteriophage concentrations were obtained by aluminum electrocoagulation and electroflotation compared with conventional aluminum sulfate coagulation. This was attributed to electrophoretic migration of viruses, which increased their concentrations in the microenvironment of the sacrificial anode where coagulant precursors are dissolved leading to better destabilization during electrolysis. In all cases, viruses were not inactivated implying measured reductions were solely due to their removal. Sweep flocculation was the primary virus destabilization mechanism. Direct evidence for virus enmeshment in flocs was provided by two independent methods: quantitative elution using beef extract at elevated pH and quantitating fluorescence from labeled viruses. Atomic force microscopy studies revealed a monotonically increasing adhesion force between viruses immobilized on AFM tips and floc surfaces with electrocoagulant dosage, which suggests secondary contributions to virus uptake on flocs from adsorption. Virus sorption mechanisms include charge neutralization and hydrophobic interactions with natural organic matter removed during coagulation. This also provided the basis for interpreting additional removal of viruses by the thick cake formed on the surface of the microfilter following electrocoagulation. Enhancements in virus removal as progressively more aluminum was electrolyzed therefore embodies contributions from (i) better encapsulation onto greater amounts of fresh Al(OH)3 precipitates, (ii) increased adsorption capacity associated with higher available coagulant surface area, (iii) greater virus-floc binding affinity due to effective charge neutralization and hydrophobic interactions, and/or (iv) additional removal by a dynamic membrane if a thick cake layer of flocs is deposited.