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Leach M, Cox C, Wickramasinghe SR, Chwatko M, Bhattacharyya D. Role of Microfiltration Membrane Morphology on Nanoparticle Purification to Enhance Downstream Purification of Viral Vectors. ACS APPLIED BIO MATERIALS 2024; 7:3932-3941. [PMID: 38822810 DOI: 10.1021/acsabm.4c00272] [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] [Indexed: 06/03/2024]
Abstract
In the rapidly advancing realms of gene therapy and biotechnology, the efficient purification of viral vectors is pivotal for ensuring the safety and efficacy of gene therapies. This study focuses on optimizing membrane selection for viral vector purification by evaluating key properties, including porosity, thickness, pore structure, and hydrophilicity. Notably, we employed adeno-associated virus (AAV)-sized nanoparticles (20 nm), 200 nm particles, and bovine serum albumin (BSA) to model viral vector harvesting. Experimental data from constant pressure normal flow filtration (NFF) at 1 and 2 bar using four commercial flat sheet membranes revealed distinct fouling behaviors. Symmetric membranes predominantly showed internal and external pore blockage, while asymmetric membranes formed a cake layer on the surface. Hydrophilicity exhibited a positive correlation with recovery, demonstrating an enhanced recovery with increased hydrophilicity. Membranes with higher porosity and interpore connectivity showcased superior throughput, reduced operating time, and increased recovery. Asymmetric polyether sulfone (PES) membranes emerged as the optimal choice, achieving ∼100% recovery of AAV-sized particles, an ∼44% reduction in model cell debris (200 nm particles), an ∼35% decrease in BSA, and the fastest operating time of all membranes tested. This systematic investigation into fouling behaviors and membrane properties not only informs optimal conditions for viral vector recovery but also lays the groundwork for advancing membrane-based strategies in bioprocessing.
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Affiliation(s)
- Mara Leach
- Department of Chemical and Materials Engineering, University of Kentucky, Lexington, Kentucky 40506, United States
| | - Catherine Cox
- Department of Chemical and Materials Engineering, University of Kentucky, Lexington, Kentucky 40506, United States
| | | | - Malgorzata Chwatko
- Department of Chemical and Materials Engineering, University of Kentucky, Lexington, Kentucky 40506, United States
| | - Dibakar Bhattacharyya
- Department of Chemical and Materials Engineering, University of Kentucky, Lexington, Kentucky 40506, United States
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Suh D, Jin H, Park H, Lee C, Cho YH, Baek Y. Effect of protein fouling on filtrate flux and virus breakthrough behaviors during virus filtration process. Biotechnol Bioeng 2023. [PMID: 37144573 DOI: 10.1002/bit.28407] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/15/2023] [Revised: 04/13/2023] [Accepted: 04/13/2023] [Indexed: 05/06/2023]
Abstract
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.
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Affiliation(s)
- Dongwoo Suh
- School of Chemical and Biological Engineering, Seoul National University (SNU), Seoul, Republic of Korea
| | - Hoeun Jin
- Department of Biological Engineering, Inha University, Incheon, Republic of Korea
| | - Hosik Park
- Green Carbon Research Center, Korea Research Institute of Chemical Technology (KRICT), Daejeon, Republic of Korea
- Department of Advanced Materials and Chemical Engineering, University of Science & Technology (UST), Daejeon, Yuseong-gu, Republic of Korea
| | - Changha Lee
- School of Chemical and Biological Engineering, Seoul National University (SNU), Seoul, Republic of Korea
| | - Young Hoon Cho
- Green Carbon Research Center, Korea Research Institute of Chemical Technology (KRICT), Daejeon, Republic of Korea
- Department of Advanced Materials and Chemical Engineering, University of Science & Technology (UST), Daejeon, Yuseong-gu, Republic of Korea
| | - Youngbin Baek
- Department of Biological Engineering, Inha University, Incheon, Republic of Korea
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Suh D, Kim M, Lee C, Baek Y. Virus filtration in biopharmaceutical downstream processes: key factors and current limitations. SEPARATION & PURIFICATION REVIEWS 2022. [DOI: 10.1080/15422119.2022.2143379] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/16/2022]
Affiliation(s)
- Dongwoo Suh
- School of Chemical and Biological Engineering, College of Engineering, Institute of Chemical Process (ICP), Seoul National University (SNU), Gwanak-gu, Republic of Korea
| | - Mina Kim
- Department of Biotechnology, Institute of Basic Science, Sungshin Women’s University, Seoul, Republic of Korea
| | - Changha Lee
- School of Chemical and Biological Engineering, College of Engineering, Institute of Chemical Process (ICP), Seoul National University (SNU), Gwanak-gu, Republic of Korea
| | - Youngbin Baek
- Department of Biological Engineering, Inha University, Incheon, Republic of Korea
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Global pore blockage - cake filtration model including pressure effects on protein fouling in virus filtration. J Memb Sci 2022. [DOI: 10.1016/j.memsci.2022.120961] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/19/2022]
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Leisi R, Rostami I, Laughhunn A, Bieri J, Roth NJ, Widmer E, Ros C. Visualizing protein fouling and its impact on parvovirus retention within distinct filter membrane morphologies. J Memb Sci 2022. [DOI: 10.1016/j.memsci.2022.120791] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022]
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6
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Effect of operating pressure on protein fouling during constant-pressure virus removal filtration. J Memb Sci 2022. [DOI: 10.1016/j.memsci.2022.120351] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/22/2022]
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Effect of pore-forming/hydrophilic additive anchorage on the mesoporous structure and sieving performance of a blended ultrafiltration (UF) membrane. J Memb Sci 2022. [DOI: 10.1016/j.memsci.2021.119904] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/18/2022]
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Johnson SA, Chen S, Bolton G, Chen Q, Lute S, Fisher J, Brorson K. Virus filtration: A Review of Current and Future Practices in Bioprocessing. Biotechnol Bioeng 2021; 119:743-761. [PMID: 34936091 DOI: 10.1002/bit.28017] [Citation(s) in RCA: 13] [Impact Index Per Article: 4.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/02/2021] [Revised: 12/01/2021] [Accepted: 12/02/2021] [Indexed: 11/06/2022]
Abstract
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.
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Affiliation(s)
- Sarah A Johnson
- Office of Biotechnology Products, CDER, FDA 10903 New Hampshire Ave., Silver Spring, Maryland, 20903
| | - Shuang Chen
- NGM Biopharmaceuticals Inc., 333 Oyster Point Blvd., South San Francisco, CA, 94080
| | - Glen Bolton
- Amgen Inc., 360 Binney Street, Cambridge, MA, 02142
| | - Qi Chen
- Genentech Inc. One DNA Way,, South San Francisco, CA, 94080
| | - Scott Lute
- Office of Biotechnology Products, CDER, FDA 10903 New Hampshire Ave., Silver Spring, Maryland, 20903
| | - John Fisher
- Genentech Inc. One DNA Way,, South San Francisco, CA, 94080
| | - Kurt Brorson
- Parexel International., 275 Grove Street Suite 101C, Newton, MA, 02466
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Brickey KP, Zydney AL, Gomez ED. FIB-SEM tomography reveals the nanoscale 3D morphology of virus removal filters. J Memb Sci 2021. [DOI: 10.1016/j.memsci.2021.119766] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
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Tang A, Ramos I, Newell K, Stewart KD. A novel high-throughput process development screening tool for virus filtration. J Memb Sci 2020. [DOI: 10.1016/j.memsci.2020.118330] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/17/2022]
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Leisi R, Bieri J, Roth NJ, Ros C. Determination of parvovirus retention profiles in virus filter membranes using laser scanning microscopy. J Memb Sci 2020. [DOI: 10.1016/j.memsci.2020.118012] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/26/2022]
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Chan Q, Entezarian M, Zhou J, Osterloh R, Huang Q, Ellefson M, Mader B, Liu Y, Swierczek M. Gold nanoparticle mixture retention test with single particle detection: A fast and sensitive probe for functional pore sizes of ultrafiltration membranes. J Memb Sci 2020. [DOI: 10.1016/j.memsci.2020.117822] [Citation(s) in RCA: 8] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/28/2022]
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Pazouki M, Noelle Wilton A, Latulippe DR. An experimental study on sterile filtration of fluorescently labeled nanoparticles – the importance of surfactant concentration. Sep Purif Technol 2019. [DOI: 10.1016/j.seppur.2019.02.038] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/15/2022]
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Fallahianbijan F, Giglia S, Carbrello C, Bell D, Zydney AL. Impact of protein fouling on nanoparticle capture within the Viresolve® Pro and Viresolve® NFP virus removal membranes. Biotechnol Bioeng 2019; 116:2285-2291. [PMID: 31081123 DOI: 10.1002/bit.27017] [Citation(s) in RCA: 20] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/11/2019] [Revised: 04/08/2019] [Accepted: 05/09/2019] [Indexed: 11/05/2022]
Abstract
Virus filtration is a robust size-based technique that can provide the high level of viral clearance required for the production of mammalian-derived biotherapeutics such as monoclonal antibodies. Several studies have shown that the retention characteristics of some, but not all, virus filters can be significantly affected by membrane fouling, but there have been no direct measurements of how protein fouling might alter the location of virus capture within these membranes. The objective of this study was to directly examine the effect of protein fouling by human immunoglobulin G (IgG) on virus capture within the Viresolve® Pro and Viresolve® NFP membranes by scanning electron microscopy using different size gold nanoparticles. IgG fouling shifted the capture location of 20 nm gold nanoparticles further upstream within the Viresolve® Pro filter due to the constriction and/or blockage of the pores in the virus retentive region of the filter. In contrast, IgG fouling had no measurable effect on the capture of 20 nm nanoparticles in the Viresolve® NFP membrane, and IgG fouling had no effect on the capture of larger 40 and 100 nm nanoparticles in either membrane. These results provide important insights into how protein fouling alters the virus retention characteristics of different virus filters.
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Affiliation(s)
- Fatemeh Fallahianbijan
- Department of Chemical Engineering, The Pennsylvania State University, University Park, Pennsylvania
| | - Sal Giglia
- MilliporeSigma Corporation, Bedford, Massachusetts
| | | | - David Bell
- MilliporeSigma Corporation, Bedford, Massachusetts
| | - Andrew L Zydney
- Department of Chemical Engineering, The Pennsylvania State University, University Park, Pennsylvania
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Bieberbach M, Kosiol P, Seay A, Bennecke M, Hansmann B, Hepbildikler S, Thom V. Investigation of fouling mechanisms of virus filters during the filtration of protein solutions using a high throughput filtration screening device. Biotechnol Prog 2019; 35:e2776. [DOI: 10.1002/btpr.2776] [Citation(s) in RCA: 8] [Impact Index Per Article: 1.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/30/2018] [Revised: 12/19/2018] [Indexed: 01/20/2023]
Affiliation(s)
| | - Peter Kosiol
- Sartorius Stedim Biotech GmbH, 37079 Göttingen Germany
| | | | | | | | | | - Volkmar Thom
- Sartorius Stedim Biotech GmbH, 37079 Göttingen Germany
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Kosiol P, Kahrs C, Thom V, Ulbricht M, Hansmann B. Investigation of virus retention by size exclusion membranes under different flow regimes. Biotechnol Prog 2018; 35:e2747. [PMID: 30431234 DOI: 10.1002/btpr.2747] [Citation(s) in RCA: 9] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/04/2017] [Revised: 10/02/2018] [Accepted: 11/09/2018] [Indexed: 11/05/2022]
Abstract
Virus removal by filter membranes is regarded as a robust and efficient unit operation, which is frequently applied in the downstream processing of biopharmaceuticals. The retention of viruses by virus filtration membranes is predominantly based on size exclusion. However, recent results using model membranes and bacteriophage PP7 point to the fact that virus retention can also significantly be influenced by adsorptive interactions between virus, product molecules, and membranes. Furthermore, the impact of flow rate and flow interruptions on virus retention have been studied and responsible mechanisms discussed. The aim of this investigation was to gain a holistic understanding of the underlying mechanisms for virus retention in size exclusion membranes as a function of membrane structure and membrane surface properties, as well as flow and solution conditions. The results of this study contribute to the differentiation between size exclusion and adsorptive effects during virus filtration and broaden the current understanding of mechanisms related to virus breakthroughs after temporary flow interruptions. Within the frame of a Design of Experiments approach it was found that the level of retention of virus filtration membranes was mostly influenced by the membrane structure during typical process-related flow conditions. The retention performance after a flow interruption was also significantly influenced by membrane surface properties and solution conditions. While size exclusion was confirmed as main retention mechanism, the analysis of all results suggests that especially after a flow interruption virus retention can be influenced by adsorptive effects between the virus and the membrane surface. © 2018 American Institute of Chemical Engineers Biotechnol. Prog., 35: e2747, 2019.
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Affiliation(s)
- Peter Kosiol
- Sartorius Stedim Biotech GmbH, 37079, Göttingen, Germany.,Universität Duisburg-Essen, Technische Chemie II, 45141, Essen, Germany
| | | | - Volkmar Thom
- Sartorius Stedim Biotech GmbH, 37079, Göttingen, Germany
| | - Mathias Ulbricht
- Universität Duisburg-Essen, Technische Chemie II, 45141, Essen, Germany
| | - Björn Hansmann
- Sartorius Stedim Biotech GmbH, 37079, Göttingen, Germany
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Nazem-Bokaee H, Fallahianbijan F, Chen D, O'Donnell SM, Carbrello C, Giglia S, Bell D, Zydney AL. Probing pore structure of virus filters using scanning electron microscopy with gold nanoparticles. J Memb Sci 2018. [DOI: 10.1016/j.memsci.2018.01.069] [Citation(s) in RCA: 32] [Impact Index Per Article: 5.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/08/2023]
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