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Brower K, Wiltberger K, Berdugo C, Bosley A, Goodrich E, Pferdeort V, Schaefer G. Process development and characterization for integrated continuous bioprocesses-Highlights from N-mAb. Biotechnol Prog 2024; 40:e3425. [PMID: 38289271 DOI: 10.1002/btpr.3425] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/09/2023] [Revised: 10/31/2023] [Accepted: 12/20/2023] [Indexed: 08/20/2024]
Abstract
The N-mAb case study was produced by the National Institute for Innovation in Manufacturing Biopharmaceuticals (NIIMBL) to support teaching and learning for both industry and to accelerate adoption of advanced manufacturing process technologies such as integrated continuous bioprocesses (ICB) for mAbs. Similar to the A-mAb case study, N-mAb presents the evolution of an integrated control strategy, from early clinical through process validation and commercial manufacturing with a focus on elements that are unique to integrated continuous bioprocesses. This publication presents a summary of the process design and characterization chapters to allow a greater focus on the unique elements relevant to that phase of development.
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Affiliation(s)
- Kevin Brower
- Sanofi, Purification Development-Mammalian Platform, Framingham, Massachusetts, USA
| | - Kelly Wiltberger
- Biogen, Biologics Development, Biogen, Research Triangle Park, North Carolina, USA
| | | | - Allen Bosley
- AstraZeneca, Purification Process Sciences, Gaithersburg, Maryland, USA
| | | | - Valerie Pferdeort
- Biogen, Cell Culture Development, Research Triangle Park, North Carolina, USA
| | - Gene Schaefer
- National Institute for Innovation in Manufacturing Biopharmaceuticals (NIIMBL), Newark, Delaware, USA
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Chen YC, Recanati G, De Mathia F, Lin DQ, Jungbauer A. Residence time distribution in continuous virus filtration. Biotechnol Bioeng 2024; 121:1876-1888. [PMID: 38494789 DOI: 10.1002/bit.28696] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/26/2023] [Revised: 02/23/2024] [Accepted: 02/27/2024] [Indexed: 03/19/2024]
Abstract
Regulatory authorities recommend using residence time distribution (RTD) to address material traceability in continuous manufacturing. Continuous virus filtration is an essential but poorly understood step in biologics manufacturing in respect to fluid dynamics and scale-up. Here we describe a model that considers nonideal mixing and film resistance for RTD prediction in continuous virus filtration, and its experimental validation using the inert tracer NaNO3. The model was successfully calibrated through pulse injection experiments, yielding good agreement between model prediction and experiment (R 2 > ${R}^{2}\gt $ 0.90). The model enabled the prediction of RTD with variations-for example, in injection volumes, flow rates, tracer concentrations, and filter surface areas-and was validated using stepwise experiments and combined stepwise and pulse injection experiments. All validation experiments achievedR 2 > ${R}^{2}\gt $ 0.97. Notably, if the process includes a porous material-such as a porous chromatography material, ultrafilter, or virus filter-it must be considered whether the molecule size affects the RTD, as tracers with different sizes may penetrate the pore space differently. Calibration of the model with NaNO3 enabled extrapolation to RTD of recombinant antibodies, which will promote significant savings in antibody consumption. This RTD model is ready for further application in end-to-end integrated continuous downstream processes, such as addressing material traceability during continuous virus filtration processes.
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Affiliation(s)
- Yu-Cheng Chen
- Key Laboratory of Biomass Chemical Engineering of Ministry of Education, Zhejiang Key Laboratory of Smart Biomaterials, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou, China
- Department of Biotechnology, University of Natural Resources and Life Sciences, Vienna, Austria
| | - Gabriele Recanati
- Department of Biotechnology, University of Natural Resources and Life Sciences, Vienna, Austria
| | - Fernando De Mathia
- Department of Biotechnology, University of Natural Resources and Life Sciences, Vienna, Austria
| | - Dong-Qiang Lin
- Key Laboratory of Biomass Chemical Engineering of Ministry of Education, Zhejiang Key Laboratory of Smart Biomaterials, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou, China
| | - Alois Jungbauer
- Department of Biotechnology, University of Natural Resources and Life Sciences, Vienna, Austria
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Hong MS, Lu AE, Ou RW, Wolfrum JM, Springs SL, Sinskey AJ, Braatz RD. Model-based control for column-based continuous viral inactivation of biopharmaceuticals. Biotechnol Bioeng 2021; 118:3215-3224. [PMID: 34101159 DOI: 10.1002/bit.27846] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/11/2021] [Revised: 04/15/2021] [Accepted: 05/30/2021] [Indexed: 11/08/2022]
Abstract
Batch low-pH hold is a common processing step to inactivate enveloped viruses for biologics derived from mammalian sources. Increased interest in the transition of biopharmaceutical manufacturing from batch to continuous operation resulted in numerous attempts to adapt batch low-pH hold to continuous processing. However, control challenges with operating this system have not been directly addressed. This article describes a low-cost, column-based continuous viral inactivation system constructed with off-the-shelf components. Model-based, reaction-invariant pH controller is implemented to account for the nonlinearities with Bayesian estimation addressing variations in the operation. The residence time distribution is modeled as a plug flow reactor with axial dispersion in series with a continuously stirred tank reactor, and is periodically estimated during operation through inverse tracer experiments. The estimated residence time distribution quantifies the minimum residence time, which is used to adjust feed flow rates. Controller validation experiments demonstrate that pH and minimum residence time setpoint tracking and disturbance rejection are achieved with fast and accurate response and no instability. Viral inactivation testing demonstrates tight control of logarithmic reduction values over extended operation. This study provides tools for the design and operation of continuous viral inactivation systems in service of increasing productivity, improving product quality, and enhancing patient safety.
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Affiliation(s)
- Moo Sun Hong
- Department of Chemical Engineering, Massachusetts Institute of Technology, Cambridge, Massachusetts, USA
| | - Amos E Lu
- Department of Chemical Engineering, Massachusetts Institute of Technology, Cambridge, Massachusetts, USA
| | - Rui Wen Ou
- Department of Biology, Massachusetts Institute of Technology, Cambridge, Massachusetts, USA
| | - Jacqueline M Wolfrum
- Center for Biomedical Innovation, Massachusetts Institute of Technology, Cambridge, Massachusetts, USA
| | - Stacy L Springs
- Center for Biomedical Innovation, Massachusetts Institute of Technology, Cambridge, Massachusetts, USA
| | - Anthony J Sinskey
- Department of Biology, Massachusetts Institute of Technology, Cambridge, Massachusetts, USA
| | - Richard D Braatz
- Department of Chemical Engineering, Massachusetts Institute of Technology, Cambridge, Massachusetts, USA
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Gerstweiler L, Bi J, Middelberg AP. Continuous downstream bioprocessing for intensified manufacture of biopharmaceuticals and antibodies. Chem Eng Sci 2021. [DOI: 10.1016/j.ces.2020.116272] [Citation(s) in RCA: 12] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/08/2023]
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Khanal O, Lenhoff AM. Developments and opportunities in continuous biopharmaceutical manufacturing. MAbs 2021; 13:1903664. [PMID: 33843449 PMCID: PMC8043180 DOI: 10.1080/19420862.2021.1903664] [Citation(s) in RCA: 24] [Impact Index Per Article: 8.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/04/2020] [Revised: 02/25/2021] [Accepted: 03/11/2021] [Indexed: 12/12/2022] Open
Abstract
Today's biologics manufacturing practices incur high costs to the drug makers, which can contribute to high prices for patients. Timely investment in the development and implementation of continuous biomanufacturing can increase the production of consistent-quality drugs at a lower cost and a faster pace, to meet growing demand. Efficient use of equipment, manufacturing footprint, and labor also offer the potential to improve drug accessibility. Although technological efforts enabling continuous biomanufacturing have commenced, challenges remain in the integration, monitoring, and control of traditionally segmented unit operations. Here, we discuss recent developments supporting the implementation of continuous biomanufacturing, along with their benefits.
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Affiliation(s)
- Ohnmar Khanal
- Department of Chemical and Biomolecular Engineering, University of Delaware, Newark, DE
| | - Abraham M. Lenhoff
- Department of Chemical and Biomolecular Engineering, University of Delaware, Newark, DE
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Fülöp G, Domokos A, Galata D, Szabó E, Gyürkés M, Szabó B, Farkas A, Madarász L, Démuth B, Lendér T, Nagy T, Kovács-Kiss D, Van der Gucht F, Marosi G, Nagy ZK. Integrated twin-screw wet granulation, continuous vibrational fluid drying and milling: A fully continuous powder to granule line. Int J Pharm 2020; 594:120126. [PMID: 33321167 DOI: 10.1016/j.ijpharm.2020.120126] [Citation(s) in RCA: 9] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/25/2020] [Revised: 11/21/2020] [Accepted: 11/24/2020] [Indexed: 12/24/2022]
Abstract
Highly homogeneous low-dose (50 μg) tablets were produced incorporating perfectly free-flowing granules prepared by a fully integrated Continuous Manufacturing (CM) line. The adopted CM equipment consisted of a Twin-Screw Wet Granulator (TSWG), a Continuous Fluid Bed Dryer (CFBD) and a Continuous Sieving (CS) unit. Throughout the experiments a pre-blend of lactose-monohydrate and corn starch was gravimetrically dosed with 1 kg/h into the TSWG, where they were successfully granulated with the drug containing water-based PVPK30 solution. The wet mass was subsequently dried in the CFBD on a vibratory conveyor belt and finally sieved in the milling unit. Granule production efficiency was maximized by determining the minimal Liquid-to-Solid (L/S) ratio (0.11). Design of Experiments (DoE) were carried out in order to evaluate the influence of the drying process parameters of the CFBD on the Loss-on-Drying (LOD) results. The manufactured granules were compressed into tablets by an industrial tablet rotary press with excellent API homogeneity (RSD < 3%). Significant scale-up was realized with the CM line by increasing the throughput rate to 10 kg/h. The manufactured granules yielded very similar results to the previous small-scale granulation runs. API homogeneity was demonstrated (RSD < 2%) with Blend Uniformity Analysis (BUA). The efficiency of TSWG granulation was compared to High-Shear Granulation (HSG) with the same L/S ratio. The final results have demonstrated that both the liquid distribution and more importantly API homogeneity was better in case of the TSWG granulation (RSD 1.3% vs. 4.5%).
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Affiliation(s)
- G Fülöp
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), Műegyetem rkp. 3, 1111 Budapest, Hungary; Gedeon Richter Plc., Formulation R&D, Gyömrői u. 19-21, H-1103 Budapest, Hungary
| | - A Domokos
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), Műegyetem rkp. 3, 1111 Budapest, Hungary
| | - D Galata
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), Műegyetem rkp. 3, 1111 Budapest, Hungary
| | - E Szabó
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), Műegyetem rkp. 3, 1111 Budapest, Hungary
| | - M Gyürkés
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), Műegyetem rkp. 3, 1111 Budapest, Hungary
| | - B Szabó
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), Műegyetem rkp. 3, 1111 Budapest, Hungary
| | - A Farkas
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), Műegyetem rkp. 3, 1111 Budapest, Hungary
| | - L Madarász
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), Műegyetem rkp. 3, 1111 Budapest, Hungary
| | - B Démuth
- Gedeon Richter Plc., Formulation R&D, Gyömrői u. 19-21, H-1103 Budapest, Hungary
| | - T Lendér
- Gedeon Richter Plc., Formulation R&D, Gyömrői u. 19-21, H-1103 Budapest, Hungary
| | - T Nagy
- Gedeon Richter Plc., Formulation R&D, Gyömrői u. 19-21, H-1103 Budapest, Hungary
| | - D Kovács-Kiss
- Gedeon Richter Plc., Formulation R&D, Gyömrői u. 19-21, H-1103 Budapest, Hungary
| | - F Van der Gucht
- ProCepT N.V., Industriepark Rosteyne 4, 9060 Zelzate, Belgium
| | - G Marosi
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), Műegyetem rkp. 3, 1111 Budapest, Hungary
| | - Z K Nagy
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), Műegyetem rkp. 3, 1111 Budapest, Hungary.
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Sencar J, Hammerschmidt N, Jungbauer A. Modeling the Residence Time Distribution of Integrated Continuous Bioprocesses. Biotechnol J 2020; 15:e2000008. [DOI: 10.1002/biot.202000008] [Citation(s) in RCA: 13] [Impact Index Per Article: 3.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/10/2020] [Revised: 04/02/2020] [Indexed: 12/19/2022]
Affiliation(s)
- Jure Sencar
- Austria Centre for Industrial Biotechnology Muthgasse 11 Vienna A‐1190 Austria
| | | | - Alois Jungbauer
- Austria Centre for Industrial Biotechnology Muthgasse 11 Vienna A‐1190 Austria
- Department of BiotechnologyUniversity of Natural Resources and Life Sciences Muthgasse 18 Vienna A‐1190 Austria
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Martins DL, Sencar J, Hammerschmidt N, Flicker A, Kindermann J, Kreil TR, Jungbauer A. Truly continuous low pH viral inactivation for biopharmaceutical process integration. Biotechnol Bioeng 2020; 117:1406-1417. [PMID: 32017010 PMCID: PMC7187162 DOI: 10.1002/bit.27292] [Citation(s) in RCA: 24] [Impact Index Per Article: 6.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/20/2019] [Revised: 12/16/2019] [Accepted: 02/02/2020] [Indexed: 12/18/2022]
Abstract
Continuous virus inactivation (VI) has received little attention in the efforts to realize fully continuous biomanufacturing in the future. Implementation of continuous VI must assure a specific minimum incubation time, typically 60 min. To guarantee the minimum incubation time, we implemented a packed bed continuous viral inactivation reactor (CVIR) with narrow residence time distribution (RTD) for low pH incubation. We show that the RTD does not broaden significantly over a wide range of linear flow velocities-which highlights the flexibility and robustness of the design. Prolonged exposure to acidic pH has no impact on bed stability, assuring constant RTD throughout long term operation. The suitability of the packed bed CVIR for low pH inactivation is shown with two industry-standard model viruses, that is xenotropic murine leukemia virus and pseudorabies virus. Controls at neutral pH showed no system-induced VI. At low pH, significant VI is observed, even after only 15 min. Based on the low pH inactivation kinetics, the continuous process is equivalent to traditional batch operation. This study establishes a concept for continuous low pH inactivation and, together with previous reports, highlights the versatility of the packed bed reactor for continuous VI, regardless of the inactivation method.
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Affiliation(s)
- Duarte L. Martins
- Austria Centre for Industrial BiotechnologyViennaAustria
- Department of BiotechnologyUniversity of Natural Resources and Life SciencesViennaAustria
| | - Jure Sencar
- Austria Centre for Industrial BiotechnologyViennaAustria
- Department of BiotechnologyUniversity of Natural Resources and Life SciencesViennaAustria
| | - Nikolaus Hammerschmidt
- Austria Centre for Industrial BiotechnologyViennaAustria
- Department of BiotechnologyUniversity of Natural Resources and Life SciencesViennaAustria
| | - Andreas Flicker
- Department of VirologyGlobal Pathogen SafetyTakedaViennaAustria
| | | | - Thomas R. Kreil
- Department of VirologyGlobal Pathogen SafetyTakedaViennaAustria
| | - Alois Jungbauer
- Austria Centre for Industrial BiotechnologyViennaAustria
- Department of BiotechnologyUniversity of Natural Resources and Life SciencesViennaAustria
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