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Reyes SJ, Lemire L, Molina RS, Roy M, L'Ecuyer-Coelho H, Martynova Y, Cass B, Voyer R, Durocher Y, Henry O, Pham PL. Multivariate data analysis of process parameters affecting the growth and productivity of stable Chinese hamster ovary cell pools expressing SARS-CoV-2 spike protein as vaccine antigen in early process development. Biotechnol Prog 2024:e3467. [PMID: 38660973 DOI: 10.1002/btpr.3467] [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: 01/05/2024] [Revised: 03/25/2024] [Accepted: 03/28/2024] [Indexed: 04/26/2024]
Abstract
The recent COVID-19 pandemic revealed an urgent need to develop robust cell culture platforms which can react rapidly to respond to this kind of global health issue. Chinese hamster ovary (CHO) stable pools can be a vital alternative to quickly provide gram amounts of recombinant proteins required for early-phase clinical assays. In this study, we analyze early process development data of recombinant trimeric spike protein Cumate-inducible manufacturing platform utilizing CHO stable pool as a preferred production host across three different stirred-tank bioreactor scales (0.75, 1, and 10 L). The impact of cell passage number as an indicator of cell age, methionine sulfoximine (MSX) concentration as a selection pressure, and cell seeding density was investigated using stable pools expressing three variants of concern. Multivariate data analysis with principal component analysis and batch-wise unfolding technique was applied to evaluate the effect of critical process parameters on production variability and a random forest (RF) model was developed to forecast protein production. In order to further improve process understanding, the RF model was analyzed with Shapley value dependency plots so as to determine what ranges of variables were most associated with increased protein production. Increasing longevity, controlling lactate build-up, and altering pH deadband are considered promising approaches to improve overall culture outcomes. The results also demonstrated that these pools are in general stable expressing similar level of spike proteins up to cell passage 11 (~31 cell generations). This enables to expand enough cells required to seed large volume of 200-2000 L bioreactor.
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Affiliation(s)
- Sebastian-Juan Reyes
- Department of Chemical Engineering, Polytechnique Montreal, Montreal, Canada
- Human Health Therapeutics Research Centre, National Research Council Canada, Canada
| | - Lucas Lemire
- Department of Chemical Engineering, Polytechnique Montreal, Montreal, Canada
- Human Health Therapeutics Research Centre, National Research Council Canada, Canada
| | | | - Marjolaine Roy
- Human Health Therapeutics Research Centre, National Research Council Canada, Canada
| | | | - Yuliya Martynova
- Human Health Therapeutics Research Centre, National Research Council Canada, Canada
| | - Brian Cass
- Human Health Therapeutics Research Centre, National Research Council Canada, Canada
| | - Robert Voyer
- Human Health Therapeutics Research Centre, National Research Council Canada, Canada
| | - Yves Durocher
- Human Health Therapeutics Research Centre, National Research Council Canada, Canada
| | - Olivier Henry
- Department of Chemical Engineering, Polytechnique Montreal, Montreal, Canada
| | - Phuong Lan Pham
- Human Health Therapeutics Research Centre, National Research Council Canada, Canada
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Hybrid Model-based Framework for Soft Sensing and Forecasting Key Process Variables in the Production of Hyaluronic Acid by Streptococcus zooepidemicus. BIOTECHNOL BIOPROC E 2023. [DOI: 10.1007/s12257-022-0247-x] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/25/2023]
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Suarez-Zuluaga DA, van der Pol LA, van 't Oever AG, Bakker WA, Thomassen YE. Development of an animal component free production process for Sabin inactivated polio vaccine. Vaccine X 2022; 12:100223. [PMID: 36217423 PMCID: PMC9547281 DOI: 10.1016/j.jvacx.2022.100223] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/08/2022] [Revised: 09/16/2022] [Accepted: 09/28/2022] [Indexed: 11/15/2022] Open
Abstract
Inactivated polio vaccine production using attenuated Sabin strains (sIPV) instead of wild type polio viruses (cIPV) is an initiative encouraged by the World Health Organization. This use of attenuated viruses is preferred as it reduces risks related to potential outbreaks during IPV production. Previously, an sIPV production process was set up based on the cIPV production process. Optimizing this process while using only animal component free (ACF) substances allows reduction of operational costs and mitigates risks of adverse effects related with animal derived compounds. Here, development of a process for production of sIPV using only ACF compounds, is described. The upstream process required a change in cell growth medium from serum-containing medium to ACF medium, while virus production media remained the same as the already used M199 medium was free of animal components. In the downstream process multiple modifications in existing unit operations were made including addition of a diafiltration step prior to inactivation. After optimizing each unit operation, robustness of the whole process was demonstrated using design of experiments (DoE) methodology. By using DoE we were able to vary different process parameters across unit operations to assess the impact on our quality attributes. The developed process was robust as the observed variation for quality attributes due to differences in process parameters remained within specification. The resulting pilot process showed not only to be robust, but also to have a considerable higher product yield when compared to the serum containing sIPV process. Product yields are now comparable to the cIPV process based on using wild type polio viruses. Moreover, the potency of the produced vaccine was comparable that of cIPV vaccine. The developed ACF sIPV process can be transferred to vaccine manufacturers at the end-of pre-clinical development phase, at lab- or pilot scale, before production of clinical trial material.
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Salim T, Chauhan G, Templeton N, Ling WLW. Using MVDA with stoichiometric balances to optimize amino acid concentrations in chemically defined CHO cell culture medium for improved culture performance. Biotechnol Bioeng 2021; 119:452-469. [PMID: 34811720 DOI: 10.1002/bit.27998] [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: 07/02/2021] [Revised: 10/22/2021] [Accepted: 11/13/2021] [Indexed: 11/07/2022]
Abstract
Chemically defined (CD) media are routinely used in the production of biologics in Chinese hamster ovary (CHO) cell culture and provide enhanced raw material control. Nutrient optimized CD media is an important path to increase cell growth and monoclonal antibody (mAb) productivity in recombinant CHO cell lines. However, nutrient optimization efforts for CD media typically rely on multifactorial and experimental design of experiment approaches or complex mathematical models of cellular metabolism or gene expression systems. Moreover, the majority of these efforts are aimed at amino acids since they constitute essential nutrients in CD media as they directly contribute to biomass and protein production. In this study, we demonstrate the utilization of multivariate data analytics (MVDA) coupled with amino acid stoichiometric balances (SBs) to increased cell growth and mAb productivity in efforts to support CD media development efforts. SBs measure the difference between theoretical demand of amino acids and the empirically measured fluxes to identify various catabolic or anabolic states of the cell. When coupled with MVDA, the statistical models were not only able to highlight key amino acids toward cell growth or productivity, but also provided direction on metabolic favorability of the amino acid. Experimental validation of our approach resulted in a 55% increase in total cell growth and about an 80% increase in total mAb productivity. Increased specific consumption of stoichiometrically balanced amino acids and decreased specific consumption of glucose was also observed in optimized CD media suggesting favorable consumption of desired nutrients and a potential for energy redistribution toward increased cellular growth and mAb productivity.
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Affiliation(s)
- Taha Salim
- Merck & Co. Inc., Kenilworth, New Jersey, USA
- Taha Salim, Regeneron, Tarrytown, New York, USA
| | | | | | - Wai Lam W Ling
- Merck & Co. Inc., Kenilworth, New Jersey, USA
- Wai L. W. Ling, Rocket Pharma, Cranbury, New Jersey, USA
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Kager J, Herwig C. Monte Carlo-Based Error Propagation for a More Reliable Regression Analysis across Specific Rates in Bioprocesses. Bioengineering (Basel) 2021; 8:160. [PMID: 34821726 PMCID: PMC8614739 DOI: 10.3390/bioengineering8110160] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/31/2021] [Revised: 10/14/2021] [Accepted: 10/19/2021] [Indexed: 11/29/2022] Open
Abstract
During process development, bioprocess data need to be converted into applicable knowledge. Therefore, it is crucial to evaluate the obtained data under the usage of transparent and reliable data reduction and correlation techniques. Within this contribution, we show a generic Monte Carlo error propagation and regression approach applied to two different, industrially relevant cultivation processes. Based on measurement uncertainties, errors for cell-specific growth, uptake, and production rates were determined across an evaluation chain, with interlinked inputs and outputs. These uncertainties were subsequently included in regression analysis to derive the covariance of the regression coefficients and the confidence bounds for prediction. The usefulness of the approach is shown within two case studies, based on the relations across biomass-specific rate control limits to guarantee high productivities in E. coli, and low lactate formation in a CHO cell fed-batch could be established. Besides the possibility to determine realistic errors on the evaluated process data, the presented approach helps to differentiate between reliable and unreliable correlations and prevents the wrong interpretations of relations based on uncertain data.
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Affiliation(s)
- Julian Kager
- Competence Center CHASE GmbH, 4040 Linz, Austria
- Research Division Biochemical Engineering, Institute of Chemical, Environmental and Bioscience Engineering, Technische Universität Wien, 1060 Vienna, Austria
| | - Christoph Herwig
- Research Division Biochemical Engineering, Institute of Chemical, Environmental and Bioscience Engineering, Technische Universität Wien, 1060 Vienna, Austria
- Christian Doppler Laboratory for Mechanistic and Physiological Methods for Improved Bioprocesses, Technische Universität Wien, Gumpendorfer Straße 1a, 1060 Vienna, Austria
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Richelle A, Lee BW, Portela RMC, Raley J, Stosch M. Analysis of Transformed Upstream Bioprocess Data Provides Insights into Biological System Variation. Biotechnol J 2020; 15:e2000113. [DOI: 10.1002/biot.202000113] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/15/2020] [Revised: 05/30/2020] [Indexed: 12/19/2022]
Affiliation(s)
- Anne Richelle
- Process Systems Biology and Engineering Center of Excellence Technical Research and Development, GSK Rixensart 1330 Belgium
| | - Boung Wook Lee
- Microbial and Cell Culture Development Biopharm Product Development & Supply, GSK King of Prussia PA 19406 USA
| | - Rui M. C. Portela
- Process Systems Biology and Engineering Center of Excellence Technical Research and Development, GSK Rixensart 1330 Belgium
| | - Jonathan Raley
- Microbial and Cell Culture Development Biopharm Product Development & Supply, GSK King of Prussia PA 19406 USA
| | - Moritz Stosch
- Process Systems Biology and Engineering Center of Excellence Technical Research and Development, GSK Rixensart 1330 Belgium
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Multivariate Monitoring Workflow for Formulation, Fill and Finish Processes. Bioengineering (Basel) 2020; 7:bioengineering7020050. [PMID: 32503165 PMCID: PMC7356889 DOI: 10.3390/bioengineering7020050] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/29/2020] [Revised: 05/29/2020] [Accepted: 06/01/2020] [Indexed: 11/17/2022] Open
Abstract
Process monitoring is a critical task in ensuring the consistent quality of the final drug product in biopharmaceutical formulation, fill, and finish (FFF) processes. Data generated during FFF monitoring includes multiple time series and high-dimensional data, which is typically investigated in a limited way and rarely examined with multivariate data analysis (MVDA) tools to optimally distinguish between normal and abnormal observations. Data alignment, data cleaning and correct feature extraction of time series of various FFF sources are resource-intensive tasks, but nonetheless they are crucial for further data analysis. Furthermore, most commercial statistical software programs offer only nonrobust MVDA, rendering the identification of multivariate outliers error-prone. To solve this issue, we aimed to develop a novel, automated, multivariate process monitoring workflow for FFF processes, which is able to robustly identify root causes in process-relevant FFF features. We demonstrate the successful implementation of algorithms capable of data alignment and cleaning of time-series data from various FFF data sources, followed by the interconnection of the time-series data with process-relevant phase settings, thus enabling the seamless extraction of process-relevant features. This workflow allows the introduction of efficient, high-dimensional monitoring in FFF for a daily work-routine as well as for continued process verification (CPV).
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Borchert D, A. Suarez-Zuluaga D, E. Thomassen Y, Herwig C. Risk assessment and integrated process modeling–an improved QbD approach for the development of the bioprocess control strategy. AIMS BIOENGINEERING 2020. [DOI: 10.3934/bioeng.2020022] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/18/2022] Open
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Kamen AA, Lua LHL, Mukhopadhyay TK. Vaccine Technology VII: Beyond the "decade of vaccines". Vaccine 2019; 37:6931-6932. [PMID: 31623914 DOI: 10.1016/j.vaccine.2019.09.083] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/25/2022]
Affiliation(s)
- Amine A Kamen
- Department of Bioengineering, McGill University, Montreal, Canada.
| | - Linda H L Lua
- Protein Expression Facility, The University of Queensland, Brisbane, Australia.
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