1
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Albano A, Colomba S, Palmese A, Salvadori J, Mencuccini L, Moriconi A, Bellato F, Malzone C, Berti S, Paludi M, Valoti C, Panariello G, Cozzolino N, Pergola C. The quest for down scale representativeness: how to exploit CFD to design a shear study for vaccines. Pharm Dev Technol 2024; 29:300-310. [PMID: 38497925 DOI: 10.1080/10837450.2024.2331243] [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: 12/16/2023] [Accepted: 03/12/2024] [Indexed: 03/19/2024]
Abstract
In this work, we exploit computational fluid dynamics (CFD) to evaluate stirred tank reactor (STR) process engineer parameters (PEP) and design a scale-down system (SDS) to be representative of the formulation and filling process steps for an Aluminum adjuvanted vaccine drug product (DP). To study the shear history in the SDS we used the concept of number of passages, combined with an appropriate stirring speed down scale strategy comprising of either (i) tip speed equivalence, widely used as a scale-up criterion for a shear-sensitive product, or (ii) rotating shear, a shear metric introduced by Metz and Otto in 1957 but never used as scaling criterion. The outcome of the CFD simulations shows that the tip equivalence generates a worst-case SDS in terms of shear, whereas the rotating shear scaling approach could be used to design a more representative SDS. We monitored the trend over time for "In Vitro Relative Potency" as DP Critical Quality Attribute for both scaling approaches, which highlighted the crucial role of choosing the appropriate scaling-down approach to be representative of the manufacturing scale during process characterization studies.
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Affiliation(s)
- Andrea Albano
- Global Drug Product Development, Technical R&D-R&D, GSK, Siena, Italy
| | - Silvio Colomba
- Global Drug Product Development, Technical R&D-R&D, GSK, Siena, Italy
| | - Angelo Palmese
- Global Drug Product Development, Technical R&D-R&D, GSK, Siena, Italy
| | - Jessica Salvadori
- Global Drug Product Development, Technical R&D-R&D, GSK, Siena, Italy
| | | | - Alessio Moriconi
- Global Drug Product Development, Technical R&D-R&D, GSK, Siena, Italy
| | | | | | | | | | | | | | | | - Carlo Pergola
- Global Drug Product Development, Technical R&D-R&D, GSK, Siena, Italy
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2
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Xia D, Mao Z, Zhou S, He X, Wang Y. Optimized Design of Solid-Liquid Dual-Impeller Mixing Systems for Enhanced Efficiency. ACS OMEGA 2023; 8:47635-47645. [PMID: 38144083 PMCID: PMC10733952 DOI: 10.1021/acsomega.3c05762] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 08/06/2023] [Revised: 11/03/2023] [Accepted: 11/22/2023] [Indexed: 12/26/2023]
Abstract
Flow interferences occur in the dual-impeller stirred tank between paddles as well as between paddles and baffles and the tank wall, leading to inefficient utilization of the stirring energy. To address this issue, this study investigates the flow characteristics within the mixing tank using Euler-Euler numerical simulation and the particle image velocimetry (PIV) experimental method. The three-dimensional nonconstant flow characteristics are analyzed to optimize the critical stirrer geometry. By employing the Sobol method, an approximate model is established for sensitivity analysis to identify key parameters affecting the solid-liquid dual-impeller stirred tank's performance. Numerical simulations demonstrate that the optimized stirred tank exhibits a significantly improved solid-liquid suspension capacity and considerably reduces flow losses near the wall and baffle areas. Under the designated conditions, the cloud height is increased by 8.7%, and power consumption is reduced by 15.6% compared to the prototype. PIV tests performed on the stirred tank before and after optimization confirmed the reliability of the obtained optimization results. The primary objective of this study is to enhance mixing efficiency and homogeneity in solid-liquid mixing tanks while concurrently minimizing energy consumption and cost. These results validate the feasibility of employing a multiobjective optimal design approach that combines the RBF agent model with the Sobol method. The findings offer valuable insights for the design of similar mixing tanks.
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Affiliation(s)
- Ding Xia
- College
of Mechanical Engineering, Zhejiang University
of Technology, Hangzhou 310023, China
- Institute
of Innovation Research of Shengzhou, Zhejiang
University of Technology, Shengzhou 312400, China
| | - Zijian Mao
- College
of Mechanical Engineering, Zhejiang University
of Technology, Hangzhou 310023, China
- Institute
of Innovation Research of Shengzhou, Zhejiang
University of Technology, Shengzhou 312400, China
| | - Shuiqing Zhou
- College
of Mechanical Engineering, Zhejiang University
of Technology, Hangzhou 310023, China
- Institute
of Innovation Research of Shengzhou, Zhejiang
University of Technology, Shengzhou 312400, China
| | - Xing He
- College
of Law, Zhejiang University of Technology, Hangzhou 310023, China
| | - Yixi Wang
- College
of Mechanical Engineering, Zhejiang University
of Technology, Hangzhou 310023, China
- Institute
of Innovation Research of Shengzhou, Zhejiang
University of Technology, Shengzhou 312400, China
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3
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Xu L, Jia Z, Guo M, Mao ZS, Fan Y, Zhang Q, Yang C. Enhancement of Macromixing Performance of a Stirred Tank with a Novel V-Shaped Punched Baffle. Ind Eng Chem Res 2023. [DOI: 10.1021/acs.iecr.2c03936] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/22/2023]
Affiliation(s)
- Lele Xu
- State Key Laboratory of Materials-Oriented Chemical Engineering, College of Chemical Engineering, Nanjing Tech University, Nanjing 211816, China
| | - Zhuotai Jia
- CAS Key Laboratory of Green Process and Engineering, Institute of Process Engineering, Chinese Academy of Sciences, Beijing 100190, China
- School of Chemical Engineering, University of Chinese Academy of Sciences, Beijing 100049, China
| | - Mengke Guo
- CAS Key Laboratory of Green Process and Engineering, Institute of Process Engineering, Chinese Academy of Sciences, Beijing 100190, China
- School of Chemical Engineering, University of Chinese Academy of Sciences, Beijing 100049, China
| | - Zai-Sha Mao
- CAS Key Laboratory of Green Process and Engineering, Institute of Process Engineering, Chinese Academy of Sciences, Beijing 100190, China
| | - Yiqun Fan
- State Key Laboratory of Materials-Oriented Chemical Engineering, College of Chemical Engineering, Nanjing Tech University, Nanjing 211816, China
| | - Qinghua Zhang
- CAS Key Laboratory of Green Process and Engineering, Institute of Process Engineering, Chinese Academy of Sciences, Beijing 100190, China
- School of Chemical Engineering, University of Chinese Academy of Sciences, Beijing 100049, China
| | - Chao Yang
- CAS Key Laboratory of Green Process and Engineering, Institute of Process Engineering, Chinese Academy of Sciences, Beijing 100190, China
- School of Chemical Engineering, University of Chinese Academy of Sciences, Beijing 100049, China
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Sirasitthichoke C, Salloum S, Armenante PM. Power number and hydrodynamic characterization of a stirred vessel equipped with a Retreat-Blade Impeller and different types of pharmaceutical single baffles. Chem Eng Sci 2022. [DOI: 10.1016/j.ces.2022.117725] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/03/2022]
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5
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Montante G, Paglianti A. How to evaluate the mass transfer resistances in dense solid–liquid suspensions. Chem Eng Res Des 2021. [DOI: 10.1016/j.cherd.2021.01.015] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/22/2022]
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6
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Brunner M, Brosig P, Losing M, Kunzelmann M, Calvet A, Stiefel F, Bechmann J, Unsoeld A, Schaub J. Towards robust cell culture processes - Unraveling the impact of media preparation by spectroscopic online monitoring. Eng Life Sci 2020; 19:666-680. [PMID: 32624960 PMCID: PMC6999248 DOI: 10.1002/elsc.201900050] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/21/2019] [Revised: 07/12/2019] [Accepted: 07/31/2019] [Indexed: 11/09/2022] Open
Abstract
Biopharmaceutical manufacturing processes can be affected by variability in cell culture media, e.g. caused by raw material impurities. Although efforts have been made in industry and academia to characterize cell culture media and raw materials with advanced analytics, the process of industrial cell culture media preparation itself has not been reported so far. Within this publication, we first compare mid-infrared and two-dimensional fluorescence spectroscopy with respect to their suitability as online monitoring tools during cell culture media preparation, followed by a thorough assessment of the impact of preparation parameters on media quality. Through the application of spectroscopic methods, we can show that media variability and its corresponding root cause can be detected online during the preparation process. This methodology is a powerful tool to avoid batch failure and is a valuable technology for media troubleshooting activities. Moreover, in a design of experiments approach, including additional liquid chromatography-mass spectrometry analytics, it is shown that variable preparation parameters such as temperature, power input and preparation time can have a strong impact on the physico-chemical composition of the media. The effect on cell culture process performance and product quality in subsequent fed-batch processes was also investigated. The presented results reveal the need for online spectroscopic methods during the preparation process and show that media variability can already be introduced by variation in media preparation parameters, with a potential impact on scale-up to a commercial manufacturing process.
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Affiliation(s)
- Matthias Brunner
- Bioprocess Development Biologicals Boehringer Ingelheim Pharma GmbH & Co. KG Biberach Germany
| | - Philipp Brosig
- Bioprocess Development Biologicals Boehringer Ingelheim Pharma GmbH & Co. KG Biberach Germany
| | - Monika Losing
- Bioprocess Development Biologicals Boehringer Ingelheim Pharma GmbH & Co. KG Biberach Germany
| | - Marco Kunzelmann
- Analytical Development Biologicals Boehringer Ingelheim Pharma GmbH & Co. KG Biberach Germany
| | - Amandine Calvet
- Bioprocess Development Biologicals Boehringer Ingelheim Pharma GmbH & Co. KG Biberach Germany
| | - Fabian Stiefel
- Bioprocess Development Biologicals Boehringer Ingelheim Pharma GmbH & Co. KG Biberach Germany
| | - Jan Bechmann
- Bioprocess Development Biologicals Boehringer Ingelheim Pharma GmbH & Co. KG Biberach Germany
| | - Andreas Unsoeld
- Bioprocess Development Biologicals Boehringer Ingelheim Pharma GmbH & Co. KG Biberach Germany
| | - Jochen Schaub
- Bioprocess Development Biologicals Boehringer Ingelheim Pharma GmbH & Co. KG Biberach Germany
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McLaughlin AM, Robertson J, Ni XW. Investigation of dissolution rate kinetics of bulk pharmaceutical feed streams within a stirred tank vessel and a twin screw extruder. Pharm Dev Technol 2019; 25:219-226. [PMID: 31651201 DOI: 10.1080/10837450.2019.1685543] [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: 10/25/2022]
Abstract
The introduction of continuous manufacturing of pharmaceuticals has highlighted the challenging area of continuous dissolution of solids for work ups to flow chemistry systems. In this study, the use of a 16 mm twin screw extruder (TSE) as a platform technology for solid feeds is investigated using four solid pharmaceutical ingredients (PI) in a mixture of water and IPA. In order for comparison, the same experiments were also carried out in a batch traditional stirred tank vessel (STV). The objectives of this work are to gain further scientific understanding on dissolution kinetics and to compare kinetics in both a batch and continuous system. The concentration of each PI during dissolution is monitored using an in-line UV-ATR probe, allowing the extraction of dissolution kinetics. Faster dissolution rates are achieved in the TSE than in the STV due to higher power dissipation generated by the aggressive shear mixing and thermal energy within the TSE. Complete dissolution of paracetamol is obtained within the residence time of the TSE; complete dissolution of benzoic acid and acetylsalicylic acid are achieved at higher barrel temperatures; however full dissolution of nicotinic acid is not achievable in the TSE under the experimental conditions.
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Affiliation(s)
- Arabella M McLaughlin
- EPSRC Centre for Continuous Manufacturing and Crystallisation (CMAC), Centre for Oscillatory Baffled Reactor Applications (COBRA), School of Engineering and Physical Science, Heriot-Watt University, Edinburgh, UK
| | - John Robertson
- EPSRC Future Continuous Manufacturing and Advanced Crystallisation Research Hub, University of Strathclyde, Glasgow, UK
| | - Xiong-Wei Ni
- EPSRC Centre for Continuous Manufacturing and Crystallisation (CMAC), Centre for Oscillatory Baffled Reactor Applications (COBRA), School of Engineering and Physical Science, Heriot-Watt University, Edinburgh, UK
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Montante G, Carletti C, Maluta F, Paglianti A. Solid Dissolution and Liquid Mixing in Turbulent Stirred Tanks. Chem Eng Technol 2019. [DOI: 10.1002/ceat.201800726] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/08/2022]
Affiliation(s)
- Giuseppina Montante
- Alma Mater Studiorum – Università di BolognaDipartimento di Chimica Industriale “Toso Montanari” via Terracini 34 40131 Bologna Italy
| | - Claudio Carletti
- Alma Mater Studiorum – Università di BolognaDipartimento di Chimica Industriale “Toso Montanari” via Terracini 34 40131 Bologna Italy
| | - Francesco Maluta
- Alma Mater Studiorum – Università di BolognaDipartimento di Ingegneria Civile, Chimica, Ambientale e dei Materiali via Terracini 34 40131 Bologna Italy
| | - Alessandro Paglianti
- Alma Mater Studiorum – Università di BolognaDipartimento di Ingegneria Civile, Chimica, Ambientale e dei Materiali via Terracini 34 40131 Bologna Italy
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9
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McLaughlin AM, Robertson J, Ni XW. On the Use of a Twin Screw Extruder for Continuous Solid Feeding and Dissolution for Continuous Flow Processes. Org Process Res Dev 2018. [DOI: 10.1021/acs.oprd.8b00187] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Arabella M. McLaughlin
- EPSRC Centre for Continuous Manufacturing and Crystallisation (CMAC), Centre for Oscillatory Baffled Reactor Applications (COBRA), School of Engineering and Physical Science, Heriot-Watt University, Edinburgh EH14 4AS, U.K
| | - John Robertson
- EPSRC Future Continuous Manufacturing and Advanced Crystallisation Research Hub, University of Strathclyde Technology and Innovation Centre, 99 George Street, Glasgow G1 1RD, U.K
| | - Xiong-Wei Ni
- EPSRC Centre for Continuous Manufacturing and Crystallisation (CMAC), Centre for Oscillatory Baffled Reactor Applications (COBRA), School of Engineering and Physical Science, Heriot-Watt University, Edinburgh EH14 4AS, U.K
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10
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Carletti C, Bikić S, Montante G, Paglianti A. Mass Transfer in Dilute Solid–Liquid Stirred Tanks. Ind Eng Chem Res 2018. [DOI: 10.1021/acs.iecr.7b04730] [Citation(s) in RCA: 13] [Impact Index Per Article: 2.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Claudio Carletti
- Dipartimento di Chimica Industriale “Toso Montanari”, Alma Mater Studiorum, Università di Bologna, via Terracini 34, 40131 Bologna, Italy
| | - Siniša Bikić
- Faculty of Technical Sciences, University of Novi Sad, Novi Sad, Serbia
| | - Giuseppina Montante
- Dipartimento di Chimica Industriale “Toso Montanari”, Alma Mater Studiorum, Università di Bologna, via Terracini 34, 40131 Bologna, Italy
| | - Alessandro Paglianti
- Dipartimento di Ingegneria Civile, Chimica, Ambientale e dei Materiali, Alma Mater Studiorum, Università di Bologna, via Terracini 34, 40131 Bologna, Italy
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11
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Yu Z, Finch BA, Hale DA. Mixing of Stratified Miscible Liquids in an Unbaffled Tank with Application in High Concentration Protein Drug Product Manufacturing. Ind Eng Chem Res 2018. [DOI: 10.1021/acs.iecr.7b04618] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
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12
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Tamburini A, Brucato A, Busciglio A, Cipollina A, Grisafi F, Micale G, Scargiali F, Vella G. Solid–Liquid Suspensions in Top-Covered Unbaffled Vessels: Influence of Particle Size, Liquid Viscosity, Impeller Size, and Clearance. Ind Eng Chem Res 2014. [DOI: 10.1021/ie500203r] [Citation(s) in RCA: 38] [Impact Index Per Article: 3.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- A. Tamburini
- Dipartimento di Ingegneria
Chimica, Gestionale, Informatica, Meccanica, Università di Palermo, Viale delle Scienze Ed. 6, 90128 Palermo, Italy
| | - A. Brucato
- Dipartimento di Ingegneria
Chimica, Gestionale, Informatica, Meccanica, Università di Palermo, Viale delle Scienze Ed. 6, 90128 Palermo, Italy
| | - A. Busciglio
- Dipartimento di Ingegneria
Chimica, Gestionale, Informatica, Meccanica, Università di Palermo, Viale delle Scienze Ed. 6, 90128 Palermo, Italy
| | - A. Cipollina
- Dipartimento di Ingegneria
Chimica, Gestionale, Informatica, Meccanica, Università di Palermo, Viale delle Scienze Ed. 6, 90128 Palermo, Italy
| | - F. Grisafi
- Dipartimento di Ingegneria
Chimica, Gestionale, Informatica, Meccanica, Università di Palermo, Viale delle Scienze Ed. 6, 90128 Palermo, Italy
| | - G. Micale
- Dipartimento di Ingegneria
Chimica, Gestionale, Informatica, Meccanica, Università di Palermo, Viale delle Scienze Ed. 6, 90128 Palermo, Italy
| | - F. Scargiali
- Dipartimento di Ingegneria
Chimica, Gestionale, Informatica, Meccanica, Università di Palermo, Viale delle Scienze Ed. 6, 90128 Palermo, Italy
| | - G. Vella
- Dipartimento di Ingegneria
Chimica, Gestionale, Informatica, Meccanica, Università di Palermo, Viale delle Scienze Ed. 6, 90128 Palermo, Italy
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Kiss N, Brenn G, Suzzi D, Scheler S, Jennewein H, Wieser J, Khinast J. The Influence of Process Parameters on the Properties of PLGA-Microparticles Produced by the Emulsion Extraction Method. AIChE J 2012. [DOI: 10.1002/aic.13968] [Citation(s) in RCA: 8] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/10/2022]
Affiliation(s)
- Nikolett Kiss
- Institute of Fluid Mechanics and Heat Transfer; Graz University of Technology; Inffeldgasse 25/F; 8010; Graz; Austria
| | - Günter Brenn
- Institute of Fluid Mechanics and Heat Transfer; Graz University of Technology; Inffeldgasse 25/F; 8010; Graz; Austria
| | - Daniele Suzzi
- Qpunkt GmbH; Gewerbepark 11; A-8075; Hart bei Graz; Austria
| | - Stefan Scheler
- Sandoz GmbH; Sandoz Development Center Austria; Biochemiestrasse 10; A-6250; Kundl; Austria
| | - Herwig Jennewein
- Sandoz GmbH; Sandoz Development Center Austria; Biochemiestrasse 10; A-6250; Kundl; Austria
| | - Juliana Wieser
- Research Center Pharmaceutical Engineering; Inffeldgasse 21a; A-8010; Graz; Austria
| | - Johannes Khinast
- Research Center Pharmaceutical Engineering; Inffeldgasse 21a; A-8010; Graz; Austria
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Hörmann T, Suzzi D, Adam S, Khinast JG. DOE-Based CFD Optimization of Pharmaceutical Mixing Processes. J Pharm Innov 2012. [DOI: 10.1007/s12247-012-9142-x] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/27/2022]
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