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Liu N, Xu T. Virus filtration using small pore virus filter in downstream processing of biotherapeutic products: The effect of operating pressure. Biologicals 2023; 84:101718. [PMID: 37837714 DOI: 10.1016/j.biologicals.2023.101718] [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: 12/11/2022] [Revised: 09/18/2023] [Accepted: 10/01/2023] [Indexed: 10/16/2023] Open
Abstract
Virus filtration is a robust and effective method to remove potential virus contaminants. Planova 20 N, a virus filter form Asahi Kasei Bioprocess, has been widely used in the manufacturing process of biotherapeutics. Previous studies have shown that parvovirus removal by Planova 20 N can be impacted by low operation pressure and depressurization. Therefore, it is critical to define an operating pressure range for robust virus removal. In this work, the effect of pressure combined with depressurization on virus removal by Planova 20 N was investigated. Our studies showed that effective virus removal can be achieved in the pressure range from 0.7 bar to 1.6 bar. The data also suggest that re-starting with higher pressure after depressurization is highly desirable for large-scale manufacture to mitigate virus leakage risk. In addition, skipping buffer flush post mainstream filtration minimizes the likelihood of depressurization.
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Affiliation(s)
- Na Liu
- Downstream Process Development (DSPD), WuXi Biologics, 288 Fute Zhong Road, Waigaoqiao Free Trade Zone, Shanghai, 200131, China.
| | - Tiandan Xu
- Downstream Process Development (DSPD), WuXi Biologics, 288 Fute Zhong Road, Waigaoqiao Free Trade Zone, Shanghai, 200131, China
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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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Shirataki H, Wickramasinghe SR. Modeling virus filtration based on a multilayer membrane morphology and pore size distribution. Biochem Eng J 2023. [DOI: 10.1016/j.bej.2023.108903] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 03/29/2023]
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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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Ide S. Filter made of cuprammonium regenerated cellulose for virus removal: a mini-review. CELLULOSE (LONDON, ENGLAND) 2021; 29:2779-2793. [PMID: 34840442 PMCID: PMC8609256 DOI: 10.1007/s10570-021-04319-2] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 06/30/2021] [Accepted: 11/05/2021] [Indexed: 06/13/2023]
Abstract
In 1989, Asahi Kasei commercialized a porous hollow fiber membrane filter (Planova™) made of cuprammonium regenerated cellulose, making it possible for the first time in the world to "remove viruses from protein solutions by membrane filtration". Planova has demonstrated its usefulness in separating proteins and viruses. Filters that remove viruses from protein solutions, i.e., virus removal filters (VFs), have become one of the critical modern technologies to assure viral safety of biological products. It has also become an indispensable technology for the future. The performance characteristics of VFs can be summarized in two points: 1) the virus removal performance increases as the virus diameter increases, and 2) the recovery rate of proteins with molecular weights greater than 10,000 exceeds the practical level. This paper outlines the emergence of VF and its essential roles in the purification process of biological products, requirements for VF, phase separation studies for cuprammonium cellulose solution, comparison between Planova and other regenerated cellulose flat membranes made from other cellulose solutions, and the development of Planova. The superior properties of Planova can be attributed to its highly interconnected three-dimensional network structure. Furthermore, future trends in the VF field, the subject of this review, are discussed.
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Affiliation(s)
- Shoichi Ide
- Planova Production Department, Bioprocess Division, Asahi Kasei Medical Co. Ltd, Asahi-machi, Nobeoka, Miyazaki 882-0847 Japan
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Fukuda M, Furuya T, Sadano K, Tokumine A, Mori T, Saomoto H, Sakai K. Electron Microscopic Confirmation of Anisotropic Pore Characteristics for ECMO Membranes Theoretically Validating the Risk of SARS-CoV-2 Permeation. MEMBRANES 2021; 11:membranes11070529. [PMID: 34357179 PMCID: PMC8305908 DOI: 10.3390/membranes11070529] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 05/24/2021] [Accepted: 07/12/2021] [Indexed: 11/17/2022]
Abstract
The objective of this study is to clarify the pore structure of ECMO membranes by using our approach and theoretically validate the risk of SARS-CoV-2 permeation. There has not been any direct evidence for SARS-CoV-2 leakage through the membrane in ECMO support for critically ill COVID-19 patients. The precise pore structure of recent membranes was elucidated by direct microscopic observation for the first time. The three types of membranes, polypropylene, polypropylene coated with thin silicone layer, and polymethylpentene (PMP), have unique pore structures, and the pore structures on the inner and outer surfaces of the membranes are completely different anisotropic structures. From these data, the partition coefficients and intramembrane diffusion coefficients of SARS-CoV-2 were quantified using the membrane transport model. Therefore, SARS-CoV-2 may permeate the membrane wall with the plasma filtration flow or wet lung. The risk of SARS-CoV-2 permeation is completely different due to each anisotropic pore structure. We theoretically demonstrate that SARS-CoV-2 is highly likely to permeate the membrane transporting from the patient’s blood to the gas side, and may diffuse from the gas side outlet port of ECMO leading to the extra-circulatory spread of the SARS-CoV-2 (ECMO infection). Development of a new generation of nanoscale membrane confirmation is proposed for next-generation extracorporeal membrane oxygenator and system with long-term durability is envisaged.
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Affiliation(s)
- Makoto Fukuda
- Department of Biomedical Engineering, Kindai University, 930 Nishimitani, Kinokawa-city, Wakayama 649-6493, Japan; (T.F.); (K.S.); (A.T.)
- Correspondence:
| | - Tomoya Furuya
- Department of Biomedical Engineering, Kindai University, 930 Nishimitani, Kinokawa-city, Wakayama 649-6493, Japan; (T.F.); (K.S.); (A.T.)
| | - Kazunori Sadano
- Department of Biomedical Engineering, Kindai University, 930 Nishimitani, Kinokawa-city, Wakayama 649-6493, Japan; (T.F.); (K.S.); (A.T.)
| | - Asako Tokumine
- Department of Biomedical Engineering, Kindai University, 930 Nishimitani, Kinokawa-city, Wakayama 649-6493, Japan; (T.F.); (K.S.); (A.T.)
| | - Tomohiro Mori
- Industrial Technology Center of Wakayama Prefecture, 60 Ogura, Wakayama-city, Wakayama 649-6261, Japan; (T.M.); (H.S.)
| | - Hitoshi Saomoto
- Industrial Technology Center of Wakayama Prefecture, 60 Ogura, Wakayama-city, Wakayama 649-6261, Japan; (T.M.); (H.S.)
| | - Kiyotaka Sakai
- Department of Chemical Engineering, Waseda University, 3-4-1 Okubo, Shinjuku-ku, Tokyo 169-8555, Japan;
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