Portable Analytical Techniques for Monitoring Volatile Organic Chemicals in Biomanufacturing Processes: Recent Advances and Limitations

Advances and opportunities in process analytical technologies for viral vector manufacturing

Viral vectors are an emerging, exciting class of biologics whose application in vaccines, oncology, and gene therapy has grown exponentially in recent years. Following first regulatory approval, this class of therapeutics has been vigorously pursued to treat monogenic disorders including orphan diseases, entering hundreds of new products into pipelines. Viral vector manufacturing supporting clinical efforts has spurred the introduction of a broad swath of analytical techniques dedicated to assessing the diverse and evolving panel of Critical Quality Attributes (CQAs) of these products. Herein, we provide an overview of the current state of analytics enabling measurement of CQAs such as capsid and vector identities, product titer, transduction efficiency, impurity clearance etc. We highlight orthogonal methods and discuss the advantages and limitations of these techniques while evaluating their adaptation as process analytical technologies. Finally, we identify gaps and propose opportunities in enabling existing technologies for real-time monitoring from hardware, software, and data analysis viewpoints for technology development within viral vector biomanufacturing.

Advances in bioreactor control for production of biotherapeutic products

Advanced control strategies are well established in chemical, pharmaceutical, and food processing industries. Over the past decade, the application of these strategies is being explored for control of bioreactors for manufacturing of biotherapeutics. Most of the industrial bioreactor control strategies apply classical control techniques, with the control system designed for the facility at hand. However, with the recent progress in sensors, machinery, and industrial internet of things, and advancements in deeper understanding of the biological processes, coupled with the requirement of flexible production, the need to develop a robust and advanced process control system that can ease process intensification has emerged. This has further fuelled the development of advanced monitoring approaches, modeling techniques, process analytical technologies, and soft sensors. It is seen that proper application of these concepts can significantly improve bioreactor process performance, productivity, and reproducibility. This review is on the recent advancements in bioreactor control and its related aspects along with the associated challenges. This study also offers an insight into the future prospects for development of control strategies that can be designed for industrial-scale production of biotherapeutic products.

Advanced spectroscopic analysis and 15N-isotopic labelling study of nitrate and nitrite reduction to ammonia and nitrous oxide by E. coli

Nitrate and nitrite reduction to ammonia and nitrous oxide by anaerobic E. coli batch cultures is investigated by advanced spectroscopic analytical techniques with ¹⁵N-isotopic labelling. Non-invasive, in situ analysis of the headspace is achieved using White cell FTIR and cavity-enhanced Raman (CERS) spectroscopies alongside liquid-phase Raman spectroscopy. For gas-phase analysis, White cell FTIR measures CO₂, ethanol and N₂O while CERS allows H₂, N₂ and O₂ monitoring. The 6 m pathlength White cell affords trace gas detection of N₂O with a noise equivalent detection limit of 60 nbar or 60 ppbv in 1 atm. Quantitative analysis is discussed for all four ¹⁴N/¹⁵N-isotopomers of N₂O. Monobasic and dibasic phosphates, acetate, formate, glucose and NO₃^- concentrations are obtained by liquid-phase Raman spectroscopy, with a noise equivalent detection limit of 0.6 mM for NO₃^- at 300 s integration time. Concentrations of the phosphate anions are used to calculate the pH in situ using a modified Henderson-Hasselbalch equation. NO₂^- concentrations are determined by sampling for colorimetric analysis and NH₄⁺ by basifying samples to release ¹⁴N/¹⁵N-isotopomers of NH₃ for measurement in a second FTIR White cell. The reductions of ¹⁵NO₃^-, ¹⁵NO₂^-, and mixed ¹⁵NO₃^- and ¹⁴NO₂^- by anaerobic E. coli batch cultures are discussed. In a major pathway, NO₃^- is reduced to NH₄⁺via NO₂^-, with the bulk of NO₂^- reduction occurring after NO₃^- depletion. Using isotopically labelled ¹⁵NO₃^-, ¹⁵NH₄⁺ production is distinguished from background ¹⁴NH₄⁺ in the growth medium. In a minor pathway, NO₂^- is reduced to N₂O via the toxic radical NO. With excellent detection sensitivities, N₂O serves as a monitor for trace NO₂^- reduction, even when cells are predominantly reducing NO₃^-. The analysis of N₂O isotopomers reveals that for cultures supplemented with mixed ¹⁵NO₃^- and ¹⁴NO₂^- enzymatic activity to reduce ¹⁴NO₂^- occurs immediately, even before ¹⁵NO₃^- reduction begins. Optical density and pH measurements are discussed in the context of acetate, formate and CO₂ production. H₂ production is repressed by NO₃^-; but in experiments with NO₂^- supplementation only, CERS detects H₂ produced by formate disproportionation after NO₂^- depletion.

Bioreactor control systems in the biopharmaceutical industry: a critical perspective

Industrial-scale bioprocessing underpins much of the production of pharmaceuticals, nutraceuticals, food, and beverage processing industries of the modern world. The profitability of these processes increasingly leverages the economies of scale and scope that are critically dependent on the product yields, titers, and productivity. Most of the processes are controlled using classical control approaches and represent over 90% of the industrial controls used in bioprocessing industries. However, with the advances in the production processes, especially in the biopharmaceutical and nutraceutical industries, monitoring and control of bioprocesses such as fermentations with GMO organisms, and downstream processing has become increasingly complex and the inadequacies of the classical and some of the modern control systems techniques is becoming apparent. Therefore, with increasing research complexity, nonlinearity, and digitization in process, there has been a critical need for advanced process control that is more effective, and easier process intensification and product yield (both by quality and quantity) can be achieved. In this review, industrial aspects of a process and automation along with various commercial control strategies have been extensively discussed to give an insight into the future prospects of industrial development and possible new strategies for process control and automation with a special focus on the biopharmaceutical industry.

Supplementary Information

The online version contains supplementary material available at 10.1007/s43393-021-00048-6.