1
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Chan YJ, Dileep D, Rothstein SM, Cochran EW, Reuel NF. Single-Use, Metabolite Absorbing, Resonant Transducer (SMART) Culture Vessels for Label-Free, Continuous Cell Culture Progression Monitoring. ADVANCED SCIENCE (WEINHEIM, BADEN-WURTTEMBERG, GERMANY) 2024:e2401260. [PMID: 38900081 DOI: 10.1002/advs.202401260] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 02/03/2024] [Revised: 05/16/2024] [Indexed: 06/21/2024]
Abstract
Secreted metabolites are an important class of bio-process analytical technology (PAT) targets that can correlate to cell conditions. However, current strategies for measuring metabolites are limited to discrete measurements, resulting in limited understanding and ability for feedback control strategies. Herein, a continuous metabolite monitoring strategy is demonstrated using a single-use metabolite absorbing resonant transducer (SMART) to correlate with cell growth. Polyacrylate is shown to absorb secreted metabolites from living cells containing hydroxyl and alkenyl groups such as terpenoids, that act as a plasticizer. Upon softening, the polyacrylate irreversibly conformed into engineered voids above a resonant sensor, changing the local permittivity which is interrogated, contact-free, with a vector network analyzer. Compared to sensing using the intrinsic permittivity of cells, the SMART approach yields a 20-fold improvement in sensitivity. Tracking growth of many cell types such as Chinese hamster ovary, HEK293, K562, HeLa, and E. coli cells as well as perturbations in cell proliferation during drug screening assays are demonstrated. The sensor is benchmarked to show continuous measurement over six days, ability to track different growth conditions, selectivity to transducing active cell growth metabolites against other components found in the media, and feasibility to scale out for high throughput campaigns.
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Affiliation(s)
- Yee Jher Chan
- Chemical and Biological Engineering, Iowa State University, Ames, IA, 50011, USA
| | - Dhananjay Dileep
- Chemical and Biological Engineering, Iowa State University, Ames, IA, 50011, USA
| | | | - Eric W Cochran
- Chemical and Biological Engineering, Iowa State University, Ames, IA, 50011, USA
| | - Nigel F Reuel
- Chemical and Biological Engineering, Iowa State University, Ames, IA, 50011, USA
- Skroot Laboratory Inc, Ames, IA, 50010, USA
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2
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Sripada SA, Hosseini M, Ramesh S, Wang J, Ritola K, Menegatti S, Daniele MA. Advances and opportunities in process analytical technologies for viral vector manufacturing. Biotechnol Adv 2024; 74:108391. [PMID: 38848795 DOI: 10.1016/j.biotechadv.2024.108391] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/14/2023] [Revised: 03/14/2024] [Accepted: 05/29/2024] [Indexed: 06/09/2024]
Abstract
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.
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Affiliation(s)
- Sobhana A Sripada
- Department of Chemical and Biomolecular Engineering, North Carolina State University, 911 Partners Way, Raleigh, NC, 27695, USA
| | - Mahshid Hosseini
- Joint Department of Biomedical Engineering, North Carolina State University, and University of North Carolina, Chapel Hill, 911 Oval Dr., Raleigh, NC 27695, USA
| | - Srivatsan Ramesh
- Department of Chemical and Biomolecular Engineering, North Carolina State University, 911 Partners Way, Raleigh, NC, 27695, USA
| | - Junhyeong Wang
- Joint Department of Biomedical Engineering, North Carolina State University, and University of North Carolina, Chapel Hill, 911 Oval Dr., Raleigh, NC 27695, USA
| | - Kimberly Ritola
- North Carolina Viral Vector Initiative in Research and Learning (NC-VVIRAL), North Carolina State University, 890 Oval Dr, Raleigh, NC 27695, USA; Neuroscience Center, Brain Initiative Neurotools Vector Core, University of North Carolina at Chapel Hill, Chapel Hill, North Carolina, USA
| | - Stefano Menegatti
- Department of Chemical and Biomolecular Engineering, North Carolina State University, 911 Partners Way, Raleigh, NC, 27695, USA; North Carolina Viral Vector Initiative in Research and Learning (NC-VVIRAL), North Carolina State University, 890 Oval Dr, Raleigh, NC 27695, USA; Biomanufacturing Training and Education Center, North Carolina State University, 890 Main Campus Dr, Raleigh, NC 27695, USA.
| | - Michael A Daniele
- Joint Department of Biomedical Engineering, North Carolina State University, and University of North Carolina, Chapel Hill, 911 Oval Dr., Raleigh, NC 27695, USA; North Carolina Viral Vector Initiative in Research and Learning (NC-VVIRAL), North Carolina State University, 890 Oval Dr, Raleigh, NC 27695, USA; Department of Electrical and Computer Engineering, North Carolina State University, 890 Oval Dr, Raleigh, NC 27695, USA.
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3
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Allampalli SSP, Sivaprakasam S. Unveiling the potential of specific growth rate control in fed-batch fermentation: bridging the gap between product quantity and quality. World J Microbiol Biotechnol 2024; 40:196. [PMID: 38722368 DOI: 10.1007/s11274-024-03993-1] [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: 02/21/2024] [Accepted: 04/18/2024] [Indexed: 05/18/2024]
Abstract
During the epoch of sustainable development, leveraging cellular systems for production of diverse chemicals via fermentation has garnered attention. Industrial fermentation, extending beyond strain efficiency and optimal conditions, necessitates a profound understanding of microorganism growth characteristics. Specific growth rate (SGR) is designated as a key variable due to its influence on cellular physiology, product synthesis rates and end-product quality. Despite its significance, the lack of real-time measurements and robust control systems hampers SGR control strategy implementation. The narrative in this contribution delves into the challenges associated with the SGR control and presents perspectives on various control strategies, integration of soft-sensors for real-time measurement and control of SGR. The discussion highlights practical and simple SGR control schemes, suggesting their seamless integration into industrial fermenters. Recommendations provided aim to propose new algorithms accommodating mechanistic and data-driven modelling for enhanced progress in industrial fermentation in the context of sustainable bioprocessing.
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Affiliation(s)
- Satya Sai Pavan Allampalli
- BioPAT Laboratory, Department of Biosciences and Bioengineering, Indian Institute of Technology Guwahati, Assam, 781039, India
| | - Senthilkumar Sivaprakasam
- BioPAT Laboratory, Department of Biosciences and Bioengineering, Indian Institute of Technology Guwahati, Assam, 781039, India.
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4
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Rydal T, Frandsen J, Nadal-Rey G, Albæk MO, Ramin P. Bringing a scalable adaptive hybrid modeling framework closer to industrial use: Application on a multiscale fungal fermentation. Biotechnol Bioeng 2024; 121:1609-1625. [PMID: 38454575 DOI: 10.1002/bit.28670] [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: 10/04/2023] [Revised: 12/22/2023] [Accepted: 01/26/2024] [Indexed: 03/09/2024]
Abstract
Digitalization has paved the way for new paradigms such as digital shadows and digital twins for fermentation processes, opening the door for real-time process monitoring, control, and optimization. With a digital shadow, real-time model adaptation to accommodate complex metabolic phenomena such as metabolic shifts of a process can be monitored. Despite the many benefits of digitalization, the potential has not been fully reached in the industry. This study investigates the development of a digital shadow for a very complex fungal fermentation process in terms of microbial physiology and fermentation operation on pilot-scale at Novonesis and the challenges thereof. The process has historically been difficult to optimize and control due to a lack of offline measurements and an absence of biomass measurements. Pilot-scale and lab-scale fermentations were conducted for model development and validation. With all available pilot-scale data, a data-driven soft sensor was developed to estimate the main substrate concentration (glucose) with a normalized root mean squared error (N-RMSE) of 2%. This robust data-driven soft sensor was able to estimate accurately in lab-scale (volume < 20× pilot) with a N-RMSE of 7.8%. A hybrid soft sensor was developed by combining the data-driven soft sensor with a mass balance to estimate the glycerol and biomass concentrations on pilot-scale data with N-RMSEs of 11% and 21%, respectively. A digital shadow modeling framework was developed by coupling a mechanistic model (MM) with the hybrid soft sensor. The digital shadow modeling framework significantly improved the predictability compared with the MM. The contribution of this study brings the application of digital shadows closer to industrial implementation. It demonstrates the high potential of using this type of modeling framework for scale-up and leads the way to a new generation of in silico-based process development.
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Affiliation(s)
- Thomas Rydal
- Fermentation Pilot Plant, Novonesis A/S, Bagsværd, Denmark
| | - Jesper Frandsen
- Department of Chemical and Biochemical Engineering, Process and Systems Engineering Centre (PROSYS), Technical University of Denmark, Kongens Lyngby, Denmark
| | | | | | - Pedram Ramin
- Department of Chemical and Biochemical Engineering, Process and Systems Engineering Centre (PROSYS), Technical University of Denmark, Kongens Lyngby, Denmark
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5
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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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6
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Kumar V, Barwal A, Sharma N, Mir DS, Kumar P, Kumar V. Therapeutic proteins: developments, progress, challenges, and future perspectives. 3 Biotech 2024; 14:112. [PMID: 38510462 PMCID: PMC10948735 DOI: 10.1007/s13205-024-03958-z] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/03/2023] [Accepted: 02/13/2024] [Indexed: 03/22/2024] Open
Abstract
Proteins are considered magic molecules due to their enormous applications in the health sector. Over the past few decades, therapeutic proteins have emerged as a promising treatment option for various diseases, particularly cancer, cardiovascular disease, diabetes, and others. The formulation of protein-based therapies is a major area of research, however, a few factors still hinder the large-scale production of these therapeutic products, such as stability, heterogenicity, immunogenicity, high cost of production, etc. This review provides comprehensive information on various sources and production of therapeutic proteins. The review also summarizes the challenges currently faced by scientists while developing protein-based therapeutics, along with possible solutions. It can be concluded that these proteins can be used in combination with small molecular drugs to give synergistic benefits in the future.
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Affiliation(s)
- Vimal Kumar
- University Institute of Biotechnology, Chandigarh University, Gharuan, Mohali, Punjab 140413 India
| | - Arti Barwal
- Department of Microbial Biotechnology, Panjab University, South Campus, Sector-25, Chandigarh, 160014 India
| | - Nitin Sharma
- Department of Biotechnology, Chandigarh Group of Colleges, Mohali, Punjab 140307 India
| | - Danish Shafi Mir
- University Institute of Biotechnology, Chandigarh University, Gharuan, Mohali, Punjab 140413 India
| | - Pradeep Kumar
- Faculty of Applied Sciences and Biotechnology, Shoolini University of Biotechnology and Management Sciences, Solan, 173229 India
| | - Vikas Kumar
- University Institute of Biotechnology, Chandigarh University, Gharuan, Mohali, Punjab 140413 India
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7
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Iglesias CF, Bolic M. How Not to Make the Joint Extended Kalman Filter Fail with Unstructured Mechanistic Models. SENSORS (BASEL, SWITZERLAND) 2024; 24:653. [PMID: 38276345 PMCID: PMC11154378 DOI: 10.3390/s24020653] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 11/21/2023] [Revised: 12/22/2023] [Accepted: 01/06/2024] [Indexed: 01/27/2024]
Abstract
The unstructured mechanistic model (UMM) allows for modeling the macro-scale of a phenomenon without known mechanisms. This is extremely useful in biomanufacturing because using the UMM for the joint estimation of states and parameters with an extended Kalman filter (JEKF) can enable the real-time monitoring of bioprocesses with unknown mechanisms. However, the UMM commonly used in biomanufacturing contains ordinary differential equations (ODEs) with unshared parameters, weak variables, and weak terms. When such a UMM is coupled with an initial state error covariance matrix P(t=0) and a process error covariance matrix Q with uncorrelated elements, along with just one measured state variable, the joint extended Kalman filter (JEKF) fails to estimate the unshared parameters and state simultaneously. This is because the Kalman gain corresponding to the unshared parameter remains constant and equal to zero. In this work, we formally describe this failure case, present the proof of JEKF failure, and propose an approach called SANTO to side-step this failure case. The SANTO approach consists of adding a quantity to the state error covariance between the measured state variable and unshared parameter in the initial P(t = 0) of the matrix Ricatti differential equation to compute the predicted error covariance matrix of the state and prevent the Kalman gain from being zero. Our empirical evaluations using synthetic and real datasets reveal significant improvements: SANTO achieved a reduction in root-mean-square percentage error (RMSPE) of up to approximately 17% compared to the classical JEKF, indicating a substantial enhancement in estimation accuracy.
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Affiliation(s)
- Cristovão Freitas Iglesias
- School of Electrical Engineering and Computer Science (EECS), University of Ottawa, Ottawa, ON K1N 6N5, Canada
| | - Miodrag Bolic
- School of Electrical Engineering and Computer Science (EECS), University of Ottawa, Ottawa, ON K1N 6N5, Canada
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8
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Espinel-Ríos S, Morabito B, Pohlodek J, Bettenbrock K, Klamt S, Findeisen R. Toward a modeling, optimization, and predictive control framework for fed-batch metabolic cybergenetics. Biotechnol Bioeng 2024; 121:366-379. [PMID: 37942516 DOI: 10.1002/bit.28575] [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: 02/04/2023] [Revised: 09/22/2023] [Accepted: 10/14/2023] [Indexed: 11/10/2023]
Abstract
Biotechnology offers many opportunities for the sustainable manufacturing of valuable products. The toolbox to optimize bioprocesses includes extracellular process elements such as the bioreactor design and mode of operation, medium formulation, culture conditions, feeding rates, and so on. However, these elements are frequently insufficient for achieving optimal process performance or precise product composition. One can use metabolic and genetic engineering methods for optimization at the intracellular level. Nevertheless, those are often of static nature, failing when applied to dynamic processes or if disturbances occur. Furthermore, many bioprocesses are optimized empirically and implemented with little-to-no feedback control to counteract disturbances. The concept of cybergenetics has opened new possibilities to optimize bioprocesses by enabling online modulation of the gene expression of metabolism-relevant proteins via external inputs (e.g., light intensity in optogenetics). Here, we fuse cybergenetics with model-based optimization and predictive control for optimizing dynamic bioprocesses. To do so, we propose to use dynamic constraint-based models that integrate the dynamics of metabolic reactions, resource allocation, and inducible gene expression. We formulate a model-based optimal control problem to find the optimal process inputs. Furthermore, we propose using model predictive control to address uncertainties via online feedback. We focus on fed-batch processes, where the substrate feeding rate is an additional optimization variable. As a simulation example, we show the optogenetic control of the ATPase enzyme complex for dynamic modulation of enforced ATP wasting to adjust product yield and productivity.
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Affiliation(s)
- Sebastián Espinel-Ríos
- Analysis and Redesign of Biological Networks, Max Planck Institute for Dynamics of Complex Technical Systems, Magdeburg, Germany
| | - Bruno Morabito
- Yokogawa Insilico Biotechnology GmbH, Stuttgart, Germany
| | - Johannes Pohlodek
- Control and Cyber-Physical Systems Laboratory, Technical University of Darmstadt, Darmstadt, Germany
| | - Katja Bettenbrock
- Analysis and Redesign of Biological Networks, Max Planck Institute for Dynamics of Complex Technical Systems, Magdeburg, Germany
| | - Steffen Klamt
- Analysis and Redesign of Biological Networks, Max Planck Institute for Dynamics of Complex Technical Systems, Magdeburg, Germany
| | - Rolf Findeisen
- Control and Cyber-Physical Systems Laboratory, Technical University of Darmstadt, Darmstadt, Germany
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9
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Nettleton DF, Marí-Buyé N, Marti-Soler H, Egan JR, Hort S, Horna D, Costa M, Vallejo Benítez-Cano E, Goldrick S, Rafiq QA, König N, Schmitt RH, R. Reyes A. Smart Sensor Control and Monitoring of an Automated Cell Expansion Process. SENSORS (BASEL, SWITZERLAND) 2023; 23:9676. [PMID: 38139523 PMCID: PMC10748109 DOI: 10.3390/s23249676] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 10/12/2023] [Revised: 11/19/2023] [Accepted: 12/05/2023] [Indexed: 12/24/2023]
Abstract
Immune therapy for cancer patients is a new and promising area that in the future may complement traditional chemotherapy. The cell expansion phase is a critical part of the process chain to produce a large number of high-quality, genetically modified immune cells from an initial sample from the patient. Smart sensors augment the ability of the control and monitoring system of the process to react in real-time to key control parameter variations, adapt to different patient profiles, and optimize the process. The aim of the current work is to develop and calibrate smart sensors for their deployment in a real bioreactor platform, with adaptive control and monitoring for diverse patient/donor cell profiles. A set of contrasting smart sensors has been implemented and tested on automated cell expansion batch runs, which incorporate advanced data-driven machine learning and statistical techniques to detect variations and disturbances of the key system features. Furthermore, a 'consensus' approach is applied to the six smart sensor alerts as a confidence factor which helps the human operator identify significant events that require attention. Initial results show that the smart sensors can effectively model and track the data generated by the Aglaris FACER bioreactor, anticipate events within a 30 min time window, and mitigate perturbations in order to optimize the key performance indicators of cell quantity and quality. In quantitative terms for event detection, the consensus for sensors across batch runs demonstrated good stability: the AI-based smart sensors (Fuzzy and Weighted Aggregation) gave 88% and 86% consensus, respectively, whereas the statistically based (Stability Detector and Bollinger) gave 25% and 42% consensus, respectively, the average consensus for all six being 65%. The different results reflect the different theoretical approaches. Finally, the consensus of batch runs across sensors gave even higher stability, ranging from 57% to 98% with an average consensus of 80%.
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Affiliation(s)
| | | | | | - Joseph R. Egan
- Department of Biochemical Engineering, University College London, London WC1E 6BT, UK; (J.R.E.); (Q.A.R.)
| | - Simon Hort
- Fraunhofer Institute for Production Technology, 52074 Aachen, Germany (N.K.); (R.H.S.)
| | - David Horna
- Aglaris Cell, 28760 Madrid, Spain; (N.M.-B.)
- Aglaris Ltd., Stevenage SG1 2FX, UK
| | - Miquel Costa
- Aglaris Cell, 28760 Madrid, Spain; (N.M.-B.)
- Aglaris Ltd., Stevenage SG1 2FX, UK
| | | | - Stephen Goldrick
- Department of Biochemical Engineering, University College London, London WC1E 6BT, UK; (J.R.E.); (Q.A.R.)
| | - Qasim A. Rafiq
- Department of Biochemical Engineering, University College London, London WC1E 6BT, UK; (J.R.E.); (Q.A.R.)
| | - Niels König
- Fraunhofer Institute for Production Technology, 52074 Aachen, Germany (N.K.); (R.H.S.)
| | - Robert H. Schmitt
- Fraunhofer Institute for Production Technology, 52074 Aachen, Germany (N.K.); (R.H.S.)
- Laboratory for Machine Tools and Production Engineering (WZL), RWTH Aachen University, 52074 Aachen, Germany
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10
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Drobnjakovic M, Hart R, Kulvatunyou BS, Ivezic N, Srinivasan V. Current challenges and recent advances on the path towards continuous biomanufacturing. Biotechnol Prog 2023; 39:e3378. [PMID: 37493037 DOI: 10.1002/btpr.3378] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/20/2023] [Revised: 05/13/2023] [Accepted: 06/21/2023] [Indexed: 07/27/2023]
Abstract
Continuous biopharmaceutical manufacturing is currently a field of intense research due to its potential to make the entire production process more optimal for the modern, ever-evolving biopharmaceutical market. Compared to traditional batch manufacturing, continuous bioprocessing is more efficient, adjustable, and sustainable and has reduced capital costs. However, despite its clear advantages, continuous bioprocessing is yet to be widely adopted in commercial manufacturing. This article provides an overview of the technological roadblocks for extensive adoptions and points out the recent advances that could help overcome them. In total, three key areas for improvement are identified: Quality by Design (QbD) implementation, integration of upstream and downstream technologies, and data and knowledge management. First, the challenges to QbD implementation are explored. Specifically, process control, process analytical technology (PAT), critical process parameter (CPP) identification, and mathematical models for bioprocess control and design are recognized as crucial for successful QbD realizations. Next, the difficulties of end-to-end process integration are examined, with a particular emphasis on downstream processing. Finally, the problem of data and knowledge management and its potential solutions are outlined where ontologies and data standards are pointed out as key drivers of progress.
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Affiliation(s)
- Milos Drobnjakovic
- Systems Integration Division, National Institute of Standards and Technology, Gaithersburg, Maryland, USA
| | - Roger Hart
- National Institute for Innovation in Manufacturing Biopharmaceuticals, Newark, New Jersey, USA
| | - Boonserm Serm Kulvatunyou
- Systems Integration Division, National Institute of Standards and Technology, Gaithersburg, Maryland, USA
| | - Nenad Ivezic
- Systems Integration Division, National Institute of Standards and Technology, Gaithersburg, Maryland, USA
| | - Vijay Srinivasan
- Systems Integration Division, National Institute of Standards and Technology, Gaithersburg, Maryland, USA
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11
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Pawar D, Lo Presti D, Silvestri S, Schena E, Massaroni C. Current and future technologies for monitoring cultured meat: A review. Food Res Int 2023; 173:113464. [PMID: 37803787 DOI: 10.1016/j.foodres.2023.113464] [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: 06/07/2023] [Revised: 08/30/2023] [Accepted: 09/10/2023] [Indexed: 10/08/2023]
Abstract
The high population growth rate, massive animal food consumption, fast economic progress, and limited food resources could lead to a food crisis in the future. There is a huge requirement for dietary proteins including cultured meat is being progressed to fulfill the need for meat-derived proteins in the diet. However, production of cultured meat requires monitoring numerous bioprocess parameters. This review presents a comprehensive overview of various widely adopted techniques (optical, spectroscopic, electrochemical, capacitive, FETs, resistive, microscopy, and ultrasound) for monitoring physical, chemical, and biological parameters that can improve the bioprocess control in cultured meat. The methods, operating principle, merits/demerits, and the main open challenges are reviewed with the aim to support the readers in advancing knowledge on novel sensing systems for cultured meat applications.
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Affiliation(s)
- Dnyandeo Pawar
- Microwave Materials Group, Centre for Materials for Electronics Technology (C-MET), Athani P.O, Thrissur, Kerala 680581, India.
| | - Daniela Lo Presti
- Unit of Measurements and Biomedical Instrumentation, Departmental Faculty of Engineering, Università Campus Bio-Medico di Roma, Via Alvaro del Portillo, 21, 00128 Rome, Italy
| | - Sergio Silvestri
- Unit of Measurements and Biomedical Instrumentation, Departmental Faculty of Engineering, Università Campus Bio-Medico di Roma, Via Alvaro del Portillo, 21, 00128 Rome, Italy
| | - Emiliano Schena
- Unit of Measurements and Biomedical Instrumentation, Departmental Faculty of Engineering, Università Campus Bio-Medico di Roma, Via Alvaro del Portillo, 21, 00128 Rome, Italy
| | - Carlo Massaroni
- Unit of Measurements and Biomedical Instrumentation, Departmental Faculty of Engineering, Università Campus Bio-Medico di Roma, Via Alvaro del Portillo, 21, 00128 Rome, Italy
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12
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Yang J, Ding A, Zhou JL, Yan BY, Gu Z, Wang HF. A Floating Capsule Electrochemical System for In Situ and Multichannel Ion-Selective Sensing. BIOSENSORS 2023; 13:914. [PMID: 37887107 PMCID: PMC10605769 DOI: 10.3390/bios13100914] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 09/05/2023] [Revised: 09/29/2023] [Accepted: 09/29/2023] [Indexed: 10/28/2023]
Abstract
Free-floating electrochemical sensors are promising for in situ bioprocess monitoring with the advantages of movability, a lowered risk of contamination, and a simplified structure of the bioreactor. Although floating sensors were developed for the measurement of physical and chemical indicators such as temperature, velocity of flow, pH, and dissolved oxygen, it is the lack of available electrochemical sensors for the determination of the inorganic ions in bioreactors that has a significant influence on cell culture. In this study, a capsule-shaped electrochemical system (iCapsuleEC) is developed to monitor ions including K+, NH4+, Na+, Ca2+, and Mg2+ based on solid-contact ion-selective electrodes (SC-ISEs). It consists of a disposable electrochemical sensor and signal-processing device with features including multichannel measurement, self-calibration, and wireless data transmission. The capacities of the iCapsuleEC were demonstrated not only for in situ measurement of ion concentrations but also for the optimization of the sensing electrodes. We also explored the possibility of the system for use in detection in simulated cell culture media.
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Affiliation(s)
- Jie Yang
- Key Laboratory of Smart Manufacturing in Energy Chemical Process Ministry of Education, East China University of Science and Technology, Shanghai 200237, China
- School of Chemistry and Molecular Engineering, East China University of Science and Technology, Shanghai 200237, China
| | - Ao Ding
- Key Laboratory of Smart Manufacturing in Energy Chemical Process Ministry of Education, East China University of Science and Technology, Shanghai 200237, China
| | - Jia-Le Zhou
- Key Laboratory of Smart Manufacturing in Energy Chemical Process Ministry of Education, East China University of Science and Technology, Shanghai 200237, China
| | - Bing-Yong Yan
- Key Laboratory of Smart Manufacturing in Energy Chemical Process Ministry of Education, East China University of Science and Technology, Shanghai 200237, China
| | - Zhen Gu
- Key Laboratory of Smart Manufacturing in Energy Chemical Process Ministry of Education, East China University of Science and Technology, Shanghai 200237, China
| | - Hui-Feng Wang
- Key Laboratory of Smart Manufacturing in Energy Chemical Process Ministry of Education, East China University of Science and Technology, Shanghai 200237, China
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13
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Berg C, Busch S, Alawiyah MD, Finger M, Ihling N, Paquet-Durand O, Hitzmann B, Büchs J. Advancing 2D fluorescence online monitoring in microtiter plates by separating scattered light and fluorescence measurement, using a tunable emission monochromator. Biotechnol Bioeng 2023; 120:2925-2939. [PMID: 37350126 DOI: 10.1002/bit.28474] [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: 04/18/2023] [Revised: 06/07/2023] [Accepted: 06/08/2023] [Indexed: 06/24/2023]
Abstract
Online fluorescence monitoring has become a key technology in modern bioprocess development, as it provides in-depth process knowledge at comparably low costs. In particular, the technology is widely established for high-throughput microbioreactor cultivation systems, due to its noninvasive character. For microtiter plates, previously also multi-wavelength 2D fluorescence monitoring was developed. To overcome an observed limitation of fluorescence sensitivity, this study presents a modified spectroscopic setup, including a tunable emission monochromator. The new optical component enables the separation of the scattered and fluorescent light measurements, which allows for the adjustment of integration times of the charge-coupled device detector. The resulting increased fluorescence sensitivity positively affected the performance of principal component analysis for spectral data of Escherichia coli batch cultivation experiments with varying sorbitol concentration supplementation. In direct comparison with spectral data recorded at short integration times, more biologically consistent signal dynamics were calculated. Furthermore, during partial least square regression for E. coli cultivation experiments with varying glucose concentrations, improved modeling performance was observed. Especially, for the growth-uncoupled acetate concentration, a considerable improvement of the root-mean-square error from 0.25 to 0.17 g/L was achieved. In conclusion, the modified setup represents another important step in advancing 2D fluorescence monitoring in microtiter plates.
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Affiliation(s)
- Christoph Berg
- AVT-Aachener Verfahrenstechnik, Biochemical Engineering, RWTH Aachen University, Aachen, Germany
| | - Selma Busch
- AVT-Aachener Verfahrenstechnik, Biochemical Engineering, RWTH Aachen University, Aachen, Germany
| | - Muthia Dewi Alawiyah
- AVT-Aachener Verfahrenstechnik, Biochemical Engineering, RWTH Aachen University, Aachen, Germany
| | - Maurice Finger
- AVT-Aachener Verfahrenstechnik, Biochemical Engineering, RWTH Aachen University, Aachen, Germany
| | - Nina Ihling
- AVT-Aachener Verfahrenstechnik, Biochemical Engineering, RWTH Aachen University, Aachen, Germany
| | - Olivier Paquet-Durand
- Department of Process Analytics & Cereal Science, Institute for Food Science and Biotechnology, University of Hohenheim, Stuttgart, Germany
| | - Bernd Hitzmann
- Department of Process Analytics & Cereal Science, Institute for Food Science and Biotechnology, University of Hohenheim, Stuttgart, Germany
| | - Jochen Büchs
- AVT-Aachener Verfahrenstechnik, Biochemical Engineering, RWTH Aachen University, Aachen, Germany
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14
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Baghini SS, Razeghian E, Malayer SK, Pecho RDC, Obaid M, Awfi ZS, Zainab HA, Shamsara M. Recent advances in the application of genetic and epigenetic modalities in the improvement of antibody-producing cell lines. Int Immunopharmacol 2023; 123:110724. [PMID: 37582312 DOI: 10.1016/j.intimp.2023.110724] [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: 01/31/2023] [Revised: 07/25/2023] [Accepted: 07/26/2023] [Indexed: 08/17/2023]
Abstract
There are numerous applications for recombinant antibodies (rAbs) in biological and toxicological research. Monoclonal antibodies are synthesized using genetic engineering and other related processes involved in the generation of rAbs. Because they can identify specific antigenic sites on practically any molecule, including medicines, hormones, microbial antigens, and cell receptors, rAbs are particularly useful in scientific research. The key benefits of rAbs are improved repeatability, control, and consistency, shorter manufacturing times than with hybridoma technology, an easier transition from one format of antibody to another, and an animal-free process. The engineering of the host cell has recently been developed method for enhancing the production efficiency and improving the quality of antibodies from mammalian cell lines. In this light, genetic engineering is mostly utilized to manage cellular chaperones, decrease cell death, increase cell viability, change the microRNAs (miRNAs) pattern in mammalian cells, and glycoengineered cell lines. Here, we shed light on how genetic engineering can be used therapeutically to produce antibodies at higher levels with greater potency and effectiveness.
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Affiliation(s)
- Sadegh Shojaei Baghini
- Plant Biotechnology Department, National Institute of Genetic Engineering and Biotechnology (NIGEB), Tehran, Iran.
| | - Ehsan Razeghian
- Human Genetics Division, Medical Biotechnology Department, National Institute of Genetics Engineering and Biotechnology (NIGEB), Tehran, Iran
| | - Setare Kakavand Malayer
- Department of Biology, Faculty of Biological Science, Tehran North Branch, Islamic Azad University, Tehran, Iran
| | | | | | - Zinah Salem Awfi
- Department of Dental Industry Techniques, Al-Noor University College, Nineveh, Iraq.
| | - H A Zainab
- Department of Pharmacy, Al-Zahrawi University College, Karbala, Iraq.
| | - Mehdi Shamsara
- Department of Animal Biotechnology, National Institute of Genetic Engineering and Biotechnology, Tehran, Iran.
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15
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Kolotyeva NA, Gilmiyarova FN, Averchuk AS, Baranich TI, Rozanova NA, Kukla MV, Tregub PP, Salmina AB. Novel Approaches to the Establishment of Local Microenvironment from Resorbable Biomaterials in the Brain In Vitro Models. Int J Mol Sci 2023; 24:14709. [PMID: 37834155 PMCID: PMC10572431 DOI: 10.3390/ijms241914709] [Citation(s) in RCA: 2] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/24/2023] [Revised: 09/19/2023] [Accepted: 09/27/2023] [Indexed: 10/15/2023] Open
Abstract
The development of brain in vitro models requires the application of novel biocompatible materials and biopolymers as scaffolds for controllable and effective cell growth and functioning. The "ideal" brain in vitro model should demonstrate the principal features of brain plasticity like synaptic transmission and remodeling, neurogenesis and angiogenesis, and changes in the metabolism associated with the establishment of new intercellular connections. Therefore, the extracellular scaffolds that are helpful in the establishment and maintenance of local microenvironments supporting brain plasticity mechanisms are of critical importance. In this review, we will focus on some carbohydrate metabolites-lactate, pyruvate, oxaloacetate, malate-that greatly contribute to the regulation of cell-to-cell communications and metabolic plasticity of brain cells and on some resorbable biopolymers that may reproduce the local microenvironment enriched in particular cell metabolites.
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Affiliation(s)
| | - Frida N. Gilmiyarova
- Department of Fundamental and Clinical Biochemistry with Laboratory Diagnostics, Samara State Medical University, 443099 Samara, Russia
| | - Anton S. Averchuk
- Brain Science Institute, Research Center of Neurology, 125367 Moscow, Russia
| | - Tatiana I. Baranich
- Brain Science Institute, Research Center of Neurology, 125367 Moscow, Russia
| | | | - Maria V. Kukla
- Brain Science Institute, Research Center of Neurology, 125367 Moscow, Russia
| | - Pavel P. Tregub
- Brain Science Institute, Research Center of Neurology, 125367 Moscow, Russia
- Department of Pathophysiology, I.M. Sechenov First Moscow State Medical University, 119991 Moscow, Russia
| | - Alla B. Salmina
- Brain Science Institute, Research Center of Neurology, 125367 Moscow, Russia
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16
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Joubert S, Stuible M, Lord-Dufour S, Lamoureux L, Vaillancourt F, Perret S, Ouimet M, Pelletier A, Bisson L, Mahimkar R, Pham PL, L Ecuyer-Coelho H, Roy M, Voyer R, Baardsnes J, Sauvageau J, St-Michael F, Robotham A, Kelly J, Acel A, Schrag JD, El Bakkouri M, Durocher Y. A CHO stable pool production platform for rapid clinical development of trimeric SARS-CoV-2 spike subunit vaccine antigens. Biotechnol Bioeng 2023. [PMID: 36987713 DOI: 10.1002/bit.28387] [Citation(s) in RCA: 6] [Impact Index Per Article: 6.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/17/2023] [Revised: 03/02/2023] [Accepted: 03/14/2023] [Indexed: 03/30/2023]
Abstract
Protein expression from stably transfected Chinese hamster ovary (CHO) clones is an established but time-consuming method for manufacturing therapeutic recombinant proteins. The use of faster, alternative approaches, such as non-clonal stable pools, has been restricted due to lower productivity and longstanding regulatory guidelines. Recently, the performance of stable pools has improved dramatically, making them a viable option for quickly producing drug substance for GLP-toxicology and early-phase clinical trials in scenarios such as pandemics that demand rapid production timelines. Compared to stable CHO clones which can take several months to generate and characterize, stable pool development can be completed in only a few weeks. Here, we compared the productivity and product quality of trimeric SARS-CoV-2 spike protein ectodomains produced from stable CHO pools or clones. Using a set of biophysical and biochemical assays we show that product quality is very similar and that CHO pools demonstrate sufficient productivity to generate vaccine candidates for early clinical trials. Based on these data, we propose that regulatory guidelines should be updated to permit production of early clinical trial material from CHO pools to enable more rapid and cost-effective clinical evaluation of potentially life-saving vaccines.
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Affiliation(s)
- Simon Joubert
- Human Health Therapeutics Research Centre, National Research Council Canada, Montréal, Québec, Canada
| | - Matthew Stuible
- Human Health Therapeutics Research Centre, National Research Council Canada, Montréal, Québec, Canada
| | - Simon Lord-Dufour
- Human Health Therapeutics Research Centre, National Research Council Canada, Montréal, Québec, Canada
| | - Linda Lamoureux
- Human Health Therapeutics Research Centre, National Research Council Canada, Montréal, Québec, Canada
| | - François Vaillancourt
- Human Health Therapeutics Research Centre, National Research Council Canada, Montréal, Québec, Canada
| | - Sylvie Perret
- Human Health Therapeutics Research Centre, National Research Council Canada, Montréal, Québec, Canada
| | - Manon Ouimet
- Human Health Therapeutics Research Centre, National Research Council Canada, Montréal, Québec, Canada
| | - Alex Pelletier
- Human Health Therapeutics Research Centre, National Research Council Canada, Montréal, Québec, Canada
| | - Louis Bisson
- Human Health Therapeutics Research Centre, National Research Council Canada, Montréal, Québec, Canada
| | - Rohan Mahimkar
- Human Health Therapeutics Research Centre, National Research Council Canada, Montréal, Québec, Canada
| | - Phuong Lan Pham
- Human Health Therapeutics Research Centre, National Research Council Canada, Montréal, Québec, Canada
| | - Helene L Ecuyer-Coelho
- Human Health Therapeutics Research Centre, National Research Council Canada, Montréal, Québec, Canada
| | - Marjolaine Roy
- Human Health Therapeutics Research Centre, National Research Council Canada, Montréal, Québec, Canada
| | - Robert Voyer
- Human Health Therapeutics Research Centre, National Research Council Canada, Montréal, Québec, Canada
| | - Jason Baardsnes
- Human Health Therapeutics Research Centre, National Research Council Canada, Montréal, Québec, Canada
| | - Janelle Sauvageau
- Human Health Therapeutics Research Centre, National Research Council Canada, Ottawa, Ontario, Canada
| | - Frank St-Michael
- Human Health Therapeutics Research Centre, National Research Council Canada, Ottawa, Ontario, Canada
| | - Anna Robotham
- Human Health Therapeutics Research Centre, National Research Council Canada, Ottawa, Ontario, Canada
| | - John Kelly
- Human Health Therapeutics Research Centre, National Research Council Canada, Ottawa, Ontario, Canada
| | - Andrea Acel
- Human Health Therapeutics Research Centre, National Research Council Canada, Montréal, Québec, Canada
| | - Joseph D Schrag
- Human Health Therapeutics Research Centre, National Research Council Canada, Montréal, Québec, Canada
| | - Majida El Bakkouri
- Human Health Therapeutics Research Centre, National Research Council Canada, Montréal, Québec, Canada
| | - Yves Durocher
- Human Health Therapeutics Research Centre, National Research Council Canada, Montréal, Québec, Canada
- Department of Biochemistry and Molecular Medicine, Faculty of Medicine, Université de Montréal, Montréal, Québec, Canada
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17
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Nikita S, Mishra S, Gupta K, Runkana V, Gomes J, Rathore AS. Advances in bioreactor control for production of biotherapeutic products. Biotechnol Bioeng 2023; 120:1189-1214. [PMID: 36760086 DOI: 10.1002/bit.28346] [Citation(s) in RCA: 3] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/21/2022] [Revised: 02/08/2023] [Accepted: 02/08/2023] [Indexed: 02/11/2023]
Abstract
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.
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Affiliation(s)
- Saxena Nikita
- Department of Chemical Engineering, DBT Centre of Excellence for Biopharmaceutical Technology, Indian Institute of Technology, Hauz Khas, Delhi, India
| | - Somesh Mishra
- Department of Chemical Engineering, DBT Centre of Excellence for Biopharmaceutical Technology, Indian Institute of Technology, Hauz Khas, Delhi, India
| | - Keshari Gupta
- TCS Research, Tata Consultancy Services Limited, Pune, India
| | | | - James Gomes
- Kusuma School of Biological Sciences, Indian Institute of Technology, Hauz Khas, Delhi, India
| | - Anurag S Rathore
- Department of Chemical Engineering, DBT Centre of Excellence for Biopharmaceutical Technology, Indian Institute of Technology, Hauz Khas, Delhi, India
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18
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Iglesias CF, Ristovski M, Bolic M, Cuperlovic-Culf M. rAAV Manufacturing: The Challenges of Soft Sensing during Upstream Processing. Bioengineering (Basel) 2023; 10:bioengineering10020229. [PMID: 36829723 PMCID: PMC9951952 DOI: 10.3390/bioengineering10020229] [Citation(s) in RCA: 3] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/10/2022] [Revised: 01/31/2023] [Accepted: 02/02/2023] [Indexed: 02/11/2023] Open
Abstract
Recombinant adeno-associated virus (rAAV) is the most effective viral vector technology for directly translating the genomic revolution into medicinal therapies. However, the manufacturing of rAAV viral vectors remains challenging in the upstream processing with low rAAV yield in large-scale production and high cost, limiting the generalization of rAAV-based treatments. This situation can be improved by real-time monitoring of critical process parameters (CPP) that affect critical quality attributes (CQA). To achieve this aim, soft sensing combined with predictive modeling is an important strategy that can be used for optimizing the upstream process of rAAV production by monitoring critical process variables in real time. However, the development of soft sensors for rAAV production as a fast and low-cost monitoring approach is not an easy task. This review article describes four challenges and critically discusses the possible solutions that can enable the application of soft sensors for rAAV production monitoring. The challenges from a data scientist's perspective are (i) a predictor variable (soft-sensor inputs) set without AAV viral titer, (ii) multi-step forecasting, (iii) multiple process phases, and (iv) soft-sensor development composed of the mechanistic model.
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Affiliation(s)
| | - Milica Ristovski
- Faculty of Engineering, University of Ottawa, Ottawa, ON K1N 6N5, Canada
- Faculty of Medicine, University of Ottawa, Ottawa, ON K1H 8M5, Canada
| | - Miodrag Bolic
- Faculty of Engineering, University of Ottawa, Ottawa, ON K1N 6N5, Canada
| | - Miroslava Cuperlovic-Culf
- Digital Technologies Research Center, National Research Council, Ottawa, ON K1A 0R6, Canada
- Department of Biochemistry, Microbiology, and Immunology, Faculty of Medicine, University of Ottawa, Ottawa, ON K1H 8M5, Canada
- Correspondence:
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19
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Wainaina S, Taherzadeh MJ. Automation and artificial intelligence in filamentous fungi-based bioprocesses: A review. BIORESOURCE TECHNOLOGY 2023; 369:128421. [PMID: 36462761 DOI: 10.1016/j.biortech.2022.128421] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Received: 10/20/2022] [Revised: 11/25/2022] [Accepted: 11/27/2022] [Indexed: 06/17/2023]
Abstract
By utilizing their powerful metabolic versatility, filamentous fungi can be utilized in bioprocesses aimed at achieving circular economy. With the current digital transformation within the biomanufacturing sector, the interest of automating fungi-based systems has intensified. The purpose of this paper was therefore to review the potentials connected to the use of automation and artificial intelligence in fungi-based systems. Automation is characterized by the substitution of manual tasks with mechanized tools. Artificial intelligence is, on the other hand, a domain within computer science that aims at designing tools and machines with the capacity to execute functions that would usually require human aptitude. Process flexibility, enhanced data reliability and increased productivity are some of the benefits of integrating automation and artificial intelligence in fungi-based bioprocesses. One of the existing gaps that requires further investigation is the use of such data-based technologies in the production of food from fungi.
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Affiliation(s)
- Steven Wainaina
- Swedish Centre for Resource Recovery, University of Borås, 50190 Borås, Sweden
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20
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Recent capillary electrophoresis applications for upstream and downstream biopharmaceutical process monitoring. Trends Analyt Chem 2023. [DOI: 10.1016/j.trac.2023.116975] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/12/2023]
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21
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Rösner LS, Walter F, Ude C, John GT, Beutel S. Sensors and Techniques for On-Line Determination of Cell Viability in Bioprocess Monitoring. BIOENGINEERING (BASEL, SWITZERLAND) 2022; 9:bioengineering9120762. [PMID: 36550968 PMCID: PMC9774925 DOI: 10.3390/bioengineering9120762] [Citation(s) in RCA: 7] [Impact Index Per Article: 3.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 09/29/2022] [Revised: 11/07/2022] [Accepted: 11/30/2022] [Indexed: 12/12/2022]
Abstract
In recent years, the bioprocessing industry has experienced significant growth and is increasingly emerging as an important economic sector. Here, efficient process management and constant control of cellular growth are essential. Good product quality and yield can only be guaranteed with high cell density and high viability. Whereas the on-line measurement of physical and chemical process parameters has been common practice for many years, the on-line determination of viability remains a challenge and few commercial on-line measurement methods have been developed to date for determining viability in industrial bioprocesses. Thus, numerous studies have recently been conducted to develop sensors for on-line viability estimation, especially in the field of optical spectroscopic sensors, which will be the focus of this review. Spectroscopic sensors are versatile, on-line and mostly non-invasive. Especially in combination with bioinformatic data analysis, they offer great potential for industrial application. Known as soft sensors, they usually enable simultaneous estimation of multiple biological variables besides viability to be obtained from the same set of measurement data. However, the majority of the presented sensors are still in the research stage, and only a few are already commercially available.
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Affiliation(s)
- Laura S. Rösner
- Institute for Technical Chemistry, Leibniz University of Hanover, 30167 Hannover, Germany
| | - Franziska Walter
- Institute for Technical Chemistry, Leibniz University of Hanover, 30167 Hannover, Germany
| | - Christian Ude
- Institute for Technical Chemistry, Leibniz University of Hanover, 30167 Hannover, Germany
| | - Gernot T. John
- PreSens Precision Sensing GmbH, Am BioPark 11, 93053 Regensburg, Germany
| | - Sascha Beutel
- Institute for Technical Chemistry, Leibniz University of Hanover, 30167 Hannover, Germany
- Correspondence:
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22
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Special Issue “Bioprocess Systems Engineering Applications in Pharmaceutical Manufacturing”. Processes (Basel) 2022. [DOI: 10.3390/pr10081634] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/17/2022] Open
Abstract
Biopharmaceutical and pharmaceutical manufacturing are strongly influenced by the process analytical technology initiative (PAT) and quality by design (QbD) methodologies, which are designed to enhance the understanding of more integrated processes [...]
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23
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Chen R, Chen XJ, Shi C, Jiao B, Shi Y, Yao B, Lin DQ, Gong W, Hsu S. Converting a mAb downstream process from batch to continuous using process modeling and process analytical technology. Biotechnol J 2022; 17:e2100351. [PMID: 35908168 DOI: 10.1002/biot.202100351] [Citation(s) in RCA: 5] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/06/2021] [Revised: 07/28/2022] [Accepted: 07/28/2022] [Indexed: 11/06/2022]
Abstract
The biopharmaceutical market is driving the revolution from traditional batch processes to continuous manufacturing for higher productivity and lower costs. In this work, a batch mAb downstream process has been converted into an integrated continuous process with the combination of multiple techniques. For process intensification, two batch mode unit operations (protein A capture chromatography, ultrafiltration/diafiltration) are converted into continuous ones; For continuity, surge tanks were used between adjacent steps, and level signals were used to trigger process start or stop, forming a holistic continuous process. For process automation, manual operations (e.g., pH and conductivity adjustment) were changed into automatic operation and load mass was controlled with process analytical technology (PAT). A model-based simulation was applied to estimate the loading conditions for the continuous capture process, resulting in 21% resin capacity utilization and 28% productivity improvement as compared to the batch process. Automatic load mass control of cation exchange chromatography was achieved through a customized in-line protein quantity monitoring system, with a difference of less than 1.3% as compared to off-line analysis. Total process time was shortened from 4 days (batch process) to less than 24 hours using the continuous downstream process with the overall productivity of 23.8 g mAb /day for the bench-scale system. Comparable yield and quality data were obtained in three test runs, indicating a successful conversion from a batch process to a continuous process. The insight of this work could be a reference to other similar situations. This article is protected by copyright. All rights reserved.
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Affiliation(s)
- Ran Chen
- Shanghai Engineering Research Center of Anti-tumor Biological Drugs, Shanghai Henlius Biotech, Inc., Shanghai, China
| | - Xu-Jun Chen
- Shanghai Engineering Research Center of Anti-tumor Biological Drugs, Shanghai Henlius Biotech, Inc., Shanghai, China
| | - Ce Shi
- Key Laboratory of Biomass Chemical Engineering of Ministry of Education, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou, China
| | - Biao Jiao
- Shanghai Engineering Research Center of Anti-tumor Biological Drugs, Shanghai Henlius Biotech, Inc., Shanghai, China
| | - Ye Shi
- Shanghai Engineering Research Center of Anti-tumor Biological Drugs, Shanghai Henlius Biotech, Inc., Shanghai, China
| | - Bin Yao
- Shanghai Engineering Research Center of Anti-tumor Biological Drugs, Shanghai Henlius Biotech, Inc., Shanghai, China
| | - Dong-Qiang Lin
- Key Laboratory of Biomass Chemical Engineering of Ministry of Education, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou, China
| | - Wei Gong
- Shanghai Engineering Research Center of Anti-tumor Biological Drugs, Shanghai Henlius Biotech, Inc., Shanghai, China
| | - Simon Hsu
- Shanghai Engineering Research Center of Anti-tumor Biological Drugs, Shanghai Henlius Biotech, Inc., Shanghai, China
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24
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Simultaneous State and Kinetic Observation of Class-Controllable Bioprocesses. MATHEMATICS 2022. [DOI: 10.3390/math10152665] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 01/27/2023]
Abstract
Monitoring of bioprocesses is a challenge in designing modern systems for control. In the biotechnology industry, the lack of reliable hardware sensors for key variables related to the metabolism of microorganisms is a topical problem. This predetermines the progress of a scientific field that relies on the development of software sensors for immeasurable variables. In this paper, a new approach for the monitoring of class-controllable bioprocesses that evolve through various physiological states (metabolic regimes) is proposed. At the core of the approach is the potential to present total biomass as a sum of the biomass concentrations obtained during each of the metabolic regimes. Algorithms for estimation of immeasurable variables and their kinetics are here derived and applied using real experimental data. As a case-study, a fed-batch process for phytase production by E. coli is considered. Effectiveness of the method is proven by using two sets of real experiments. One is used to tune the software sensors and the other to verify the approach. The stability analyses are provided, as well. The obtained results and successful verification confirm the adaptive properties of the approach. The considered software sensors will be further built into an interactive system for training specialists/students of biotechnology.
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25
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Graf A, Lemke J, Schulze M, Soeldner R, Rebner K, Hoehse M, Matuszczyk J. A Novel Approach for Non-Invasive Continuous In-Line Control of Perfusion Cell Cultivations by Raman Spectroscopy. Front Bioeng Biotechnol 2022; 10:719614. [PMID: 35547168 PMCID: PMC9081366 DOI: 10.3389/fbioe.2022.719614] [Citation(s) in RCA: 9] [Impact Index Per Article: 4.5] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/02/2021] [Accepted: 04/04/2022] [Indexed: 11/13/2022] Open
Abstract
Continuous manufacturing is becoming more important in the biopharmaceutical industry. This processing strategy is favorable, as it is more efficient, flexible, and has the potential to produce higher and more consistent product quality. At the same time, it faces some challenges, especially in cell culture. As a steady state has to be maintained over a prolonged time, it is unavoidable to implement advanced process analytical technologies to control the relevant process parameters in a fast and precise manner. One such analytical technology is Raman spectroscopy, which has proven its advantages for process monitoring and control mostly in (fed-) batch cultivations. In this study, an in-line flow cell for Raman spectroscopy is included in the cell-free harvest stream of a perfusion process. Quantitative models for glucose and lactate were generated based on five cultivations originating from varying bioreactor scales. After successfully validating the glucose model (Root Mean Square Error of Prediction (RMSEP) of ∼0.2 g/L), it was employed for control of an external glucose feed in cultivation with a glucose-free perfusion medium. The generated model was successfully applied to perform process control at 4 g/L and 1.5 g/L glucose over several days, respectively, with variability of ±0.4 g/L. The results demonstrate the high potential of Raman spectroscopy for advanced process monitoring and control of a perfusion process with a bioreactor and scale-independent measurement method.
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Affiliation(s)
- A. Graf
- Product Development, Sartorius Stedim Biotech GmbH, Göttingen, Germany
| | - J. Lemke
- Corporate Research, Sartorius Stedim Biotech GmbH, Göttingen, Germany
- *Correspondence: J. Lemke,
| | - M. Schulze
- Corporate Research, Sartorius Stedim Biotech GmbH, Göttingen, Germany
| | - R. Soeldner
- Corporate Research, Sartorius Stedim Biotech GmbH, Göttingen, Germany
| | - K. Rebner
- Process Analysis and Technology PA&T, Reutlingen University, Reutlingen, Germany
| | - M. Hoehse
- Product Development, Sartorius Stedim Biotech GmbH, Göttingen, Germany
| | - J. Matuszczyk
- Corporate Research, Sartorius Stedim Biotech GmbH, Göttingen, Germany
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