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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] [MESH Headings] [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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Kafle B, Wubshet SG, Hestnes Bakke KA, Böcker U, O'Farrell M, Dankel K, Måge I, Tschudi J, Tzimorotas D, Afseth NK, Dunker T. A portable dry film FTIR instrument for industrial food and bioprocess applications. ANALYTICAL METHODS : ADVANCING METHODS AND APPLICATIONS 2024; 16:4310-4321. [PMID: 38888190 DOI: 10.1039/d4ay00238e] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 06/20/2024]
Abstract
The main objective of this study was to design, build, and test a compact, multi-well, portable dry film FTIR system for industrial food and bioprocess applications. The system features dry film sampling on a circular rotating disc comprising 31 wells, a design that was chosen to simplify potential automation and robotic sample handling at a later stage. Calibration models for average molecular weight (AMW, 200 samples) and collagen content (68 samples) were developed from the measurements of industrially produced protein hydrolysate samples in a controlled laboratory environment. Similarly, calibration models for the prediction of lactate content in samples from cultivation media (59 samples) were also developed. The portable dry film FTIR system showed reliable model characteristics which were benchmarked with a benchtop FTIR system. Subsequently, the portable dry film FTIR system was deployed in a bioprocessing plant, and protein hydrolysate samples were measured at-line in an industrial environment. This industrial testing involved building a calibration model for predicting AMW using 60 protein hydrolysate samples measured at-line using the portable dry film FTIR system and subsequent model validation using a test set of 26 samples. The industrial calibration in terms of coefficient of determination (R2 = 0.94), root mean square of cross-validation (RMSECV = 194 g mol-1), and root mean square of prediction (RMSEP = 162 g mol-1) demonstrated low prediction errors as compared to benchtop FTIR measurements, with no statistical difference between the calibration models of the two FTIR systems. This is to the authors' knowledge the first study for developing and employing a portable dry film FTIR system in the enzymatic protein hydrolysis industry for successful at-line measurements of protein hydrolysate samples. The study therefore suggests that the portable dry film FTIR instrument has huge potential for in/at-line applications in the food and bioprocessing industries.
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Affiliation(s)
- Bijay Kafle
- Norwegian Institute of Food, Fisheries and Aquaculture Research (NOFIMA), P. O. Box 210, Ås, N-1431, Norway.
- Faculty of Science and Technology, Norwegian University of Life Sciences (NMBU), P. O. Box 5003, Ås, N-1432, Norway
| | - Sileshi Gizachew Wubshet
- Norwegian Institute of Food, Fisheries and Aquaculture Research (NOFIMA), P. O. Box 210, Ås, N-1431, Norway.
| | | | - Ulrike Böcker
- Norwegian Institute of Food, Fisheries and Aquaculture Research (NOFIMA), P. O. Box 210, Ås, N-1431, Norway.
| | | | - Katinka Dankel
- Norwegian Institute of Food, Fisheries and Aquaculture Research (NOFIMA), P. O. Box 210, Ås, N-1431, Norway.
| | - Ingrid Måge
- Norwegian Institute of Food, Fisheries and Aquaculture Research (NOFIMA), P. O. Box 210, Ås, N-1431, Norway.
| | - Jon Tschudi
- SINTEF, P. O. Box 124 Blindern, Oslo, N-0314, Norway
| | - Dimitrios Tzimorotas
- Norwegian Institute of Food, Fisheries and Aquaculture Research (NOFIMA), P. O. Box 210, Ås, N-1431, Norway.
| | - Nils Kristian Afseth
- Norwegian Institute of Food, Fisheries and Aquaculture Research (NOFIMA), P. O. Box 210, Ås, N-1431, Norway.
| | - Tim Dunker
- SINTEF, P. O. Box 124 Blindern, Oslo, N-0314, Norway
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Ou J, Cui W, Zhao Y, Tang Y, Williams A, Wasalathanthri D, Xu J, Lee J, Borys MC, Khetan A. Use of spectroscopic process analytical technology for rapid quality evaluation during preparation of CHO cell culture media. Biotechnol Prog 2024:e3477. [PMID: 38699906 DOI: 10.1002/btpr.3477] [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: 02/22/2024] [Revised: 03/27/2024] [Accepted: 04/22/2024] [Indexed: 05/05/2024]
Abstract
Media preparation parameters contribute significantly to media quality, cell culture performance, productivity, and product quality. Establishing proper media preparation procedures is critical for ensuring a robust CHO cell culture process. Process analytical technology (PAT) enables unique ways to quantify assessments and improve media quality. Here, cell culture media were prepared under a wide range of temperatures (40-80°C) and pH (7.6-10.0). Media quality profiles were compared using three real-time PATs: Fourier-transform infrared (FTIR) spectroscopy, Raman spectroscopy, and excitation-emission matrix (EEM) spectroscopy. FTIR and Raman spectroscopies identified shifts in media quality under high preparation temperature (80°C) and at differing preparation pH which negatively impacted monoclonal antibody (mAb) production. In fed-batch processes for production of three different mAbs, viable cell density (VCD) and cell viability were mostly unaffected under all media preparation temperatures, while titer and cell specific productivity of mAb decreased when cultured in basal and feed media prepared at 80°C. High feed preparation pH alone was tolerated but cell growth and productivity profiles deviated from the control condition. Further, charge variants (main, acidic, basic species) and glycosylation (G0F, afucosylation, and high mannose) were examined. Statistically significant differences were observed for one or more of these quality attributes with any shifts in media preparation. In this study, we demonstrated strong associations between media preparation conditions and cell growth, productivity, and product quality. The rapid evaluation of media by PAT implementation enabled more comprehensive understanding of different parameters on media quality and consequential effects on CHO cell culture.
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Affiliation(s)
- Jianfa Ou
- Biologics Development, Global Product Development and Supply, Bristol Myers Squibb, Devens, Massachusetts, USA
| | - Wanyue Cui
- Biologics Development, Global Product Development and Supply, Bristol Myers Squibb, Devens, Massachusetts, USA
| | - Yuxiang Zhao
- Biologics Development, Global Product Development and Supply, Bristol Myers Squibb, Devens, Massachusetts, USA
| | - Yawen Tang
- Biologics Development, Global Product Development and Supply, Bristol Myers Squibb, Devens, Massachusetts, USA
| | - Alexander Williams
- Biologics Development, Global Product Development and Supply, Bristol Myers Squibb, Devens, Massachusetts, USA
| | - Dhanuka Wasalathanthri
- Biologics Development, Global Product Development and Supply, Bristol Myers Squibb, Devens, Massachusetts, USA
| | - Jianlin Xu
- Biologics Development, Global Product Development and Supply, Bristol Myers Squibb, Devens, Massachusetts, USA
| | - Jongchan Lee
- Biologics Development, Global Product Development and Supply, Bristol Myers Squibb, Devens, Massachusetts, USA
| | - Michael C Borys
- Biologics Development, Global Product Development and Supply, Bristol Myers Squibb, Devens, Massachusetts, USA
| | - Anurag Khetan
- Biologics Development, Global Product Development and Supply, Bristol Myers Squibb, Devens, Massachusetts, USA
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Marienberg H, Desch N, Mozin V, Sykora‐Mirle L, Müller A, Roth A, Käfer M, Neef R. Automized inline monitoring in perfused mammalian cell culture by MIR spectroscopy without calibration model building. Eng Life Sci 2024; 24:e2300237. [PMID: 38444619 PMCID: PMC10910268 DOI: 10.1002/elsc.202300237] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/04/2023] [Revised: 11/10/2023] [Accepted: 11/17/2023] [Indexed: 03/07/2024] Open
Abstract
Process Analytical Technologies (PATs) are taking a key role in the run for automatization in the biopharmaceutical industry. Spectroscopic methods such as Raman spectroscopy or mid-infrared (MIR) spectroscopy are getting more recognition in the recent years for inline monitoring of bioprocesses due to their ability to measure various molecules simultaneously. However, their dependency on laborious model calibration making them a challenge to implement. In this study, a novel one-point calibration that requires a single reference point prior to the inline monitoring of glucose and lactate in bioprocesses with MIR spectroscopy is assessed with 22 mammalian cell perfusion (PER) processes in two different scales and four different products. Concentrations are predicted over all PERs runs with a root mean square error (RMSE) of 0.29 g/L for glucose and 0.24 g/L for lactate, respectively. For comparison conventional partial least square regression (PLSR) models were used and trained with spectroscopic data from six bioreactor runs in two different scales and three products. The general accuracy of those models (RMSE of 0.41 g/L for glucose and 0.16 g/L for lactate) are in the range of the accuracy of the one-point calibration. This shows the potential of the one-point calibration as an approach making spectroscopy more accessible for bioprocess development.
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Affiliation(s)
| | | | | | | | | | - Andreas Roth
- IRUBIS GmbHMunichGermany
- Hochschule MannheimMannheimGermany
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5
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Ji B, Xuan L, Zhang Y, Mu W, Paek KY, Park SY, Wang J, Gao W. Application of Data Modeling, Instrument Engineering and Nanomaterials in Selected Medid the Scientific Recinal Plant Tissue Culture. PLANTS (BASEL, SWITZERLAND) 2023; 12:1505. [PMID: 37050131 PMCID: PMC10096660 DOI: 10.3390/plants12071505] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 01/10/2023] [Revised: 03/10/2023] [Accepted: 03/24/2023] [Indexed: 06/19/2023]
Abstract
At present, most precious compounds are still obtained by plant cultivation such as ginsenosides, glycyrrhizic acid, and paclitaxel, which cannot be easily obtained by artificial synthesis. Plant tissue culture technology is the most commonly used biotechnology tool, which can be used for a variety of studies such as the production of natural compounds, functional gene research, plant micropropagation, plant breeding, and crop improvement. Tissue culture material is a basic and important part of this issue. The formation of different plant tissues and natural products is affected by growth conditions and endogenous substances. The accumulation of secondary metabolites are affected by plant tissue type, culture method, and environmental stress. Multi-domain technologies are developing rapidly, and they have made outstanding contributions to the application of plant tissue culture. The modes of action have their own characteristics, covering the whole process of plant tissue from the induction, culture, and production of natural secondary metabolites. This paper reviews the induction mechanism of different plant tissues and the application of multi-domain technologies such as artificial intelligence, biosensors, bioreactors, multi-omics monitoring, and nanomaterials in plant tissue culture and the production of secondary metabolites. This will help to improve the tissue culture technology of medicinal plants and increase the availability and the yield of natural metabolites.
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Affiliation(s)
- Baoyu Ji
- School of Pharmaceutical Science and Technology, Tianjin University, Tianjin 300072, China
- Shool of Pharmacy, Henan University of Chinese Medicine, Zhengzhou 450046, China
| | - Liangshuang Xuan
- Shool of Pharmacy, Henan University of Chinese Medicine, Zhengzhou 450046, China
| | - Yunxiang Zhang
- School of Pharmaceutical Science and Technology, Tianjin University, Tianjin 300072, China
| | - Wenrong Mu
- Shool of Pharmacy, Henan University of Chinese Medicine, Zhengzhou 450046, China
| | - Kee-Yoeup Paek
- Department of Horticultural Science, Chungbuk National University, Cheongju 28644, Republic of Korea
| | - So-Young Park
- Department of Horticultural Science, Chungbuk National University, Cheongju 28644, Republic of Korea
| | - Juan Wang
- School of Pharmaceutical Science and Technology, Tianjin University, Tianjin 300072, China
| | - Wenyuan Gao
- School of Pharmaceutical Science and Technology, Tianjin University, Tianjin 300072, China
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Milewska A, Baekelandt G, Boutaieb S, Mozin V, Falconbridge A. In-line monitoring of protein concentration with MIR spectroscopy during UFDF. Eng Life Sci 2022; 23:e2200050. [PMID: 36751473 PMCID: PMC9893749 DOI: 10.1002/elsc.202200050] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/25/2022] [Revised: 11/22/2022] [Accepted: 12/13/2022] [Indexed: 12/25/2022] Open
Abstract
Rapid increase of product titers in upstream processes has presented challenges for downstream processing, where purification costs increase linearly with the increase of the product yield. Hence, innovative solutions are becoming increasingly popular. Process Analytical Technology (PAT) tools, such as spectroscopic techniques, are on the rise due to their capacity to provide real-time, precise analytics. This ensures consistent product quality and increased process understanding, as well as process control. Mid-infrared spectroscopy (MIR) has emerged as a highly promising technique within recent years, owing to its ability to monitor several critical process parameters at the same time and unchallenging spectral analysis and data interpretation. For in-line monitoring, Attenuated Total Reflectance-Fourier Transform Infrared Spectroscopy (ATR-FTIR) is a method of choice, as it enables reliable measurements in a liquid environment, even though water absorption bands are present in the region of interest. Here, we present MIR spectroscopy as a monitoring tool of critical process parameters in ultrafiltration/diafiltration (UFDF). MIR spectrometer was integrated in the UFDF process in an in-line fashion through a single-use flow cell containing a single bounce silicon ATR crystal. The results indicate that the one-point calibration algorithm applied to the MIR spectra, predicts highly accurate protein concentrations, as compared with validated offline analytical methods.
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Challenges and Opportunities of Implementing Data Fusion in Process Analytical Technology—A Review. Molecules 2022; 27:molecules27154846. [PMID: 35956791 PMCID: PMC9369811 DOI: 10.3390/molecules27154846] [Citation(s) in RCA: 10] [Impact Index Per Article: 5.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/30/2022] [Revised: 07/20/2022] [Accepted: 07/22/2022] [Indexed: 12/03/2022] Open
Abstract
The release of the FDA’s guidance on Process Analytical Technology has motivated and supported the pharmaceutical industry to deliver consistent quality medicine by acquiring a deeper understanding of the product performance and process interplay. The technical opportunities to reach this high-level control have considerably evolved since 2004 due to the development of advanced analytical sensors and chemometric tools. However, their transfer to the highly regulated pharmaceutical sector has been limited. To this respect, data fusion strategies have been extensively applied in different sectors, such as food or chemical, to provide a more robust performance of the analytical platforms. This survey evaluates the challenges and opportunities of implementing data fusion within the PAT concept by identifying transfer opportunities from other sectors. Special attention is given to the data types available from pharmaceutical manufacturing and their compatibility with data fusion strategies. Furthermore, the integration into Pharma 4.0 is discussed.
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Adejimi OE, Ignat T, Sadhasivam G, Zakin V, Schmilovitch Z, Shapiro OH. Low-Resolution Raman Spectroscopy for the detection of contaminant species in algal bioreactors. THE SCIENCE OF THE TOTAL ENVIRONMENT 2022; 809:151138. [PMID: 34695468 DOI: 10.1016/j.scitotenv.2021.151138] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Received: 07/28/2021] [Revised: 10/17/2021] [Accepted: 10/17/2021] [Indexed: 06/13/2023]
Abstract
Fouling of aquatic systems by harmful microalgal and cyanobacterial species is an environmental and public health concern. Microalgal bioreactors are engineered ecosystems for the cultivation of algal biomass to meet the increasing demand for alternative protein sources and algae-derived products. Such bioreactors are often open or semi-open ponds or raceways that are prone to contamination by contaminant photosynthetic microorganisms, including harmful cyanobacterial species (HCBs). HCBs affect the quality of products through the accumulation of off-flavours, reducing their acceptance by consumers, and through the production of several different toxins collectively known as cyanotoxins. The density of cultured species within the bioreactor environment creates difficulty in detecting low concentrations of contaminant cells, and there is currently no technology enabling rapid monitoring of contaminations. The present study demonstrates the potential of Low-Resolution Raman Spectroscopy (LRRS) as a tool for rapid detection of low concentrations of HCBs within dense populations of the spirulina (Arthrospira platensis) cultures. An LRRS system adapted for the direct measurement of raw biomass samples was used to assemble a database of Raman spectral signatures, from eight algal and cyanobacterial strains. This dataset was used to develop both quantitative and discriminative chemometric models. The results obtained from the chemometric analyses demonstrate the ability of the LRRS to detect and quantify algal and cyanobacterial species at concentrations as low as 103 cells/mL and to robustly discriminate between species at concentrations of 104 cells/mL. The LRRS and chemometric analyses were further able to detect the presence of low concentrations (103cells/mL) of contaminating species, including the toxic cyanobacterium Microcystis aeruginosa, within dense (>107 cells/mL) spirulina cultures. The results presented provide a first demonstration of the potential of LRRS technology for real-time detection of contaminant species within microalgal bioreactors, and possibly for early detection of developing harmful algal blooms in other aquatic ecosystems.
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Affiliation(s)
- Olubunmi E Adejimi
- Department of Food Sciences, Agricultural Research Organization (The Volcani Center), P.O.Box 6, 5025001 Rishon LeZion, Israel; Institute of Plant Science and Genetics in Agriculture, The Hebrew University of Jerusalem, P.O.Box 12, Rehovot 7610001, Israel
| | - Timea Ignat
- Institute of Agricultural Engineering (IAE), Agricultural Research Organization (The Volcani Center), P.O.Box 6, 5025001 Rishon LeZion, Israel
| | - Giji Sadhasivam
- Department of Food Sciences, Agricultural Research Organization (The Volcani Center), P.O.Box 6, 5025001 Rishon LeZion, Israel
| | - Varda Zakin
- Department of Food Sciences, Agricultural Research Organization (The Volcani Center), P.O.Box 6, 5025001 Rishon LeZion, Israel
| | - Ze'ev Schmilovitch
- Institute of Agricultural Engineering (IAE), Agricultural Research Organization (The Volcani Center), P.O.Box 6, 5025001 Rishon LeZion, Israel
| | - Orr H Shapiro
- Department of Food Sciences, Agricultural Research Organization (The Volcani Center), P.O.Box 6, 5025001 Rishon LeZion, Israel.
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Zalai D, Kopp J, Kozma B, Küchler M, Herwig C, Kager J. Microbial technologies for biotherapeutics production: Key tools for advanced biopharmaceutical process development and control. DRUG DISCOVERY TODAY. TECHNOLOGIES 2021; 38:9-24. [PMID: 34895644 DOI: 10.1016/j.ddtec.2021.04.001] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 07/01/2020] [Revised: 03/14/2021] [Accepted: 04/06/2021] [Indexed: 12/26/2022]
Abstract
Current trends in the biopharmaceutical market such as the diversification of therapies as well as the increasing time-to-market pressure will trigger the rethinking of bioprocess development and production approaches. Thereby, the importance of development time and manufacturing costs will increase, especially for microbial production. In the present review, we investigate three technological approaches which, to our opinion, will play a key role in the future of biopharmaceutical production. The first cornerstone of process development is the generation and effective utilization of platform knowledge. Building processes on well understood microbial and technological platforms allows to accelerate early-stage bioprocess development and to better condense this knowledge into multi-purpose technologies and applicable mathematical models. Second, the application of verified scale down systems and in silico models for process design and characterization will reduce the required number of large scale batches before dossier submission. Third, the broader availability of mathematical process models and the improvement of process analytical technologies will increase the applicability and acceptance of advanced control and process automation in the manufacturing scale. This will reduce process failure rates and subsequently cost of goods. Along these three aspects we give an overview of recently developed key tools and their potential integration into bioprocess development strategies.
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Affiliation(s)
- Denes Zalai
- Richter-Helm BioLogics GmbH & Co. KG, Suhrenkamp 59, 22335 Hamburg, Germany.
| | - Julian Kopp
- Research Division Biochemical Engineering, Institute of Chemical Environmental and Bioscience Engineering, Vienna University of Technology, Vienna, Austria
| | - Bence Kozma
- Research Division Biochemical Engineering, Institute of Chemical Environmental and Bioscience Engineering, Vienna University of Technology, Vienna, Austria
| | - Michael Küchler
- Richter-Helm BioLogics GmbH & Co. KG, Suhrenkamp 59, 22335 Hamburg, Germany
| | - Christoph Herwig
- Research Division Biochemical Engineering, Institute of Chemical Environmental and Bioscience Engineering, Vienna University of Technology, Vienna, Austria; Competence Center CHASE GmbH, Altenbergerstraße 69, 4040 Linz, Austria
| | - Julian Kager
- Research Division Biochemical Engineering, Institute of Chemical Environmental and Bioscience Engineering, Vienna University of Technology, Vienna, Austria
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Efromson JP, Li S, Lynch MD. BioSamplr: An open source, low cost automated sampling system for bioreactors. HARDWAREX 2021; 9:e00177. [PMID: 35492036 PMCID: PMC9041172 DOI: 10.1016/j.ohx.2021.e00177] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 10/25/2020] [Revised: 01/31/2021] [Accepted: 01/31/2021] [Indexed: 05/30/2023]
Abstract
Autosampling from bioreactors reduces error, increases reproducibility and offers improved aseptic handling when compared to manual sampling. Additionally, autosampling greatly decreases the hands-on time required for a bioreactor experiment and enables sampling 24 h a day. We have designed, built and tested a low cost, open source, automated bioreactor sampling system, the BioSamplr. The BioSamplr can take up to ten samples from a bioreactor at a desired sample interval and cools them to a desired temperature. The device, assembled from low cost and 3D printed components, is controlled wirelessly by a Raspberry Pi, and records all sampling data to a log file. The cost and accessibility of the BioSamplr make it useful for laboratories without access to more expensive and complex autosampling systems.
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Affiliation(s)
- John P. Efromson
- Department of Biomedical Engineering, Duke University, United States
| | - Shuai Li
- Department of Chemistry, Duke University, United States
| | - Michael D. Lynch
- Department of Biomedical Engineering, Duke University, United States
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Alimagham F, Winterburn J, Dolman B, Domingues PM, Everest F, Platkov M, Basov S, Izakson G, Katzir A, Elliott SR, Hutter T. Real-time bioprocess monitoring using a mid-infrared fibre-optic sensor. Biochem Eng J 2021. [DOI: 10.1016/j.bej.2020.107889] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/25/2022]
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12
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A Nuclear Magnetic Resonance (NMR) Platform for Real-Time Metabolic Monitoring of Bioprocesses. Molecules 2020; 25:molecules25204675. [PMID: 33066296 PMCID: PMC7587382 DOI: 10.3390/molecules25204675] [Citation(s) in RCA: 8] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/31/2020] [Revised: 09/28/2020] [Accepted: 10/03/2020] [Indexed: 01/05/2023] Open
Abstract
We present a Nuclear Magnetic Resonance (NMR) compatible platform for the automated real-time monitoring of biochemical reactions using a flow shuttling configuration. This platform requires a working sample volume of ∼11 mL and it can circulate samples with a flow rate of 28 mL/min, which makes it suitable to be used for real-time monitoring of biochemical reactions. Another advantage of the proposed low-cost platform is the high spectral resolution. As a proof of concept, we acquire 1H NMR spectra of waste orange peel, bioprocessed using Trichoderma reesei fungus, and demonstrate the real-time measurement capability of the platform. The measurement is performed over more than 60 h, with a spectrum acquired every 7 min, such that over 510 data points are collected without user intervention. The designed system offers high resolution, automation, low user intervention, and, therefore, time-efficient measurement per sample.
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Miclotte G, Martens K, Fostier J. Computational assessment of the feasibility of protonation-based protein sequencing. PLoS One 2020; 15:e0238625. [PMID: 32915813 PMCID: PMC7485799 DOI: 10.1371/journal.pone.0238625] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [MESH Headings] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/22/2019] [Accepted: 08/20/2020] [Indexed: 02/05/2023] Open
Abstract
Recent advances in DNA sequencing methods revolutionized biology by providing highly accurate reads, with high throughput or high read length. These read data are being used in many biological and medical applications. Modern DNA sequencing methods have no equivalent in protein sequencing, severely limiting the widespread application of protein data. Recently, several optical protein sequencing methods have been proposed that rely on the fluorescent labeling of amino acids. Here, we introduce the reprotonation-deprotonation protein sequencing method. Unlike other methods, this proposed technique relies on the measurement of an electrical signal and requires no fluorescent labeling. In reprotonation-deprotonation protein sequencing, the terminal amino acid is identified through its unique protonation signal, and by repeatedly cleaving the terminal amino acids one-by-one, each amino acid in the peptide is measured. By means of simulations, we show that, given a reference database of known proteins, reprotonation-deprotonation sequencing has the potential to correctly identify proteins in a sample. Our simulations provide target values for the signal-to-noise ratios that sensor devices need to attain in order to detect reprotonation-deprotonation events, as well as suitable pH values and required measurement times per amino acid. For instance, an SNR of 10 is required for a 61.71% proteome recovery rate with 100 ms measurement time per amino acid.
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Affiliation(s)
| | | | - Jan Fostier
- IDLab, Ghent University-Imec, Ghent, Belgium
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Towards smart biomanufacturing: a perspective on recent developments in industrial measurement and monitoring technologies for bio-based production processes. J Ind Microbiol Biotechnol 2020; 47:947-964. [PMID: 32895764 PMCID: PMC7695667 DOI: 10.1007/s10295-020-02308-1] [Citation(s) in RCA: 35] [Impact Index Per Article: 8.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/22/2020] [Accepted: 08/31/2020] [Indexed: 12/22/2022]
Abstract
The biomanufacturing industry has now the opportunity to upgrade its production processes to be in harmony with the latest industrial revolution. Technology creates capabilities that enable smart manufacturing while still complying with unfolding regulations. However, many biomanufacturing companies, especially in the biopharma sector, still have a long way to go to fully benefit from smart manufacturing as they first need to transition their current operations to an information-driven future. One of the most significant obstacles towards the implementation of smart biomanufacturing is the collection of large sets of relevant data. Therefore, in this work, we both summarize the advances that have been made to date with regards to the monitoring and control of bioprocesses, and highlight some of the key technologies that have the potential to contribute to gathering big data. Empowering the current biomanufacturing industry to transition to Industry 4.0 operations allows for improved productivity through information-driven automation, not only by developing infrastructure, but also by introducing more advanced monitoring and control strategies.
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15
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Digital Twins in Pharmaceutical and Biopharmaceutical Manufacturing: A Literature Review. Processes (Basel) 2020. [DOI: 10.3390/pr8091088] [Citation(s) in RCA: 60] [Impact Index Per Article: 15.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/17/2022] Open
Abstract
The development and application of emerging technologies of Industry 4.0 enable the realization of digital twins (DT), which facilitates the transformation of the manufacturing sector to a more agile and intelligent one. DTs are virtual constructs of physical systems that mirror the behavior and dynamics of such physical systems. A fully developed DT consists of physical components, virtual components, and information communications between the two. Integrated DTs are being applied in various processes and product industries. Although the pharmaceutical industry has evolved recently to adopt Quality-by-Design (QbD) initiatives and is undergoing a paradigm shift of digitalization to embrace Industry 4.0, there has not been a full DT application in pharmaceutical manufacturing. Therefore, there is a critical need to examine the progress of the pharmaceutical industry towards implementing DT solutions. The aim of this narrative literature review is to give an overview of the current status of DT development and its application in pharmaceutical and biopharmaceutical manufacturing. State-of-the-art Process Analytical Technology (PAT) developments, process modeling approaches, and data integration studies are reviewed. Challenges and opportunities for future research in this field are also discussed.
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16
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Domján J, Fricska A, Madarász L, Gyürkés M, Köte Á, Farkas A, Vass P, Fehér C, Horváth B, Könczöl K, Pataki H, Nagy ZK, Marosi GJ, Hirsch E. Raman-based dynamic feeding strategies using real-time glucose concentration monitoring system during adalimumab producing CHO cell cultivation. Biotechnol Prog 2020; 36:e3052. [PMID: 32692473 DOI: 10.1002/btpr.3052] [Citation(s) in RCA: 10] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/09/2020] [Revised: 07/06/2020] [Accepted: 07/17/2020] [Indexed: 02/05/2023]
Abstract
The use of Process Analytical Technology tools coupled with chemometrics has been shown great potential for better understanding and control of mammalian cell cultivations through real-time process monitoring. In-line Raman spectroscopy was utilized to determine the glucose concentration of the complex bioreactor culture medium ensuring real-time information for our process control system. This work demonstrates a simple and fast method to achieve a robust partial least squares calibration model under laboratory conditions in an early phase of the development utilizing shake flask and bioreactor cultures. Two types of dynamic feeding strategies were accomplished where the multi-component feed medium additions were controlled manually and automatically based on the Raman monitored glucose concentration. The impact of these dynamic feedings was also investigated and compared to the traditional bolus feeding strategy on cellular metabolism, cell growth, productivity, and binding activity of the antibody product. Both manual and automated dynamic feeding strategies were successfully applied to maintain the glucose concentration within a narrower and lower concentration range. Thus, besides glucose, the glutamate was also limited at low level leading to reduced production of inhibitory metabolites, such as lactate and ammonia. Consequently, these feeding control strategies enabled to provide beneficial cultivation environment for the cells. In both experiments, higher cell growth and prolonged viable cell cultivation were achieved which in turn led to increased antibody product concentration compared to the reference bolus feeding cultivation.
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Affiliation(s)
- Júlia Domján
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Budapest, Hungary
| | - Annamária Fricska
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Budapest, Hungary
| | - Lajos Madarász
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Budapest, Hungary
| | - Martin Gyürkés
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Budapest, Hungary
| | - Ákos Köte
- Department of Automation and Applied Informatics, Budapest University of Technology and Economics, Budapest, Hungary
| | - Attila Farkas
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Budapest, Hungary
| | - Panna Vass
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Budapest, Hungary
| | - Csaba Fehér
- Department of Applied Biotechnology and Food Science, Budapest University of Technology and Economics, Budapest, Hungary
| | - Balázs Horváth
- Department of Biotechnology, Gedeon Richter Plc, Budapest, Hungary
| | - Kálmán Könczöl
- Department of Biotechnology, Gedeon Richter Plc, Budapest, Hungary
| | - Hajnalka Pataki
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Budapest, Hungary
| | - Zsombor Kristóf Nagy
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Budapest, Hungary
| | - György János Marosi
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Budapest, Hungary
| | - Edit Hirsch
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Budapest, Hungary
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17
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Rafferty C, Johnson K, O'Mahony J, Burgoyne B, Rea R, Balss KM. Analysis of chemometric models applied to Raman spectroscopy for monitoring key metabolites of cell culture. Biotechnol Prog 2020; 36:e2977. [DOI: 10.1002/btpr.2977] [Citation(s) in RCA: 11] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/27/2018] [Revised: 03/02/2019] [Accepted: 01/22/2020] [Indexed: 01/23/2023]
Affiliation(s)
- Carl Rafferty
- BioTherapeutic DevelopmentJanssen Sciences Ireland UC Cork Ireland
- Biological SciencesCork Institute of Technology Cork Ireland
| | | | - Jim O'Mahony
- Biological SciencesCork Institute of Technology Cork Ireland
| | - Barbara Burgoyne
- Product Quality ManagementJanssen Sciences Ireland UC Cork Ireland
| | - Rosemary Rea
- Biological SciencesCork Institute of Technology Cork Ireland
| | - Karin M. Balss
- Advanced Technology Center of ExcellenceJanssen Supply Group New Jersey
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18
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Culture medium density as a simple monitoring tool for cell integrity of Escherichia coli. J Biotechnol 2020; 324S:100017. [PMID: 34154736 DOI: 10.1016/j.btecx.2020.100017] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/20/2020] [Revised: 04/29/2020] [Accepted: 04/30/2020] [Indexed: 11/20/2022]
Abstract
During the expression of recombinant proteins in the periplasm of Escherichia coli, the integrity of the outer membrane can change, so that product leaks to the medium. Additional stress can induce lysis, the complete disintegration of both inner and outer membrane, leading to release of both product and host cell proteins. Whether leakiness is unwanted or intentional, appropriate monitoring of leakiness and its distinction from lysis is necessary to ensure product quality and process performance. Here, we investigated a novel monitoring tool for leakiness and lysis based on the measurement of the culture supernatant density. The method benefits from short analysis time and low analytical error, simple result output, relatively low cost, low risk of operator errors and the option of easy on-line implementation. Although limitations exist regarding selectivity, we could show that the method is capable of detecting changes in cell integrity. This tool is therefore an interesting addition to the monitoring toolbox for industrial E. coli bioprocesses.
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19
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Pais DAM, Portela RMC, Carrondo MJT, Isidro IA, Alves PM. Enabling PAT in insect cell bioprocesses:
In situ
monitoring of recombinant adeno‐associated virus production by fluorescence spectroscopy. Biotechnol Bioeng 2019; 116:2803-2814. [DOI: 10.1002/bit.27117] [Citation(s) in RCA: 11] [Impact Index Per Article: 2.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/20/2018] [Revised: 04/22/2019] [Accepted: 07/09/2019] [Indexed: 12/25/2022]
Affiliation(s)
- Daniel A. M. Pais
- iBET, Instituto de Biologia Experimental e Tecnológica Oeiras Portugal
- Instituto de Tecnologia Química e Biológica António XavierUniversidade Nova de Lisboa Oeiras Portugal
| | - Rui M. C. Portela
- iBET, Instituto de Biologia Experimental e Tecnológica Oeiras Portugal
| | | | - Inês A. Isidro
- iBET, Instituto de Biologia Experimental e Tecnológica Oeiras Portugal
- Instituto de Tecnologia Química e Biológica António XavierUniversidade Nova de Lisboa Oeiras Portugal
| | - Paula M. Alves
- iBET, Instituto de Biologia Experimental e Tecnológica Oeiras Portugal
- Instituto de Tecnologia Química e Biológica António XavierUniversidade Nova de Lisboa Oeiras Portugal
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20
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Santos RM, Kaiser P, Menezes JC, Peinado A. Improving reliability of Raman spectroscopy for mAb production by upstream processes during bioprocess development stages. Talanta 2019; 199:396-406. [DOI: 10.1016/j.talanta.2019.02.088] [Citation(s) in RCA: 13] [Impact Index Per Article: 2.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/13/2018] [Revised: 02/22/2019] [Accepted: 02/26/2019] [Indexed: 10/27/2022]
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21
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On-line glucose monitoring by near infrared spectroscopy during the scale up steps of mammalian cell cultivation process development. Bioprocess Biosyst Eng 2019; 42:921-932. [PMID: 30806782 PMCID: PMC6527534 DOI: 10.1007/s00449-019-02091-z] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.2] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/15/2018] [Accepted: 02/15/2019] [Indexed: 12/30/2022]
Abstract
NIR spectroscopy is a non-destructive tool for in-situ, on-line bioprocess monitoring. One of its most frequent applications is the determination of metabolites during cultivation, especially glucose. Previous studies have usually investigated the applicability of Near Infrared (NIR) spectroscopy at one bioreactor scale but the effect of scale up was not explored. In this study, the complete scale up from shake flask (1 L) through 20 L, 100 L and 1000 L up to 5000 L bioreactor volume level was monitored with on-line NIR spectroscopy. The differences between runs and scales were examined using principal component analysis. The bioreactor runs were relatively similar regardless of scales but the shake flasks differed strongly from bioreactor runs. The glucose concentration throughout five 5000 L scale bioreactor runs were predicted by partial least squares regression models that were based on pre-processed spectra of bioreactor runs and combinations of them. The model that produced the lowest error of prediction (4.18 mM on a 29 mM concentration range) for all five runs in the prediction set was based on the combination of 20 L and 100 L data. This result demonstrated the capabilities and the limitations of an NIR system for glucose monitoring in mammalian cell cultivations.
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22
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Guerra A, von Stosch M, Glassey J. Toward biotherapeutic product real-time quality monitoring. Crit Rev Biotechnol 2019; 39:289-305. [DOI: 10.1080/07388551.2018.1524362] [Citation(s) in RCA: 26] [Impact Index Per Article: 5.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/15/2022]
Affiliation(s)
- André Guerra
- School of Chemical Engineering and Advanced Materials, Newcastle University, Newcastle upon Tyne, United Kingdom
| | - Moritz von Stosch
- School of Chemical Engineering and Advanced Materials, Newcastle University, Newcastle upon Tyne, United Kingdom
| | - Jarka Glassey
- School of Chemical Engineering and Advanced Materials, Newcastle University, Newcastle upon Tyne, United Kingdom
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23
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Matthews TE, Smelko JP, Berry B, Romero-Torres S, Hill D, Kshirsagar R, Wiltberger K. Glucose monitoring and adaptive feeding of mammalian cell culture in the presence of strong autofluorescence by near infrared Raman spectroscopy. Biotechnol Prog 2018; 34:1574-1580. [PMID: 30281947 DOI: 10.1002/btpr.2711] [Citation(s) in RCA: 21] [Impact Index Per Article: 3.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/21/2018] [Revised: 06/13/2018] [Accepted: 08/16/2018] [Indexed: 01/19/2023]
Abstract
Raman spectroscopy offers an attractive platform for real-time monitoring and control of metabolites and feeds in cell culture processes, including mammalian cell culture for biopharmaceutical production. However, specific cell culture processes may generate substantial concentrations of chemical species and byproducts with high levels of autofluorescence when excited with the standard 785 nm wavelength. Shifting excitation further toward the near-infrared allows reduction or elimination of process autofluorescence. We demonstrate such a reduction in a highly autofluorescent mammalian cell culture process. Using the Kaiser RXN2-1000 platform, which utilizes excitation at 993 nm, we developed multivariate glucose models in a cell culture process which was previously impossible using 785 nm excitation. Additionally, the glucose level in the production bioreactor was controlled entirely by Raman adaptive feeding, allowing for maintenance of glucose levels at an arbitrary set point for the duration of the culture. © 2018 American Institute of Chemical Engineers Biotechnol. Prog., 34:1574-1580, 2018.
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Affiliation(s)
- Thomas E Matthews
- Biogen, Inc., Engineering and Technology, 5000 Davis Dr, Durham, NC, 27709
| | - John P Smelko
- Biogen, Inc., Engineering and Technology, 5000 Davis Dr, Durham, NC, 27709
| | - Brandon Berry
- Biogen, Inc., Engineering and Technology, 5000 Davis Dr, Durham, NC, 27709
| | - Saly Romero-Torres
- Biogen, Inc., Engineering and Technology, 5000 Davis Dr, Durham, NC, 27709
| | - Dan Hill
- Biogen, Inc., Engineering and Technology, 5000 Davis Dr, Durham, NC, 27709
| | - Rashmi Kshirsagar
- Biogen, Inc., Engineering and Technology, 5000 Davis Dr, Durham, NC, 27709
| | - Kelly Wiltberger
- Biogen, Inc., Engineering and Technology, 5000 Davis Dr, Durham, NC, 27709
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24
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Baradez MO, Biziato D, Hassan E, Marshall D. Application of Raman Spectroscopy and Univariate Modelling As a Process Analytical Technology for Cell Therapy Bioprocessing. Front Med (Lausanne) 2018; 5:47. [PMID: 29556497 PMCID: PMC5844923 DOI: 10.3389/fmed.2018.00047] [Citation(s) in RCA: 24] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/01/2017] [Accepted: 02/08/2018] [Indexed: 11/13/2022] Open
Abstract
Cell therapies offer unquestionable promises for the treatment, and in some cases even the cure, of complex diseases. As we start to see more of these therapies gaining market authorization, attention is turning to the bioprocesses used for their manufacture, in particular the challenge of gaining higher levels of process control to help regulate cell behavior, manage process variability, and deliver product of a consistent quality. Many processes already incorporate the measurement of key markers such as nutrient consumption, metabolite production, and cell concentration, but these are often performed off-line and only at set time points in the process. Having the ability to monitor these markers in real-time using in-line sensors would offer significant advantages, allowing faster decision-making and a finer level of process control. In this study, we use Raman spectroscopy as an in-line optical sensor for bioprocess monitoring of an autologous T-cell immunotherapy model produced in a stirred tank bioreactor system. Using reference datasets generated on a standard bioanalyzer, we develop chemometric models from the Raman spectra for glucose, glutamine, lactate, and ammonia. These chemometric models can accurately monitor donor-specific increases in nutrient consumption and metabolite production as the primary T-cell transition from a recovery phase and begin proliferating. Using a univariate modeling approach, we then show how changes in peak intensity within the Raman spectra can be correlated with cell concentration and viability. These models, which act as surrogate markers, can be used to monitor cell behavior including cell proliferation rates, proliferative capacity, and transition of the cells to a quiescent phenotype. Finally, using the univariate models, we also demonstrate how Raman spectroscopy can be applied for real-time monitoring. The ability to measure these key parameters using an in-line Raman optical sensor makes it possible to have immediate feedback on process performance. This could help significantly improve cell therapy bioprocessing by allowing proactive decision-making based on real-time process data. Going forward, these types of in-line sensors also open up opportunities to improve bioprocesses further through concepts such as adaptive manufacturing.
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Affiliation(s)
| | | | - Enas Hassan
- Cell and Gene Therapy Catapult, London, United Kingdom
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25
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Kozma B, Hirsch E, Gergely S, Párta L, Pataki H, Salgó A. On-line prediction of the glucose concentration of CHO cell cultivations by NIR and Raman spectroscopy: Comparative scalability test with a shake flask model system. J Pharm Biomed Anal 2017; 145:346-355. [DOI: 10.1016/j.jpba.2017.06.070] [Citation(s) in RCA: 16] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/08/2017] [Revised: 06/30/2017] [Accepted: 06/30/2017] [Indexed: 10/19/2022]
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26
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Chopda VR, Pathak M, Batra J, Gomes J, Rathore AS. Enabler for process analytical technology implementation in Pichia pastoris fermentation: Fluorescence-based soft sensors for rapid quantitation of product titer. Eng Life Sci 2016; 17:448-457. [PMID: 32624790 DOI: 10.1002/elsc.201600155] [Citation(s) in RCA: 5] [Impact Index Per Article: 0.6] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/15/2016] [Revised: 08/11/2016] [Accepted: 10/13/2016] [Indexed: 11/07/2022] Open
Abstract
Rapid quantitation of product titer is a critical input for control of any bioprocess. This measurement, however, is marred by the myriad components that are present in the fermentation broth, often requiring extensive sample pretreatment before analysis. Spectroscopy techniques such as fluorescence spectroscopy are widely recognized as potential monitoring tools. Here, we investigate the possibility of using fluorescence of the culture supernatant as a potential at-line monitoring tool to measure the concentration of a recombinant therapeutic protein expressed in a Pichia pastoris fed-batch fermentation. We propose an integrated method wherein both the target protein and total protein concentrations are predicted using intrinsic riboflavin fluorescence and extrinsic fluorescence, respectively. The root mean square error for estimating the concentrations of the target protein (using riboflavin fluorescence) and total protein (using extrinsic fluorescence) have been estimated to be <0.1 and <0.2, respectively. The proposed approach has been validated for two different biotherapeutic products, human serum albumin and granulocyte colony stimulating factor, that were expressed using Mut+ and Muts strains of P. pastoris, respectively. The proposed approach is rapid (1 min analysis time, 10 min total with at line sampling) and thus could be a significant enabler for process analytical technology implementation in Pichia fermentation.
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Affiliation(s)
- Viki R Chopda
- Department of Chemical Engineering IIT Delhi New Delhi India
| | - Mili Pathak
- Department of Chemical Engineering IIT Delhi New Delhi India
| | - Jyoti Batra
- Department of Chemical Engineering IIT Delhi New Delhi India
| | - James Gomes
- Kusuma School of Biological Sciences IIT Delhi New Delhi India
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27
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Hirsch E, Pataki H, Farkas A, Bata H, Vass P, Fehér C, Barta Z, Párta L, Csontos I, Ballagi A, Nagy ZK, Marosi GJ. Raman-Based Feedback Control of the Enzymatic Hydrolysis of Lactose. Org Process Res Dev 2016. [DOI: 10.1021/acs.oprd.6b00212] [Citation(s) in RCA: 10] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Edit Hirsch
- Department
of Organic Chemistry and Technology, Budapest University of Technology and Economics, Müegyetem rkp. 3, H-1111 Budapest, Hungary
| | - Hajnalka Pataki
- Department
of Organic Chemistry and Technology, Budapest University of Technology and Economics, Müegyetem rkp. 3, H-1111 Budapest, Hungary
| | - Attila Farkas
- Department
of Organic Chemistry and Technology, Budapest University of Technology and Economics, Müegyetem rkp. 3, H-1111 Budapest, Hungary
| | - Henrik Bata
- Department
of Organic Chemistry and Technology, Budapest University of Technology and Economics, Müegyetem rkp. 3, H-1111 Budapest, Hungary
| | - Panna Vass
- Department
of Organic Chemistry and Technology, Budapest University of Technology and Economics, Müegyetem rkp. 3, H-1111 Budapest, Hungary
| | - Csaba Fehér
- Department
of Applied Biotechnology and Food Science, Budapest University of Technology and Economics, Müegyetem rkp. 3, H-1111 Budapest, Hungary
| | - Zsolt Barta
- Department
of Applied Biotechnology and Food Science, Budapest University of Technology and Economics, Müegyetem rkp. 3, H-1111 Budapest, Hungary
| | - László Párta
- Gedeon Richter Plc., Gyömröi
út 19-21, H-1103 Budapest, Hungary
| | - István Csontos
- Department
of Organic Chemistry and Technology, Budapest University of Technology and Economics, Müegyetem rkp. 3, H-1111 Budapest, Hungary
| | - András Ballagi
- Department
of Applied Biotechnology and Food Science, Budapest University of Technology and Economics, Müegyetem rkp. 3, H-1111 Budapest, Hungary
- Gedeon Richter Plc., Gyömröi
út 19-21, H-1103 Budapest, Hungary
| | - Zsombor K. Nagy
- Department
of Organic Chemistry and Technology, Budapest University of Technology and Economics, Müegyetem rkp. 3, H-1111 Budapest, Hungary
| | - György J. Marosi
- Department
of Organic Chemistry and Technology, Budapest University of Technology and Economics, Müegyetem rkp. 3, H-1111 Budapest, Hungary
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28
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Workflow for multi-analyte bioprocess monitoring demonstrated on inline NIR spectroscopy of P. chrysogenum fermentation. Anal Bioanal Chem 2016; 409:797-805. [PMID: 27640207 DOI: 10.1007/s00216-016-9918-9] [Citation(s) in RCA: 6] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/25/2016] [Revised: 08/22/2016] [Accepted: 08/30/2016] [Indexed: 10/21/2022]
Abstract
Fourier transform near-infrared (FT-NIR) spectroscopy combined with multivariate analysis has been applied in bioprocesses for a couple of decades. Nevertheless the papers published in this field are case-specific and do not focus on providing the community generic workflows to conduct experiments, especially as a standard Design of Experiment (DoE) for a multi-analyte process might require overwhelming amount of measurements. In this paper, a workflow for feasibility studies and inline implementation of FT-NIR spectrometer in multi-analyte fermentation processes is presented. The workflow is applied to Penicillium crysogenum fermentation, where the similarities in chemical structures and growth trends between the key analytes together with the aeration and growing fungi make the task challenging: first, the pure analytes are measured off-line with FT-NIR and clustered using principal component analysis. To study the separability of the gained clusters, a DoE approach by spiking is applied. The multivariate modelling of the separable analytes is conducted using the off-line and inline data followed by a comparison of the properties of the different models. Finally, the model output constraints are set by means of outlier diagnostics. As a result, biomass, penicillin (PEN), phenoxyacetic acid (POX), ammonia and biomass were shown to be separable with root mean square error of predictions of 2.62 g/l, 0.34 g/l, 0.51 g/l and 18.3 mM, respectively. Graphical abstract Flowchart illustrating the workflow for feasibility studies and implementation of models for inline monitoring of Ammonia, Biomass, Phenoxyacetic acid and Penicillin.
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29
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Esmonde-White KA, Cuellar M, Uerpmann C, Lenain B, Lewis IR. Raman spectroscopy as a process analytical technology for pharmaceutical manufacturing and bioprocessing. Anal Bioanal Chem 2016; 409:637-649. [PMID: 27491299 PMCID: PMC5233728 DOI: 10.1007/s00216-016-9824-1] [Citation(s) in RCA: 150] [Impact Index Per Article: 18.8] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/23/2016] [Revised: 07/13/2016] [Accepted: 07/21/2016] [Indexed: 11/30/2022]
Abstract
Adoption of Quality by Design (QbD) principles, regulatory support of QbD, process analytical technology (PAT), and continuous manufacturing are major factors effecting new approaches to pharmaceutical manufacturing and bioprocessing. In this review, we highlight new technology developments, data analysis models, and applications of Raman spectroscopy, which have expanded the scope of Raman spectroscopy as a process analytical technology. Emerging technologies such as transmission and enhanced reflection Raman, and new approaches to using available technologies, expand the scope of Raman spectroscopy in pharmaceutical manufacturing, and now Raman spectroscopy is successfully integrated into real-time release testing, continuous manufacturing, and statistical process control. Since the last major review of Raman as a pharmaceutical PAT in 2010, many new Raman applications in bioprocessing have emerged. Exciting reports of in situ Raman spectroscopy in bioprocesses complement a growing scientific field of biological and biomedical Raman spectroscopy. Raman spectroscopy has made a positive impact as a process analytical and control tool for pharmaceutical manufacturing and bioprocessing, with demonstrated scientific and financial benefits throughout a product’s lifecycle.
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Affiliation(s)
- Karen A Esmonde-White
- Kaiser Optical System, Inc, 371 Parkland Plaza, Ann Arbor, MI, 48103, USA.
- University of Michigan Medical School, Ann Arbor, MI, 48109-5624, USA.
| | - Maryann Cuellar
- Kaiser Optical System, Inc, 371 Parkland Plaza, Ann Arbor, MI, 48103, USA
| | - Carsten Uerpmann
- Kaiser Optical Systems SARL, 5 Allée Moulin Berger, 69130, Ecully, France
| | - Bruno Lenain
- Kaiser Optical Systems SARL, 5 Allée Moulin Berger, 69130, Ecully, France
| | - Ian R Lewis
- Kaiser Optical System, Inc, 371 Parkland Plaza, Ann Arbor, MI, 48103, USA
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30
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Lewis AM, Croughan WD, Aranibar N, Lee AG, Warrack B, Abu-Absi NR, Patel R, Drew B, Borys MC, Reily MD, Li ZJ. Understanding and Controlling Sialylation in a CHO Fc-Fusion Process. PLoS One 2016; 11:e0157111. [PMID: 27310468 PMCID: PMC4911072 DOI: 10.1371/journal.pone.0157111] [Citation(s) in RCA: 27] [Impact Index Per Article: 3.4] [Reference Citation Analysis] [Abstract] [MESH Headings] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/12/2016] [Accepted: 05/24/2016] [Indexed: 12/13/2022] Open
Abstract
A Chinese hamster ovary (CHO) bioprocess, where the product is a sialylated Fc-fusion protein, was operated at pilot and manufacturing scale and significant variation of sialylation level was observed. In order to more tightly control glycosylation profiles, we sought to identify the cause of variability. Untargeted metabolomics and transcriptomics methods were applied to select samples from the large scale runs. Lower sialylation was correlated with elevated mannose levels, a shift in glucose metabolism, and increased oxidative stress response. Using a 5-L scale model operated with a reduced dissolved oxygen set point, we were able to reproduce the phenotypic profiles observed at manufacturing scale including lower sialylation, higher lactate and lower ammonia levels. Targeted transcriptomics and metabolomics confirmed that reduced oxygen levels resulted in increased mannose levels, a shift towards glycolysis, and increased oxidative stress response similar to the manufacturing scale. Finally, we propose a biological mechanism linking large scale operation and sialylation variation. Oxidative stress results from gas transfer limitations at large scale and the presence of oxygen dead-zones inducing upregulation of glycolysis and mannose biosynthesis, and downregulation of hexosamine biosynthesis and acetyl-CoA formation. The lower flux through the hexosamine pathway and reduced intracellular pools of acetyl-CoA led to reduced formation of N-acetylglucosamine and N-acetylneuraminic acid, both key building blocks of N-glycan structures. This study reports for the first time a link between oxidative stress and mammalian protein sialyation. In this study, process, analytical, metabolomic, and transcriptomic data at manufacturing, pilot, and laboratory scales were taken together to develop a systems level understanding of the process and identify oxygen limitation as the root cause of glycosylation variability.
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Affiliation(s)
- Amanda M. Lewis
- Biologics Development, Global Manufacturing and Supply, Bristol-Myers Squibb Company, Devens, MA, United States of America
- * E-mail:
| | - William D. Croughan
- Biologics Development, Global Manufacturing and Supply, Bristol-Myers Squibb Company, Devens, MA, United States of America
| | - Nelly Aranibar
- Research and Development, Bristol-Myers Squibb Company, Princeton, NJ, United States of America
| | - Alison G. Lee
- Biologics Development, Global Manufacturing and Supply, Bristol-Myers Squibb Company, Devens, MA, United States of America
| | - Bethanne Warrack
- Research and Development, Bristol-Myers Squibb Company, Princeton, NJ, United States of America
| | - Nicholas R. Abu-Absi
- Biologics Development, Global Manufacturing and Supply, Bristol-Myers Squibb Company, Devens, MA, United States of America
| | - Rutva Patel
- Biologics Development, Global Manufacturing and Supply, Bristol-Myers Squibb Company, Devens, MA, United States of America
| | - Barry Drew
- Biologics Development, Global Manufacturing and Supply, Bristol-Myers Squibb Company, Devens, MA, United States of America
| | - Michael C. Borys
- Biologics Development, Global Manufacturing and Supply, Bristol-Myers Squibb Company, Devens, MA, United States of America
| | - Michael D. Reily
- Research and Development, Bristol-Myers Squibb Company, Princeton, NJ, United States of America
| | - Zheng Jian Li
- Biologics Development, Global Manufacturing and Supply, Bristol-Myers Squibb Company, Devens, MA, United States of America
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Musmann C, Joeris K, Markert S, Solle D, Scheper T. Spectroscopic methods and their applicability for high-throughput characterization of mammalian cell cultures in automated cell culture systems. Eng Life Sci 2016. [DOI: 10.1002/elsc.201500122] [Citation(s) in RCA: 11] [Impact Index Per Article: 1.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/14/2022] Open
Affiliation(s)
- Carsten Musmann
- Roche Diagnostics GmbH; Pharma Biotech Production and Development; Penzberg Germany
| | - Klaus Joeris
- Roche Diagnostics GmbH; Pharma Biotech Production and Development; Penzberg Germany
| | - Sven Markert
- Roche Diagnostics GmbH; Pharma Biotech Production and Development; Penzberg Germany
| | - Dörte Solle
- University of Hannover; Institute for Technical Chemistry; Hannover Germany
| | - Thomas Scheper
- University of Hannover; Institute for Technical Chemistry; Hannover Germany
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McElearney K, Ali A, Gilbert A, Kshirsagar R, Zang L. Tryptophan oxidation catabolite,N-formylkynurenine, in photo degraded cell culture medium results in reduced cell culture performance. Biotechnol Prog 2015; 32:74-82. [DOI: 10.1002/btpr.2198] [Citation(s) in RCA: 10] [Impact Index Per Article: 1.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/28/2015] [Revised: 10/24/2015] [Indexed: 12/14/2022]
Affiliation(s)
- Kyle McElearney
- Cell Culture Development, Biogen; 225 Binney Street Cambridge MA 02142
| | - Amr Ali
- Cell Culture Development, Biogen; 225 Binney Street Cambridge MA 02142
| | - Alan Gilbert
- Cell Culture Development, Biogen; 225 Binney Street Cambridge MA 02142
| | - Rashmi Kshirsagar
- Cell Culture Development, Biogen; 225 Binney Street Cambridge MA 02142
| | - Li Zang
- Analytical Development, Biogen; 225 Binney Street Cambridge MA 02142
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33
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The role of high-throughput mini-bioreactors in process development and process optimization for mammalian cell culture. ACTA ACUST UNITED AC 2015. [DOI: 10.4155/pbp.15.22] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/17/2022]
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34
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Biechele P, Busse C, Solle D, Scheper T, Reardon K. Sensor systems for bioprocess monitoring. Eng Life Sci 2015. [DOI: 10.1002/elsc.201500014] [Citation(s) in RCA: 120] [Impact Index Per Article: 13.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/21/2022] Open
Affiliation(s)
- Philipp Biechele
- Institute of Technical Chemistry; Leibniz University; Hannover Germany
| | - Christoph Busse
- Institute of Technical Chemistry; Leibniz University; Hannover Germany
| | - Dörte Solle
- Institute of Technical Chemistry; Leibniz University; Hannover Germany
| | - Thomas Scheper
- Institute of Technical Chemistry; Leibniz University; Hannover Germany
| | - Kenneth Reardon
- Department of Chemical and Biological Engineering; Colorado State University; Fort Collins CO USA
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