Closed, one-stop intelligent and accurate particle characterization based on micro-Raman spectroscopy and digital microfluidics

Monoclonal antibodies are prone to form protein particles through aggregation, fragmentation, and oxidation under varying stress conditions during the manufacturing, shipping, and storage of parenteral drug products. According to pharmacopeia requirements, sub-visible particle levels need to be controlled throughout the shelf life of the product. Therefore, in addition to determining particle counts, it is crucial to accurately characterize particles in drug product to understand the stress condition of exposure and to implement appropriate mitigation actions for a specific formulation. In this study, we developed a new method for intelligent characterization of protein particles using micro-Raman spectroscopy on a digital microfluidic chip (DMF). Several microliters of protein particle solutions induced by stress degradation were loaded onto a DMF chip to generate multiple droplets for Raman spectroscopy testing. By training multiple machine learning classification models on the obtained Raman spectra of protein particles, eight types of protein particles were successfully characterized and predicted with high classification accuracy (93%-100%). The advantages of the novel particle characterization method proposed in this study include a closed system to prevent particle contamination, one-stop testing of morphological and chemical structure information, low sample volume consumption, reusable particle droplets, and simplified data analysis with high classification accuracy. It provides great potential to determine the probable root cause of the particle source or stress conditions by a single testing, so that an accurate particle control strategy can be developed and ultimately extend the product shelf-life.

Physiochemical characteristics, morphology, and lubricating properties of size-specific whey protein particles by acid or ion aggregation

To investigate the influence of particle characteristics on their lubricating capacity, microparticles of controlled size (~300, ~700, and ~1900 nm) were prepared from whey proteins using two different approaches: reducing the pH and increasing the calcium ion concentration. The physiochemical, morphological, and tribological properties of the two types of particles were determined. Both treatments pronouncedly decreased the absolute value of zeta-potential and surface hydrophobicity of whey proteins, with calcium ions showing a more severe effect on zeta-potential. The viscosity of the particle suspensions increased with particle size, and ion-induced samples showed higher viscosity than acid-induced ones. Morphology investigation revealed that particle aggregation and irregularity increased with particle size increase. Distinct lubricating behaviors were observed for the two particle types within different size ranges. Viscosity played a more important role in lubrication when the particle size was small, while particle characteristics became more dominant for large particles.

Effect of the Tubing Material Used in Peristaltic Pumping in Tangential Flow Filtration Processes of Biopharmaceutics on Particle Formation and Flux

Tangential flow filtration (TFF) is a central step in manufacturing of biopharmaceutics. Membrane clogging leads to decreased permeate flux, longer process time and potentially complete failure of the process. The effect of peristaltic pumping with tubings made of three different materials on protein particle formation during TFF was monitored via micro flow imaging, turbidity and photo documentation. At low protein concentrations, pumping with a membrane pump resulted in a stable flux with low protein particle concentration. Using a peristaltic pump led to markedly higher protein particle formation dependent on tubing type. With increasing protein particle formation propensity of the tubing, the permeate flux rate became lower and the process took longer. The protein particles formed in the pump were captured in the cassette and accumulated on the membrane leading to blocking. Using tubing with a hydrophilic copolymer modification counteracted membrane clogging and flux decrease by reducing protein particle formation. In ultrafiltration mode the permeate flux decrease was governed by the viscosity increase rather than by the protein aggregation; but using modified tubing is still beneficial due to a lower particle burden of the product. In summary, using tubing material for peristaltic pumping in TFF processes which leads a less protein particle formation, especially tubing material with hydrophilic modification, is highly beneficial for membrane flux and particle burden of the product.

Reaching the breaking point: Effect of tubing characteristics on protein particle formation during peristaltic pumping

Peristaltic pumping has been identified as a cause for protein particle formation during manufacturing of biopharmaceuticals. To give advice on tubing selection, we evaluated the physicochemical parameters and the propensity for tubing and protein particle formation using a monoclonal antibody (mAb) for five different tubings. After pumping, particle levels originating from tubing and protein differed substantially between the tubing types. An overall low shedding of tubing particles by wear was linked to low surface roughness and high abrasion resistance. The formation of mAb particles upon pumping was dependent on the tubing hardness and surface chemistry. Defined stretching of tubing filled with mAb solution revealed that aggregation increased with higher strain beyond the breaking point of the protein film adsorbed to the tubing wall. This is in line with the decrease in protein particle concentration with increasing tubing hardness. Furthermore, material composition influenced particle formation propensity. Faster adsorption to materials with higher hydrophobicity is suspected to lead to a higher protein film renewal rate resulting in higher protein particle counts. Overall, silicone tubing with high hardness led to least protein particles during peristaltic pumping. Results from this study emphasize the need of proper tubing selection to minimize protein particle generation upon pumping.

A Collaborative Study on the Classification of Silicone Oil Droplets and Protein Particles Using Flow Imaging Method

In this study, we conducted a collaborative study on the classification between silicone oil droplets and protein particles detected using the flow imaging (FI) method toward proposing a standardized classifier/model. We compared four approaches, including a classification filter composed of particle characteristic parameters, principal component analysis, decision tree, and convolutional neural network in the performance of the developed classifier/model. Finally, the points to be considered were summarized for measurement using the FI method, and for establishing the classifier/model using machine learning to differentiate silicone oil droplets and protein particles.

Removal of denatured protein particles enhanced UASB treatment of oxytetracycline production wastewater

Enhanced hydrolysis, which can selectively destroy antibiotic potency, has been previously demonstrated to be an effective pretreatment technology for the biological treatment of antibiotic production wastewater. However, full-scale application of enhanced hydrolysis to the treatment of real oxytetracycline production wastewater showed that the up-flow anaerobic sludge blanket (UASB) reactors treating the pretreated wastewater could only be stable under a low organic loading rate (OLR) of 1.8 ± 0.4 g·COD/L/d. Deterioration of UASB was also confirmed in treating the same wastewater using a bench-scale reactor (R1) at an OLR of 4.4 ± 0.3 g·COD/L/d. Assuming that the particles formed due to the denaturation of soluble proteins under the hydrolysis temperature (110 °C), resulting in the significant increase of suspended solids (SS) in oxytetracycline production wastewater from less than 200 mg/L to 1200 ± 500 mg/L, were responsible for the deterioration of UASB, the pretreated wastewater was filtered using polypropylene cotton fiber and ultrafiltration membrane, and then fed into two parallel bench-scale UASB reactors (R2 and R3). Both reactors maintained a stable COD removal (53.2% ~ 61.1%) even at an OLR as high as 8.0 g·COD/L/d. When the feed of R3 was switched to unfiltered wastewater, however, deterioration of the reactor occurred again. Microscopic observation showed that the granules in R3 were fully covered by protein particles after the switch of the feed. It was possible that the tight layer of the denatured protein particles blocked the inner pores of the granules, resulting in the obstruction of substrate transfer and biogas emission, while removing the protein particles could abate such blockage problem. This study provides a scientific basis for the efficient treatment of antibiotic production wastewater.

Fatty Acids Can Induce the Formation of Proteinaceous Particles in Monoclonal Antibody Formulations

The presence of subvisible or visible particles in mAb formulations can pose significant challenges to pharmaceutical development as it can lead to reduced shelf life, batch rejection, and recalls. Among all type of particles, proteinaceous particles are the most concerning due to their potential role in immunogenicity. Nevertheless, the underlying mechanism for protein particle formation remains poorly understood. Past research highlighted the importance of interfaces and mechanical agitation in causing protein particle formation. Current research suggests that fatty acids, as impurities present in excipients or as a result of polysorbate degradation, can also induce protein assembly and promote particle formation. In this work, we assessed oleic and lauric acid for their impact on particle formation as each represents the main hydrolysis product of PS80 or PS20, respectively. It was found that co-existence of either fatty acids with 10 mg/mL mAb A can cause protein particles, with a similar morphology to those observed previously in mAb formulations. FTIR spectra showed that the particles are proteinaceous, heterogeneous in its composition, but contain corresponding fatty acids. Interestingly, it was found that oleic acid is significantly more effective in causing protein particles than lauric acid in these experiments. This suggests that PS20 containing formulations might have a lower likelihood to have protein particles compared to PS80 containing mAb formulations if hydrolysis of polysorbate were to occur. Lastly, the presence of 0.01% polysorbate in the mAb A formulation was able to fully mitigate the effect of fatty acids and reduce the protein particles significantly, suggesting a potential mechanism where interfacial action is involved. The present study can help to understand the root cause for protein particles in a mAb formulation where fatty acids are introduced because of polysorbate hydrolysis. With further work, it will help to shed light into product control strategy as well as design approaches for robust mAb products.

Preheat-induced soy protein particles with tunable heat stability

Recently, there is a growing interest in developing protein-enriched beverages with improved nutritional and functional properties. However, this is challenged by heat-induced aggregation and gelation of edible proteins, which limits their practical applications in high protein systems. In this study, soy protein particles (SPPs) with tunable heat stability were prepared by simply preheating soy proteins suspensions (pH 6.4 and 1% (w/v) concentration) at different temperatures and times. Results showed that heat-stabled SPPs were successfully obtained at high preheating temperatures with prolonged time. The SPPs structures were found to be highly unfolded, denatured, and compact. In addition, these particles exhibited lower viscosities and higher flow behavior index without gelation, whereas those prepared at lower preheating temperatures were found to readily gel after reheating. These results provide useful insights on how heat stable SPPs can be prepared, which extends their further application in protein-enriched beverages and relevant products.

The analysis of the causes of protein precipitate formation in the blanched soymilk

This paper explored the causes of protein precipitate formation in blanched soymilk prepared by blanching soybeans through studying the changes in composition and amount of protein particles during its thermal processing. Compared with the traditional method of preparing soymilk, blanching changed the thermal aggregation behavior of protein particles. Results showed that when blanching was applied to soybeans, β-conglycinin (7S) was denatured in the blanched soybeans, which resulted in the fixation and aggregation of 7S prior to the grinding processing. Therefore, 7S lost its inhibitory ability on the growth of other protein aggregation, explaining the increased insoluble precipitates in the blanched soymilk.