High throughput process development workflow with advanced decision-support for antibody purification.

Chromatography remains the workhorse in antibody purification; however process development and characterisation still require significant resources. The high number of operating parameters involved requires extensive experimentation, traditionally performed at small- and pilot-scale, leading to demands in terms of materials and time that can be a challenge. The main objective of this research was the establishment of a novel High Throughput Process Development (HTPD) workflow combining scale-down chromatography experimentation with advanced decision-support techniques in order to minimise the consumption of resources and accelerate the development timeframe.

Economic evaluation of the primary recovery of tetracycline with traditional and novel aqueous two-phase systems.

Antibiotics are a key pharmaceutical to inhibit growth or kill microorganisms. They represent a profitable market and, in particular, tetracycline has been listed as an essential medicine by the WHO. Therefore it is important to improve their production processes.

Data-driven multi-objective optimization via grid compatible simplex technique and desirability approach for challenging high throughput chromatography applications.

Recently, a grid compatible Simplex variant has been demonstrated to identify optima consistently and rapidly in challenging high throughput (HT) applications in early bioprocess development. Here, this method is extended by deploying it to multi-objective optimization problems. Three HT chromatography case studies are presented, each posing challenging early development situations and including three responses which were amalgamated by the adoption of the desirability approach.

Effects of bed compression on protein separation on gel filtration chromatography at bench and pilot scale.

Background: Poorly packed chromatography columns are known to reduce drastically the column efficiency and produce broader peaks. Controlled bed compression has been suggested to be a useful approach for solving this problem. Here the relationship between column efficiency and resolution of protein separation are examined when preparative chromatography media were compressed using mechanical and hydrodynamic methods.

Optimization-based framework for resin selection strategies in biopharmaceutical purification process development.

This work addresses rapid resin selection for integrated chromatographic separations when conducted as part of a high-throughput screening exercise during the early stages of purification process development. An optimization-based decision support framework is proposed to process the data generated from microscale experiments to identify the best resins to maximize key performance metrics for a biopharmaceutical manufacturing process, such as yield and purity. A multiobjective mixed integer nonlinear programming model is developed and solved using the ε-constraint method.

Life-cycle and cost of goods assessment of fed-batch and perfusion-based manufacturing processes for mAbs.

Life-cycle assessment (LCA) is an environmental assessment tool that quantifies the environmental impact associated with a product or a process (e.g., water consumption, energy requirements, and solid waste generation).

Integrated economic and experimental framework for screening of primary recovery technologies for high cell density CHO cultures.

Increases in mammalian cell culture titres and densities have placed significant demands on primary recovery operation performance. This article presents a methodology which aims to screen rapidly and evaluate primary recovery technologies for their scope for technically feasible and cost-effective operation in the context of high cell density mammalian cell cultures. It was applied to assess the performance of current (centrifugation and depth filtration options) and alternative (tangential flow filtration (TFF)) primary recovery strategies.

Economic analysis of uricase production under uncertainty: Contrast of chromatographic purification and aqueous two-phase extraction (with and without PEG recycle).

Uricase is the enzyme responsible for the breakdown of uric acid, the key molecule leading to gout in humans, into allantoin, but it is absent in humans. It has been produced as a PEGylated pharmaceutical where the purification is performed through three sequential chromatographic columns. More recently an aqueous two-phase system (ATPS) was reported that could recover Uricase with high yield and purity.

Economic analysis of Royalactin production under uncertainty: Evaluating the effect of parameter optimization.

Royalactin is a protein with several different potential uses in humans. Research, in insects and in mammalian cells, has shown that it can accelerate cell division and prevent apoptosis. The method of action is through the use of the epidermal growth factor receptor, which is present in humans.

Representative mammalian cell culture test materials for assessment of primary recovery technologies: a rapid method with industrial applicability.

Mammalian cell culture material is often difficult to produce accurately and reproducibly for downstream studies. This article presents a methodology for the creation of a set of cell culture test materials where key variables including cell density, cell viability, product, and the host cell protein (HCP) load can be manipulated individually. The methodology was developed using a glutamine synthetase Chinese hamster ovary cell line cultured at 5-L and 70-L scales.

Integration of host strain bioengineering and bioprocess development using ultra-scale down studies to select the optimum combination: an antibody fragment primary recovery case study.

An ultra scale-down primary recovery sequence was established for a platform E. coli Fab production process. It was used to evaluate the process robustness of various bioengineered strains.

Investigating the use of column inserts to achieve better chromatographic bed support.

Chromatography plays an important role in the downstream processing of proteins. Over the past years, there has been a steady move toward the adoption of more rigid, porous particles to combine ease of manufacture with increased levels of productivity. The latter is still constrained by the onset of compression where the level of wall support becomes incapable of withstanding flow-induced particle drag.

Automated methods for accurate determination of the critical velocity of packed bed chromatography.

Knowing the critical velocity (ucrit) of a chromatography column is an important part of process development as it allows the optimization of chromatographic flow conditions. The conventional flow step method for determining ucrit is prone to error as it depends heavily on human judgment. In this study, two automated methods for determining ucrit have been developed: the automatic flow step (AFS) method and the automatic pressure step (APS) method.

Demonstration of the use of windows of operation to visualize the effects of fouling on the performance of a chromatographic step.

The high resolution afforded by packed bed chromatography makes it an indispensable operation in the downstream processing of therapeutic molecules. Packed bed performance is however inherently susceptible to changes in feed stream characteristics and fouling processes. The impact of fouling is seldom considered during the early stages of bioprocess development which is concerned with the selection of purification conditions.

Integrated use of ultra scale-down and financial modeling to identify optimal conditions for the precipitation and centrifugal recovery of milk proteins.

This article investigates the integrated application of ultra scale-down (USD) techniques and economic modeling as a means for identifying optimal bioprocess operating conditions. The benefits of the approach are illustrated for the recovery of lactoperoxidase (LPO) from bovine milk. In the process, milk is skimmed to deplete its lipid content, before being subjected to low pH incubation with acetic acid in order to precipitate the primary impurity (casein).

The simplex algorithm for the rapid identification of operating conditions during early bioprocess development: case studies in FAb' precipitation and multimodal chromatography.

This study describes a data-driven algorithm as a rapid alternative to conventional Design of Experiments (DoE) approaches for identifying feasible operating conditions during early bioprocess development. In general, DoE methods involve fitting regression models to experimental data, but if model fitness is inadequate then further experimentation is required to gain more confidence in the location of an optimum. This can be undesirable during very early process development when feedstock is in limited supply and especially if a significant percentage of the tested conditions are ultimately found to be sub-optimal.

An automated packed protein G micro-pipette tip assay for rapid quantification of polyclonal antibodies in ovine serum.

The demands on the biopharmaceutical sector to expedite process development have instigated the deployment of micro-biochemical engineering techniques to acquire manufacturing insight with extremely small sample volumes. In conjunction with automated liquid handlers, this permits the simultaneous evaluation of multiple operating conditions and reduces manual intervention. For these benefits to be sustained, novel ways are now required to accelerate analysis and so prevent this becoming a throughput bottleneck.

Application of agent-based system for bioprocess description and process improvement.

Modeling plays an important role in bioprocess development for design and scale-up. Predictive models can also be used in biopharmaceutical manufacturing to assist decision-making either to maintain process consistency or to identify optimal operating conditions. To predict the whole bioprocess performance, the strong interactions present in a processing sequence must be adequately modeled.

High-throughput screening techniques for rapid PEG-based precipitation of IgG4 mAb from clarified cell culture supernatant.

Locating optimal protein precipitation conditions for complex biological feed materials is problematic. This article describes the application of a series of high-throughput platforms for the rapid identification and selection of conditions for the precipitation of an IgG(4) monoclonal antibody (mAb) from a complex feedstock using only microliter quantities of material. The approach uses 96-microwell filter plates combined with high-throughput analytical methods and a method for well volume determination for product quantification.

Exploiting the intracellular compartmentalization characteristics of the S. cerevisiae host cell for enhancing primary purification of lipid-envelope virus-like particles.

This article demonstrates how the intracellular compartmentalization of the S. cerevisiae host cell can be exploited to impart selectivity during the primary purification of lipid-envelope virus-like particles (VLPs). The hepatitis B surface antigen (HBsAg) was used as the VLP model in this study.

A microscale approach for predicting the performance of chromatography columns used to recover therapeutic polyclonal antibodies.

A microscale approach is described which screens conditions for recovering polyclonal antibodies from ovine sera by mixed-mode cation-exchange chromatography. The impact of pH and loading buffer salt concentration were assessed using robotically operated 20microL packed pipette tips. Low salt concentrations delivered capacities up to 41mg/mL, while only half this level was obtained at high salt concentrations.

A methodology for the comparative evaluation of alternative bioseparation technologies.

Advances in upstream technologies and growing commercial demand have led to cell culture processes of ever larger volumes and expressing at higher product titers. This has increased the burden on downstream processing. Concerns regarding the capacity limitations of packed-bed chromatography have led process engineers to begin investigating new bioseparation techniques that may be considered as "alternatives" to chromatography, and which could potentially offer higher processing capacities but at a lower cost.

Ultra scale-down of protein refold screening in microwells: challenges, solutions and application.

Steps for the refolding of proteins from solubilized inclusion bodies or misfolded product often represent bottlenecks in process development, where optimal conditions are typically derived empirically. To expedite refolding optimization, microwell screening may be used to test multiple conditions in parallel. Fast, accurate, and reproducible assays are required for such screening processes, and the results derived must be representative of the process at full scale.

Study of detergent-mediated liberation of hepatitis B virus-like particles from S. cerevisiae homogenate: identifying a framework for the design of future-generation lipoprotein vaccine processes.

Virus-like particles (VLPs) are expressed intracellularly in Saccharomyces cerevisiae and the recovery process involves the use of a detergent, which facilitates the release of VLP from host cell components. The detergent-mediated liberation of VLPs is a critical step in primary recovery and is responsible for setting the backdrop for subsequent purification in terms of product yield and characteristics of the process stream. In this paper the use of Triton X-100 detergent for the recovery of lipid envelope VLPs, using the hepatitis B surface antigen (HBsAg) as the VLP model, was investigated.

A methodical approach to ultra-scale-down of process sequences: application to casein removal from the milk of transgenic animals.

Scale-down models of individual operations are widely used in biopharmaceutical process development to obtain information about the performance of production-scale equipment on the basis of inexpensive and efficient laboratory-scale tests, for the purposes of validation or optimization or characterization studies. We have investigated the ability of scale-down models of whole process sequences to provide reliable information for process scale-up from laboratory- to pilot-scales of operation. Using the example of the recovery of a protein from transgenic milk, we have conducted an a priori scale-down analysis of a projected pilot-scale process sequence.