An ultra scale-down method to investigate monoclonal antibody processing during tangential flow filtration using ultrafiltration membranes.

The availability of material for experimental studies is a key constraint in the development of full-scale bioprocesses. This is especially true for the later stages in a bioprocess sequence such as purification and formulation, where the product is at a relatively high concentration and traditional scale-down models can require significant volumes. Using a combination of critical flow regime analysis, bioprocess modelling, and experimentation, ultra scale-down (USD) methods can yield bioprocess information using only millilitre quantities before embarking on highly demanding full-scale studies. In this study the performance of a pilot-scale tangential flow filtration (TFF) system based on a membrane flat-sheet cassette using pumped flow was predicted by devising an USD device comprising a stirred cell using a rotating disc. The USD device operates with just 2.1 cm2 of membrane area and, for example, just 1.7 mL of feed for diafiltration studies. The novel features of the design involve optimisation of the disc location and the membrane configuration to yield an approximately uniform shear rate. This is characterised using computational fluid dynamics for a defined layer above the membrane surface. A pilot-scale TFF device operating at ~500-fold larger feed volume and membrane area was characterised in terms of the shear rate derived from flow rate-pressure drop relationships for the cassette. Good agreement was achieved between the USD and TFF devices for the flux and resistance values at equivalent average shear rates for a monoclonal antibody diafiltration stage.

An ultra scale-down methodology to characterize aspects of the response of human cells to processing by membrane separation operations.

Tools that allow cost-effective screening of the susceptibility of cell lines to operating conditions which may apply during full scale processing are central to the rapid development of robust processes for cell-based therapies. In this paper, an ultra scale-down (USD) device has been developed for the characterization of the response of a human cell line to membrane-based processing, using just a small quantity of cells that is often all that is available at the early discovery stage. The cell line used to develop the measurements was a clinically relevant human fibroblast cell line. The impact was evaluated by cell damage on completion of membrane processing as assessed by trypan blue exclusion and release of intracellular lactate dehydrogenase (LDH). Similar insight was gained from both methods and this allowed the extension of the use of the LDH measurements to examine cell damage as it occurs during processing by a combination of LDH appearance in the permeate and mass balancing of the overall operation. Transmission of LDH was investigated with time of operation and for the two disc speeds investigated (6,000 and 10,000 rpm or ϵmax ≈ 1.9 and 13.5 W mL-1 , respectively). As expected, increased energy dissipation rate led to increased transmission as well as significant increases in rate and extent of cell damage. The method developed can be used to test the impact of varying operating conditions and cell lines on cell damage and morphological changes. Biotechnol. Bioeng. 2017;114: 1241-1251. © 2017 The Authors. Biotechnology and Bioengineering Published by Wiley Periodicals, Inc.

Relationship between preparation of cells for therapy and cell quality using artificial neural network analysis.

OBJECTIVE: The successful preparation of cells for therapy depends on the characterization of causal factors affecting cell quality. Ultra scale-down methods are used to characterize cells in terms of their response to process engineering causal factors of hydrodynamic shear stress and time. This response is in turn characterized in terms of causal factors relating to variations as may naturally occur during cell preparation, i.e., passage number, generation number, time of the final passage stage and hold time in formulation medium. METHODS: To investigate the influence of all of these causal factors we have adopted a non-linear, multivariate predictive artificial neural network (ANN) based modeling approach to help create clearer insights into their effect on cell membrane integrity and surface marker content. A prostate cancer cell line candidate for cancer therapy (P4E6) was used and cell surface markers CD9, CD147 and HLA A-C were investigated. RESULTS: All causal factors studied were found to be significant in establishing an ANN model for the prediction of cell quality parameters with the extent of exposure to shear stress being the most significant and then passage number (range 57-66) and generation number (range 10-19) determining most strongly the cells' resistance to shear stress. Both the operation of the final cell passage and the hold time of the cells in a formulation buffer also determine the cells' resistance to shear stress. The processing parameters related to cell handling after preparation, i.e., shear stress and time of exposure were found to be the most influential affecting cell quality. CONCLUSION: CD9 surface marker loss was the most sensitive indicator of the effects of shear stress followed by loss of membrane integrity and then HLA A-C, while CD147 remained unaffected by shear stress or even prone to increase. Also greater stability of cell surface marker presence was noted for cells generated at greater passage numbers or generation numbers or for reduction in hold time in formulation buffer.

Windows of operation for bioreactor design for the controlled formation of tissue-engineered arteries.

The availability of large numbers of units of artificial arteries would offer significant benefits to the clinical management of bypass surgery. Tissue engineering offers the potential of providing vessels that can mimic the morphology, function, and physiological environment of native vessels. Ideally this would involve culturing stem cells in vitro within a biodegradable tubular scaffold so as to construct tissue for implantation. Essential to establishing a robust process for the production of tissue-engineered arteries is the understanding of the impact of changes in the operating conditions and bioreactor design on the construct formation. In this article, models of transport phenomena were developed to predict the critical flow rates and mass transfer requirements of a prototype bioreactor for the formation of tissue-engineered arteries. The impact of the cell concentration, tube geometry, oxygen effective diffusivity in alginate, substrate and metabolite concentration levels, feed rate, and recycle rate on the design of the bioreactor was visualized using windows of operation and contour plots. The result of this analysis determined the best configuration of the bioreactor that meets the cellular transport requirements as well as being reliable in performance while seeking to reduce the amount of nutrients to be used.

Adapted ultra scale-down approach for predicting the centrifugal separation behavior of high cell density cultures.

The work presented here describes an ultra scale-down (USD) methodology for predicting centrifugal clarification performance in the case of high cell density fermentation broths. Existing USD approaches generated for dilute systems led to a 5- to 10-fold overprediction of clarification performance when applied to such high cell density feeds. This is due to increased interparticle forces, leading to effects such as aggregation, flocculation, or even blanket sedimentation, occurring in the low shear environment of a laboratory centrifuge, which will not be apparent in the settling region of a continuous-flow industrial centrifuge. A USD methodology was created based upon the dilution of high solids feed material to approximately 2% wet wt/vol prior to the application of the clarification test. At this level of dilution cell-cell interactions are minimal. The dilution alters the level of hindered settling in the feed suspensions, and so mathematical corrections are applied to the resultant clarification curves to mimic the original feed accurately. The methodology was successfully verified: corrected USD curves accurately predicted pilot-scale clarification performance of high cell density broths of Saccharomyces cerevisiae and Escherichia coli cells. The USD method allows for the rapid prediction of large-scale clarification of high solids density material using millilitre quantities of feed. The advantages of this method to the biochemical engineer, such as the enabling of rapid process design and scale-up, are discussed.

Prediction of shear damage of plasmid DNA in pump and centrifuge operations using an ultra scale-down device.

Supercoiled circular (SC) plasmid DNA is often subjected to fluid stress in large-scale manufacturing processes. It is thus important to characterize the engineering environment within a particular unit operation as well as within the associated ancillary equipment during process design for plasmid DNA manufacture so as to avoid shear-induced degradation of the SC isoform, which would compromise product efficacy in therapeutic applications. In the past few years, ultra scale-down (USD) tools were developed within our laboratory to mimic the engineering environments experienced by biomolecules within a range of manufacturing-scale ancillary, primary recovery, and purification operations, using milliliter quantities of material. Through the use of a USD shear device, the effect of elongational strain rate on SC plasmid DNA degradation was studied in this paper, and from that, the impact of a centrifugal pump, a Mono pump, and a disk-stack centrifuge feed zone on SC plasmid DNA degradation was predicted and experimentally verified at scale. Model predictions, over the range of conditions studied, were in good agreement with experimental values, demonstrating the potential of the USD approach as a decisional tool during bioprocess design.