Proteomic analysis of host cell protein fouling during bioreactor harvesting.

Chinese hamster ovary (CHO) cells are among the most common cell lines used for therapeutic protein production. Membrane fouling during bioreactor harvesting is a major limitation for the downstream purification of therapeutic proteins. Host cell proteins (HCP) are the most challenging impurities during downstream purification processes. The present work focuses on identification of HCP foulants during CHO bioreactor harvesting using reverse asymmetrical commercial membrane BioOptimal™ MF-SL. In order to investigate foulants and fouling behavior during cell clarification, for the first time a novel backwash process was developed to effectively elute almost all the HCP and DNA from the fouled membrane filter. The isoelectric points (pIs) and molecular weights (MWs) of major HCP in the bioreactor harvest and fouled on the membrane were successfully characterized using two-dimensional gel electrophoresis (2D SDS-PAGE). In addition, a total of 8 HCP were identified using matrix-assisted laser desorption/ionization-mass spectroscopy (MALDI-MS). The majority of these HCP are enzymes or associated with exosomes, both of which can form submicron-sized particles which could lead to the plugging of the filters.

Use of scanning electron microscopy and energy dispersive X-ray spectroscopy to identify key fouling species during alternating tangential filtration.

Alternating tangential flow filtration (ATF) has become one of the primary methods for cell retention and clarification in perfusion bioreactors. However, membrane fouling can cause product sieving losses that limit the performance of these systems. This study used scanning electron microscopy and energy dispersive X-ray spectroscopy to identify the nature and location of foulants on 0.2 µm polyethersulfone hollow fiber membranes after use in industrial Chinese hamster ovary cell perfusion bioreactors for monoclonal antibody production. Membrane fouling was dominated by proteinaceous material, primarily host cell proteins along with some monoclonal antibody. Fouling occurred primarily on the lumen surface with much less protein trapped within the depth of the fiber. Protein deposition was also most pronounced near the inlet/exit of the hollow fibers, which are the regions with the greatest flux (and transmembrane pressure) during the cyclical operation of the ATF. These results provide important insights into the underlying phenomena governing the fouling behavior of ATF systems for continuous bioprocessing.

Factors affecting robustness of anion exchange chromatography: Selective retention of minute virus of mice using membrane media.

Mobile and stationary phase factors were investigated in order to identify conditions for effective capture of minute virus of mice (MVM), a potential adventitious contaminant in biomanufacturing, using anion exchange membrane chromatography (AEX). The initial study was conducted for Membrane A for a range of feed conditions using bovine serum albumin (BSA) as a model protein mimicking acidic host-cell proteins (HCPs) competitive for virus binding. The effects of pH (6-8), salt concentration (0-150 mM NaCl) and level of BSA (0-10 g/L) were systematically investigated. It was found that higher BSA concentration has the most negative impact on MVM binding followed by the increased conductivity of the feed solution. The effect of pH on MVM binding is also detected but has a less impact compared to other two factors in the range of feed conditions investigated. In addition to Membrane A, three other AEX membranes (Membrane B, C and D) were investigated for MVM binding at a selected feed condition. Based on properties of the membranes investigated, it was found that ligand charge density has the most significant impact on MVM binding performance of AEX membranes from stationary phase perspective.

Electrospun Hydrophobic Interaction Chromatography (HIC) Membranes for Protein Purification.

Responsive membranes for hydrophobic interaction chromatography have been fabricated by functionalizing poly(N-vinylcaprolactam) (PVCL) ligands on the substrate of electrospun regenerated cellulose nanofibers. Both static and dynamic binding capacities and product recovery were investigated using bovine serum albumin (BSA) and Immunoglobulin G (IgG) as model proteins. The effects of ligand chain length and chain density on static binding capacity were also studied. A static binding capacity of ~25 mg/mL of membrane volume (MV) can be achieved in optimal ligand grafting conditions. For dynamic binding studies, protein binding capacity increased with protein concentration from 0.1 to 1.0 g/L. Dynamic binding capacity increased from ~8 mg/mL MV at 0.1 g/L BSA to over 30 mg/mL at 1.0 g/L BSA. However, BSA recovery decreased as protein concentration increased from ~98% at 0.1 g/L BSA to 51% at 1 g/L BSA loading concentration. There is a clear trade-off between binding capacity and recovery rate. The electrospun substrate with thicker fibers and more open pore structures is superior to thinner fibrous membrane substrates.

Process- and Product-Related Foulants in Virus Filtration.

Regulatory authorities place stringent guidelines on the removal of contaminants during the manufacture of biopharmaceutical products. Monoclonal antibodies, Fc-fusion proteins, and other mammalian cell-derived biotherapeutics are heterogeneous molecules that are validated based on the production process and not on molecular homogeneity. Validation of clearance of potential contamination by viruses is a major challenge during the downstream purification of these therapeutics. Virus filtration is a single-use, size-based separation process in which the contaminating virus particles are retained while the therapeutic molecules pass through the membrane pores. Virus filtration is routinely used as part of the overall virus clearance strategy. Compromised performance of virus filters due to membrane fouling, low throughput and reduced viral clearance, is of considerable industrial significance and is frequently a major challenge. This review shows how components generated during cell culture, contaminants, and product variants can affect virus filtration of mammalian cell-derived biologics. Cell culture-derived foulants include host cell proteins, proteases, and endotoxins. We also provide mitigation measures for each potential foulant.

Retention and Fouling during Nanoparticle Filtration: Implications for Membrane Purification of Biotherapeutics.

One major challenge in the development of nanoparticle-based therapeutics, including viral vectors for the delivery of gene therapies, is the development of cost-effective purification technologies. The objective of this study was to examine fouling and retention behaviors during the filtration of model nanoparticles through membranes of different pore sizes and the effect of solution conditions. Data were obtained with 30 nm fluorescently labeled polystyrene latex nanoparticles using both cellulosic and polyethersulfone membranes at a constant filtrate flux, and both pressure and nanoparticle transmission were evaluated as a function of cumulative filtrate volume. The addition of NaCl caused a delay in nanoparticle transmission and an increase in fouling. Nanoparticle transmission was also a function of particle hydrophobicity. These results provide important insights into the factors controlling transmission and fouling during nanoparticle filtration as well as a framework for the development of membrane processes for the purification of nanoparticle-based therapeutics.

Cationic Covalent Organic Framework as an Ion Exchange Material for Efficient Adsorptive Separation of Biomolecules.

Although covalent organic frameworks (COFs) have earned significant interest in separation applications, the use of COFs in biomolecule separation remains unexplored. We examined the ionic COF Py-BPy2+-COF as an ion exchange material for biomolecule separation. After characterizing the properties of the synthesized COF with a variety of techniques, binding experiments with both large and small biomolecules were performed. High adsorption capacities of amino acids with different hydrophobicity and charge, as well as proteins of different isoelectric points and molecular weights, were determined in batch equilibrium experiments. Desorption experiments with mixtures of model proteins demonstrated an ability to successfully separate one protein from another with the selectivity hypothesized to be a combination of the isoelectric point, hydrophobicity, and ability to penetrate the crystalline material. Overall, the results demonstrated that Py-BPy2+-COF can be exploited as a robust crystalline anion exchange biomolecule separation material.

High Performance Mixed-Matrix Electrospun Membranes for Ammonium Removal from Wastewaters.

Mixed-matrix electrospun membranes were developed to investigate ammonium removal from low ammonium concentration wastewaters for the first time. Particles derived from the inexpensive zeolite 13X were successfully incorporated into polyethersulfone (PES) matrices. The fabricated mixed-matrix electrospun membranes demonstrate high ammonium removal capacity reaching over 55 mg/gzeolite, more than 2.5 times higher than the previously fabricated mixed-matrix membranes via non-solvent induced phase inversion. Moreover, the membranes fabricated exhibit high permeability and ease of regeneration. Over 90% of total ammonium nitrogen (TAN) can be removed from low TAN wastewaters such as aquaculture wastewaters. In addition to zeolite 13X, other zeolite particles including zeolite Y, zeolite 3A and 4A were also incorporated into the membrane matrix. The inexpensive zeolite 13X show the highest ammonium exchange capacity. Particle type, loading and the level of its dispersion all affect TAN removal capacity.

Remote Performance Modulation of Ultrafiltration Membranes by Magnetically and Thermally Responsive Polymer Chains.

Ultrafiltration membranes, that respond to an external magnetic field and local temperature have been developed. Surface-initiated activator-generated electron transfer (AGET) atom transfer radical polymerization (ATRP) has been used to graft poly(N-isopropylacrylamide) (PNIPAm) from the surface of 300 kDa regenerated cellulose membranes. The polymerization initiator was selectively attached to the entire membrane surface, only the outer membrane surface or only the inner pore surface. A superparamagnetic nanoparticle was attached to the end of the polymer chain. The DI water flux as well as the flux and rejection of bovine serum albumin were investigated in the absence and presence of a 20 and 1000 Hz oscillating magnetic field. In an oscillating magnetic field, the tethered superparamagnetic nanoparticles can cause movement of the PNIPAm chains or induce heating. A 20 Hz magnetic field maximizes movement of the chains. A 1000 Hz magnetic field leads to greater induced heating. PNIPAm displays a lower critical solution temperature at 32 °C. Heating leads to collapse of the PNIPAm chains above their Lower Critical Solution Temperature (LCST). This work highlights the versatility of selectively grafting polymer chains containing a superparamagnetic nanoparticle from specific membrane locations. Depending on the frequency of the oscillating external magnetic field, membrane properties may be tuned.

The effects of flux on the clearance of minute virus of mice during constant flux virus filtration.

Constant flux virus filtration experiments were conducted to evaluate minute virus of mice retention behavior of four commercial virus filters for continuous bioprocessing applications. Fluxes chosen were guided by the Peclet number and the processing logistics as well as based on the filter characteristics. At the low flux condition of 5 LM-2H-1 (LMH) when diffusive force dominates, a significant breakthrough was observed for all the filtrate fractions for the filtration of a low fouling monoclonal antibody for three of the four filters. When both diffusive and convective forces are equally important at 40 LMH, virus breakthrough in buffer chase was observed only in one of the four filters investigated. When convective force dominates at 60 LMH or above, a high degree of virus clearance was observed for all three parvovirus filters investigated. Our work shed light on virus clearance during constant flux virus filtration for future continuous biomanufacturing.

Modeling flux in tangential flow filtration using a reverse asymmetric membrane for Chinese hamster ovary cell clarification.

Tangential flow filtration is advantageous for bioreactor clarification as the permeate stream could be introduced directly to the subsequent product capture step. However, membrane fouling coupled with high product rejection has limited its use. Here, the performance of a reverse asymmetric hollow fiber membrane where the more open pore structure faces the feed stream and the barrier layer faces the permeate stream has been investigated. The open surface contains pores up to 40 µm in diameter while the tighter barrier layer has an average pore size of 0.4 µm. Filtration of Chinese hamster ovary cell feed streams has been investigated under conditions that could be expected in fed batch operations. The performance of the reverse asymmetric membrane is compared to that of symmetric hollow fiber membranes with nominal pore sizes of 0.2 and 0.65 µm. Laser scanning confocal microscopy was used to observe the locations of particle entrapment. The throughput of the reverse asymmetric membrane is significantly greater than the symmetric membranes. The membrane stabilizes an internal high permeability cake that acts like a depth filter. This stabilized cake can remove particulate matter that would foul the barrier layer if it faced the feed stream. An empirical model has been developed to describe the variation of flux and transmembrane pressure drop during filtration using reverse asymmetric membranes. Our results suggest that using a reverse asymmetric membrane could avoid severe flux decline associated with fouling of the barrier layer during bioreactor clarification.

Modeling tangential flow filtration using reverse asymmetric membranes for bioreactor harvesting.

Tangential flow filtration (TFF) has many advantages for bioreactor harvesting, as the permeate could be introduced directly to the subsequent capture step. However, membrane fouling has limited its widespread use. This is particularly problematic given the high cell densities encountered today. Here, a reverse asymmetric membrane, where the more open surface faces the feed stream and the tighter barrier layer faces the permeate stream, has been investigated. The open surface contains pores up to 40 µm in diameter while the tighter barrier layer has an average pore size of 0.4 µm. Filtration of yeast suspensions has been conducted under a range of conditions. The yeast cells are trapped in the open pore structure. The membrane stabilizes an internal porous cake that acts like a depth filter. This stabilized cake layer can remove particulate matter that would foul the barrier layer if it faced the feed stream. As filtration continues, a surface cake layer forms on the membrane surface. A resistance in series model has been developed to describe the permeate flux during TFF. The model contains three fitted parameters which can easily be determined from constant pressure normal flow filtration experiments and total recycle constant flux TFF experiments. The model can be used to estimate the capacity of the filter for a given feed stream. Our results suggest that using a reverse asymmetric membrane could avoid severe flux decline associated with fouling of the barrier layer during bioreactor harvesting.

Cu(I/II) Metal-Organic Frameworks Incorporated Nanofiltration Membranes for Organic Solvent Separation.

Copper-based metal-organic frameworks (MOFs) with different oxidation states and near-uniform particle sizes have been successfully synthesized. Mixed-matrix polyimide membranes incorporating 0.1-7 wt% of Cu(II) benzene-1,2,5-tricarboxylic acid (Cu(II)BTC), Cu(I/II)BTC and Cu(I) 1,2-ethanedisulfonic acid (EDS) (Cu(I)EDS) MOFs were fabricated via non-solvent-induced phase inversion process. These membranes are found to be solvent resistant and mechanically stable. Liquid phase nanofiltration experiments were performed to separate toluene from n-heptane at room temperature. These membranes demonstrate preferential adsorption and permeation of the aromatic toluene over aliphatic n-heptane. The amount of MOF particles incorporated, the oxidation state of the Cu ion and membrane, and barrier layer thickness have a significant impact on the separation factor. Toluene/heptane separation factor at 1.47, 1.67 and 1.79 can be obtained for membranes incorporating 7 wt% Cu(II)BTC, Cu(I/II)BTC and Cu(I)EDS respectively at room temperature.

Tailoring and Remotely Switching Performance of Ultrafiltration Membranes by Magnetically Responsive Polymer Chains.

Magnetically responsive ultrafiltration membranes were prepared by grafting poly(2-hydroxyethyl methacrylate) chains from the outer surface of 100-kDa regenerated cellulose ultrafiltration membranes. Surface-initiated atom transfer radical polymerization was used to graft the polymer chains. Grafting from the internal pore surface was suppressed by using glycerol as a pore-filling solvent during initiator immobilization at varied densities. Glycerol suppresses the initiator attachment to the pore surface. Polymerization times of up to four hours were investigated. Superparamagnetic nanoparticles were covalently attached to the chain end. Membrane performance was determined using bovine serum albumin and dextran as model solutes. Increasing the grafted polymer chain density and length led to a decrease in the permeate flux and an increase in the apparent rejection coefficient. In an oscillating magnetic field, movement of the grafted polymer chains led to a decrease in the permeate flux, as well as an increase in the apparent rejection coefficient of the model solutes.

Atrazine Removal from Municipal Wastewater Using a Membrane Bioreactor.

As the demand for potable water increases, direct potable reuse of wastewater is an attractive alternative method to produce potable water. However, implementation of such a process will require the removal of emerging contaminants which could accumulate in the drinking water supply. Here, the removal of atrazine, a commonly used herbicide, has been investigated. Using real and synthetic wastewater, as well as sludge from two wastewater treatment facilities in the United States in Norman, Oklahoma and Fayetteville, Arkansas, atrazine removal has been investigated. Our results indicate that about 20% of the atrazine is removed by adsorption onto the particulate matter present. Significant biodegradation of atrazine was only observed under aerobic conditions for sludge from Norman, Oklahoma. Next-generation sequencing of the activated sludge revealed the abundance of Noncardiac with known atrazine degradation pathways in the Norman aerobic sludge, which is believed to be responsible for atrazine biodegradation in our study. The detection of these bacteria could also be used to determine the likelihood of biodegradation of atrazine for a given wastewater treatment facility.

Electrospun Weak Anion-exchange Fibrous Membranes for Protein Purification.

Membrane based ion-exchange (IEX) and hydrophobic interaction chromatography (HIC) for protein purification is often used to remove impurities and aggregates operated under the flow-through mode. IEX and HIC are also limited by capacity and recovery when operated under bind-and-elute mode for the fractionation of proteins. Electrospun nanofibrous membrane is characterized by its high surface area to volume ratio and high permeability. Here tertiary amine ligands are grafted onto the electrospun polysulfone (PSf) and polyacrylonitrile (PAN) membrane substrates using UV-initiated polymerization. Static and dynamic binding capacities for model protein bovine serum albumin (BSA) were determined under appropriate bind and elute buffer conditions. Static and dynamic binding capacities in the order of ~100 mg/mL were obtained for the functionalized electrospun PAN membranes whereas these values reached ~200 mg/mL for the functionalized electrospun PSf membranes. Protein recovery of over 96% was obtained for PAN-based membranes. However, it is only 56% for PSf-based membranes. Our work indicates that surface modification of electrospun membranes by grafting polymeric ligands can enhance protein adsorption due to increased surface area-to-volume ratio.

Zwitterion Co-Polymer PEI-SBMA Nanofiltration Membrane Modified by Fast Second Interfacial Polymerization.

Nanofiltration membranes have evolved as a promising solution to tackle the clean water scarcity and wastewater treatment processes with their low energy requirement and environment friendly operating conditions. Thin film composite nanofiltration membranes with high permeability, and excellent antifouling and antibacterial properties are important component for wastewater treatment and clean drinking water production units. In the scope of this study, thin film composite nanofiltration membranes were fabricated using polyacrylonitrile (PAN) support and fast second interfacial polymerization modification methods by grafting polyethylene amine and zwitterionic sulfobutane methacrylate moieties. Chemical and physical alteration in structure of the membranes were characterized using methods like ATR-FTIR spectroscopy, XPS analysis, FESEM and AFM imaging. The effects of second interfacial polymerization to incorporate polyamide layer and 'ion pair' characteristics, in terms of water contact angle and surface charge analysis was investigated in correlation with nanofiltration performance. Furthermore, the membrane characteristics in terms of antifouling properties were evaluated using model protein foulants like bovine serum albumin and lysozyme. Antibacterial properties of the modified membranes were investigated using E. Coli as model biofoulant. Overall, the effect of second interfacial polymerization without affecting the selectivity layer of nanofiltration membrane for their potential large-scale application was investigated in detail.

Oil Deposition on Polymer Brush-Coated NF Membranes.

Membrane-based processes are attractive for treating oily wastewaters. However, membrane fouling due to the deposition of oil droplets on the membrane surface compromises performance. Here, real-time observation of the deposition of oil droplets by direct confocal microscopy was conducted. Experiments were conducted in dead-end and crossflow modes. Base NF 270 nanofiltration membranes as well as membranes modified by grafting poly(N-isopropylacrylamide) chains from the membrane surface using atom transfer radical polymerization were investigated. By using feed streams containing low and high NaCl concentrations, the grafted polymer chains could be induced to switch conformation from a hydrated to a dehydrated state, as the lower critical solution temperature for the grafted polymer chains moved above and below the room temperature, respectively. For the modified membrane, it was shown that switching conformation of the grafted polymer chains led to the partial release of adsorbed oil. The results also indicate that, unlike particles such as polystyrene beads, adsorption of oil droplets can lead to coalescence of the adsorbed oil droplets on the membrane surface. The results provide further evidence of the importance of membrane properties, feed solution characteristics, and operating mode and conditions on membrane fouling.

The effects of buffer condition on the fouling behavior of MVM virus filtration of an Fc-fusion protein.

A combined pore blockage and cake filtration model was applied to the virus filtration of an Fc-fusion protein using the three commercially available filters, F-1, F-2, and F-3 in a range of buffer conditions including sodium-phosphate and tris-acetate buffers with and without 200 mM NaCl at pH 7.5. The fouling behaviors of the three filters for the feed solutions spiked with minute virus of mice were described well by this combined model for all the solution conditions. This suggests that fouling of the virus filters is dominated by the pore blockage mechanism during the initial stage of the filtration and transformed to the cake filtration mechanism during the later stage of the filtration. Both flux and transmembrane resistance can be described well by this model. The pore blockage rate and the rate of increase of protein layer resistance over blocked pores are found to be affected by membrane properties as well as the solution conditions resulting from the modulation of interactions between virus, protein, and membrane by the solution conditions.

Atomistic Molecular Dynamics Simulations of the Lower Critical Solution Temperature Transition of Poly( N-vinylcaprolactam) in Aqueous Solutions.

Poly( N-vinylcaprolactam) (PVCL) is a thermo-responsive polymer, which exhibits a lower critical solution temperature (LCST) in an aqueous solution. The LCST of this hydrophilic-to-hydrophobic transition is found to be strongly dependent on the salt-type and salt-concentration as well as on the molecular weight and concentration of the polymer. Here, atomistic molecular dynamics simulations have been successfully conducted for the first time to investigate the LCST transition of a 100 degree of polymerization PVCL chain in water, 1 M NaCl, 3.5 M NaCl, and 0.5 M CaCl2 solutions. Our results show that steric hindrance resulting from the bulky 7-member ring on the PVCL chain plays a critical role in the conformational transition. Moreover, the degrees of hydration and dehydration below or above the transition temperature are highly dependent on the specific solution condition and temperature. Water molecules are found to be trapped inside the collapsed polymer chains leading to the varying degrees of hydration and dehydration of the polymer chain in different solutions. Calculated water diffusion coefficients for both trapped and free water molecules agree very well with experimental measurements.