A novel method for continuous chromatographic separation of monoclonal antibody charge variants by combining displacement mode chromatography and step elution.

Charge heterogeneity of monoclonal antibodies is considered a critical quality attribute and hence needs to be monitored and controlled by the manufacturer. Typically, this is accomplished via separation of charge variants on cation exchange chromatography (CEX) using a pH or conductivity based linear gradient elution. Although an effective approach, this is challenging particularly during continuous processing as creation of linear gradient during continuous processing adds to process complexity and can lead to deviations in product quality upon slightest changes in gradient formation. Moreover, the long length of elution gradient along with the required peak fractionation makes process integration difficult. In this study, we propose a novel approach for separation of charge variants during continuous CEX chromatography by utilizing a combination of displacement mode chromatography and salt-based step elution. It has been demonstrated that while the displacement mode of chromatography enables control of acidic variants ≤26% in the CEX eluate, salt-based step gradient elution manages basic charge variant ≤25% in the CEX eluate. The proposed approach has been successfully demonstrated using feed materials with varying compositions. On comparing the designed strategy with 2-column concurrent (CC) chromatography, the resin specific productivity increased by 95% and resin utilization increased by 183% with recovery of main species >99%. Further, in order to showcase the amenability of the designed CEX method in continuous operation, the method was examined in our in-house continuous mAb platform.

Continuous integrated manufacturing for biopharmaceuticals: A new paradigm or an empty promise?

Continuous integrated bioprocessing has elicited considerable interest from the biopharma industry for the many purported benefits it promises. Today many major biopharma manufacturers around the world are engaged in the development of continuous process platforms for their products. In spite of great potential, the path toward continuous integrated bioprocessing remains unclear for the biologics industry due to legacy infrastructure, process integration challenges, vague regulatory guidelines, and a diverging focus toward novel therapies. In this article, we present a review and perspective on this topic. We explore the status of the implementation of continuous integrated bioprocessing among biopharmaceutical manufacturers. We also present some of the key hurdles that manufacturers are likely to face during this implementation. Finally, we hypothesize that the real impact of continuous manufacturing is likely to come when the cost of manufacturing is a substantial portion of the cost of product development, such as in the case of biosimilar manufacturing and emerging economies.

Complete or periodic continuity in continuous manufacturing platforms for production of monoclonal antibodies?

BACKGROUND: Monoclonal antibodies (mAbs) currently dominate the biotherapeutic market. This has resulted in significant efforts towards the development of a continuous integrated platform for the manufacturing of mAbs. MAIN METHODS AND MAJOR RESULTS: In this study, a continuous mAb platform has been developed consisting of an Acoustic Wave Separator, a Cadence BioSMB PD system, a customized coiled flow reactor, a modular single-pass TFF kit, an in-line diafiltration module, and a continuous dead-end filtration skid. A three-step chromatographic purification was performed in the platform consisting of Protein A capture chromatography followed by an anion exchange membrane directly coupled to a cation exchange chromatography. Two operational case studies have been executed on the platform, namely complete continuous ("CC") and periodic continuous ("PC") modes of operation. The CC mode was designed to ensure that each unit operation had completely continuous inflow and outflow by increasing the number of columns, filtration modules and tanks, while the PC mode operated in periodic pulses with scheduled flow and hold steps. Both modes were designed to handle the same flow rate and titers from the upstream bioreactor or fed-batch harvest tank, and were compared in terms of productivity and operational complexity. Both modes offer viable options for continuous processing of mAbs and result in achievement of target critical quality attribute profiles of the final drug product over 24 h of operation. CONCLUSIONS AND IMPLICATIONS: It was found that the CC mode was superior in terms of specific productivity (20-50% higher) and consumable utilization (20% lower resin utilization), while the PC mode was operationally simpler and had lower facility costs due to significant reductions in the number of auxiliary equipment (pumps, columns, tanks, and valves). The work successfully highlighted the pros and cons of both approaches, and demonstrates that while several groups have amply shown the superiority of continuous processing over batch mode, there are intermediate variants which may be optimal in a given situation.

Economic assessment of continuous processing for manufacturing of biotherapeutics.

Continuous processing offers a promising approach to revolutionize biotherapeutics manufacturing as reflected in recent years. The current study offers a comparative economic assessment of batch and continuous processing for the production of biotherapeutic products. Granulocyte-colony stimulating factor (GCSF), a protein expressed in E. coli, and an IgG1 monoclonal antibody, were chosen as representatives of microbial and mammalian derived products for this assessment. Economic indicators-cost of goods (COGs), net present value (NPV), and payback time have been estimated for the assessment. For the case of GCSF, conversion from batch to integrated continuous manufacturing induced a $COGs/g reduction of 83% and 73% at clinical and commercial scales, respectively. For the case of mAb therapeutic, a 68% and 35% reduction in $COGs/g on translation from batch to continuous process was projected for clinical and commercial scales, respectively. Upstream mAb titer was also found to have a significant impact on the process economics. With increasing mAb titer, the $COG/g decreases in both operating modes. With titer increasing from 2 to 8 g/L, the $COG/g of batch process was reduced by 53%, and that of the continuous process was reduced by 63%. Cost savings in both the cases were attributed to increased productivity, efficient equipment and facility utilization, smaller facility footprint, and reduction in utilization of consumables like resin media and buffers actualized by the continuous processing platform. The current study quantifies the economic benefits associated with continuous processing and highlights its potential in reducing the manufacturing cost of biotherapeutics.

Development of an integrated continuous PEGylation and purification Process for granulocyte colony stimulating factor.

PEGylation of therapeutic proteins has long been recognized as a safe and effective approach to enhance pharmacokinetic properties of proteins by increasing the in-vivo half-life and thereby the bioavailability. Despite all the benefits linked to PEGylation, high cost of PEGylated products has hindered accessibility of these products to patients. Continuous processing offers a solution to this predicament with its proven capability to improve economics without sacrificing product quality. In this study, we report the development of an integrated continuous PEGylation and purification process for a therapeutic protein, PEG-GCSF. The methodology to achieve this consisted of developing the batch PEGylation and purification protocols followed by their conversion into an integrated continuous process. A batch process involving rapid and highly productive PEGylation (reaction completion within one hour of reaction time) followed by cation exchange chromatography was developed. Enabling technologies like coiled flow inversion reactor, inline concentrator and counter-current chromatography, were utilized for the successful conversion of the batch process to continuous mode. The final integrated continuous process consisted of continuous PEGylation in a coiled flow inverter reactor followed by four column continuous counter-current cation exchange chromatography. Continuous chromatography was performed in a novel displacement mode, wherein all the multi-PEGylated impurities were removed in the loading flow-through and the pure mono-PEGylated protein was obtained in a single step salt elution. In combination with our previously established GCSF manufacturing train, the end-to-end continuous manufacturing process starting from inclusion bodies to unformulated PEG-GCSF drug substance was successfully run for 12 h. All attributes were found to be consistent over the period of operation with product purity > 99 % and high molecular weight impurities < 0.5 %. We hope that the current study will lay the foundation for implementation of continuous processing as a method to improve manufacturability of PEGylated therapeutic proteins.

Non-protein A purification platform for continuous processing of monoclonal antibody therapeutics.

Protein A capture chromatography, the core of a mAb purification platform, is known to account for more than 50% of downstream processing costs along with other limitations including lack of complete stability to alkaline cleaning solutions, relatively lower binding capacity, and ligand leaching. Researchers have explored alternatives to protein A chromatography, both chromatographic and non-chromatographic, but with limited success. In this paper, we propose a non-protein A purification platform for continuous processing of monoclonal antibodies (mAbs). The proposed platform consists of precipitation in coiled flow inverter reactor, cation exchange chromatography for capture, multimodal chromatography and a salt tolerant anion exchange membrane as polishing steps. The versatility of the proposed platform has been successfully demonstrated for three different mAbs. In all cases, acceptable process yield was obtained (70-80 %) and the product quality attributes of the final unformulated drug substance were consistent and well within accepted limits (HCP < 100 ppm, DNA < 10 ppb, % aggregate content < 1%) along with desired charge variant composition.

Use of HPLC as an Enabler of Process Analytical Technology in Process Chromatography.

Online monitoring of product quality attributes using high resolution analytical tools is a prerequisite for implementation of process analytical technology (PAT) and thereby ensuring product quality and consistency. Online high-performance liquid chromatography (HPLC) has been established for real time monitoring of product quality attributes. However, requirement of liquid handling system capable of online sampling and fractionation and interfacing it with preparative scale chromatography appends to the cost and complexity of the design module of commercially available online HPLC. This paper proposes a cost-effective approach for using a traditional offline HPLC for online analysis using a 2 way/6 port valve to facilitate simultaneous automated sampling of product stream eluting from a process column and fractionation. No sample dilution is required in the proposed approach. The versatility of the proposed online configuration has been verified by demonstrating its use for two of the most common separations required during production of monoclonal antibody therapeutics: separation of aggregates and separation of charge variants. Process modeling has been performed to allow interpolation of HPLC data and facilitate pooling to achieve the desired purity (model predicted purity 99.1% vs achieved purity of 99.3% for removal of aggregates, model predicted main species yield of 62.4% vs achieved main species of 62.9% for pooling of charge variants). The study thus demonstrates that the proposed online HPLC configuration can be used for PAT applications in preparative chromatography.

Recent developments in chromatographic purification of biopharmaceuticals.

Over the last several decades, researchers have time and again proposed use of non-chromatographic methods for processing of biotherapeutic products. However, chromatography continues to be the backbone of downstream processing, particularly at process scale. There are many reasons for this, critical ones being the unparalleled scalability, robustness, and selectivity that process chromatography offers over its peers. It is no surprise then that process chromatography has been a topic of major developments in resin matrix, ligand chemistry, modalities, high throughput process development, process modelling, and approaches for control. In this review, we attempt to summarize major developments in the above-mentioned areas. Greater significance has been given to advancements in the last 5 years (2013-2017).

Role of raw materials in biopharmaceutical manufacturing: risk analysis and fingerprinting.

Accurate fingerprinting of critical raw materials that have significant impact on process performance and product quality is a necessary precursor for implementation of QbD in process and product development. This article presents a review of major developments in this space in the last 10 years, with a special emphasis on those in last 5 years. A step by step approach for managing raw materials in the QbD paradigm has been proposed. We think that it is necessary for the biotech industry to better manage variability originating from raw materials if holistic implementation of QbD is to be achieved.

Integrated Chromatographic Platform for Simultaneous Separation of Charge Variants and Aggregates from Monoclonal Antibody Therapeutic Products.

Achieving consistent product quality of a biotherapeutic is a major target for any biopharmaceutical manufacturer, even more for a biosimilar producer as comparability with the innovator product is a regulatory expectation. The complexity of biotherapeutic products and their tedious manufacturing processes, however, make this a non-trivial exercise. The primary motivation of this work is to develop an integrated chromatographic platform for purification of monoclonal antibody (mAb) therapeutics that can deliver the desired separation of both charge variants and aggregates, in addition to the process related impurities like host cell proteins (HCP) and host cell DNA. To achieve the same, an integrated two-stage chromatographic process platform consisting of cation exchange chromatography and multimodal chromatography is being proposed. The versatility of the proposed platform has been successfully demonstrated for three different mAbs. It have been shown that in each case charge variant separation is achieved with the required clearance of aggregates (<1%), HCP (<10 ppm), and DNA (<5 ppb). Moreover, the proposed platform is conducive to use for development of a continuous process and offers smaller process time, lower buffer utilization, and decreased operational costs when compared to the conventional purification platforms.

Integrated continuous processing of proteins expressed as inclusion bodies: GCSF as a case study.

Affordability of biopharmaceuticals continues to be a challenge, particularly in developing economies. This has fuelled advancements in manufacturing that can offer higher productivity and better economics without sacrificing product quality in the form of an integrated continuous manufacturing platform. While platform processes for monoclonal antibodies have existed for more than a decade, development of an integrated continuous manufacturing process for bacterial proteins has received relatively scant attention. In this study, we propose an end-to-end integrated continuous downstream process (from inclusion bodies to unformulated drug substance) for a therapeutic protein expressed in Escherichia coli as inclusion body. The final process consisted of a continuous refolding in a coiled flow inverter reactor directly coupled to a three-column periodic counter-current chromatography for capture of the product followed by a three-column con-current chromatography for polishing. The continuous bioprocessing train was run uninterrupted for 26 h to demonstrate its capability and the resulting output was analyzed for the various critical quality attributes, namely product purity (>99%), high molecular weight impurities (<0.5%), host cell proteins (<100 ppm), and host cell DNA (<10 ppb). All attributes were found to be consistent over the period of operation. The developed assembly offers smaller facility footprint, higher productivity, fewer hold steps, and significantly higher equipment and resin utilization. The complexities of process integration in the context of continuous processing have been highlighted. We hope that the study presented here will promote development of highly efficient, universal, end-to-end, fully continuous platforms for manufacturing of biotherapeutics. © 2016 American Institute of Chemical Engineers Biotechnol. Prog., 33:998-1009, 2017.

Continuous precipitation of process related impurities from clarified cell culture supernatant using a novel coiled flow inversion reactor (CFIR).

Coiled Flow Inverter Reactor (CFIR) has recently been explored for facilitating continuous operation of several unit operations involved in downstream processing of biopharmaceuticals such as viral inactivation and protein refolding. The application of CFIR for continuous precipitation of clarified cell culture supernatant has been explored. The pH based precipitation is optimized in the batch mode and then in the continuous mode in CFIR using a design of experiments (DOE) study. Improved clearance of host cell DNA (52× vs. 39× in batch), improved clearance of host cell proteins (HCP) (7× vs. 6× in batch) and comparable recovery (90 vs. 91.5 % in batch) are observed along with six times higher productivity. To further demonstrate wider applicability of CFIR in performing continuous precipitation, two more case studies involving use of two different precipitation protocols (CaCl2 based and caprylic acid based) are also performed. In both cases, clearance of host cell DNA, HCP, and product recovery are found to be comparable or better in CFIR than in batch operations. Moreover, increase in productivity of 16 times (CaCl2 based) and eight times (caprylic acid based) is obtained for the two precipitation protocols, respectively. The data clearly demonstrate that CFIR can be seamlessly integrated into a continuous bioprocess train for performing continuous precipitation of clarified cell culture supernatant. To our knowledge this is the first report of such use.