Large scale demonstration of a process analytical technology application in bioprocessing: Use of on‐line high performance liquid chromatography for making real time pooling decisions for process chromatography

Process Analytical Technology (PAT) has been gaining a lot of momentum in the biopharmaceutical community because of the potential for continuous real time quality assurance resulting in improved operational control and compliance. In previous publications, we have demonstrated feasibility of applications involving use of high performance liquid chromatography (HPLC) and ultra performance liquid chromatography (UPLC) for real‐time pooling of process chromatography column. In this article we follow a similar approach to perform lab studies and create a model for a chromatography step of a different modality (hydrophobic interaction chromatography). It is seen that the predictions of the model compare well to actual experimental data, demonstrating the usefulness of the approach across the different modes of chromatography. Also, use of online HPLC when the step is scaled up to pilot scale (a 2294 fold scale‐up from a 3.4 mL column in the lab to a 7.8 L column in the pilot plant) and eventually to manufacturing scale (a 45930 fold scale‐up from a 3.4 mL column in the lab to a 158 L column in the manufacturing plant) is examined. Overall, the results confirm that for the application under consideration, online‐HPLC offers a feasible approach for analysis that can facilitate real‐time decisions for column pooling based on product quality attributes. The observations demonstrate that the proposed analytical scheme allows us to meet two of the key goals that have been outlined for PAT, i.e., “variability is managed by the process” and “product quality attributes can be accurately and reliably predicted over the design space established for materials used, process parameters, manufacturing, environmental, and other conditions”. The application presented here can be extended to other modes of process chromatography and/or HPLC analysis. © 2009 American Institute of Chemical Engineers Biotechnol. Prog., 2010     

Penalized gaussian process regression and classification for high-dimensional nonlinear data

The model based on Gaussian process (GP) prior and a kernel covariance function can be used to fit nonlinear data with multidimensional covariates. It has been used as a flexible nonparametric approach for curve fitting, classification, clustering, and other statistical problems, and has been widely applied to deal with complex nonlinear systems in many different areas particularly in machine learning. However, it is a challenging problem when the model is used for the large-scale data sets and high-dimensional data, for example, for the meat data discussed in this article that have 100 highly correlated covariates. For such data, it suffers from large variance of parameter estimation and high predictive errors, and numerically, it suffers from unstable computation. In this article, penalized likelihood framework will be applied to the model based on GPs. Different penalties will be investigated, and their ability in application given to suit the characteristics of GP models will be discussed. The asymptotic properties will also be discussed with the relevant proofs. Several applications to real biomechanical and bioinformatics data sets will be reported.     

Anion exchange chromatography provides a robust, predictable process to ensure viral safety of biotechnology products

The mammalian cell-lines used to produce biopharmaceutical products are known to produce endogenous retrovirus-like particles and have the potential to foster adventitious viruses as well. To ensure product safety and regulatory compliance, recovery processes must be capable of removing or inactivating any viral impurities or contaminants which may be present. Anion exchange chromatography (AEX) is a common process in the recovery of monoclonal antibody products and has been shown to be effective for viral removal. To further characterize the robustness of viral clearance by AEX with respect to process variations, we have investigated the ability of an AEX process to remove three model viruses using various combinations of mAb products, feedstock conductivities and compositions, equilibration buffers, and pooling criteria. Our data indicate that AEX provides complete or near-complete removal of all three model viruses over a wide range of process conditions, including those typically used in manufacturing processes. Furthermore, this process provides effective viral clearance for different mAb products, using a variety of feedstocks, equilibration buffers, and different pooling criteria. Viral clearance is observed to decrease when feedstocks with sufficiently high conductivities are used, and the limit at which the decrease occurs is dependent on the salt composition of the feedstock. These data illustrate the robust nature of the AEX recovery process for removal of viruses, and they indicate that proper design of AEX processes can ensure viral safety of mAb products.     

Case study and application of process analytical technology (PAT) towards bioprocessing: Use of tryptophan fluorescence as at‐line tool for making pooling decisions for process chromatography

Process analytical technology (PAT) has been gaining momentum in the biopharmaceutical community due to the potential for continuous real time quality assurance resulting in improved operational control and compliance. Two imperatives for implementing any PAT tool are that “variability is managed by the process” and “product quality attributes can be accurately and reliably predicted over the design space established for materials used, process parameters, manufacturing, environmental, and other conditions.” Recently, we have been examining the feasibility of applying different analytical tools to bioprocessing unit operations. We have previously demonstarted that commercially available online‐high performance liquid chromatography and ultra performance liquid chromatography systems can be used for analysis that can facilitate real‐time decisions for column pooling based on product quality attributes (Rathore et al., 2008 a,b). In this article, we review an at‐line tool that can be used for pooling of process chromatography columns. We have demonstrated that our tryptophan fluorescence method offers a feasible approach and meets the requirements of a PAT application. It is significantly faster than the alternative of fractionation, offline analysis followed by pooling. Although the method as presented here is not an online method, this technique may offer better resolution for certain applications and may be a more optimal approach as it is very conducive to implementation in a manufacturing environment. This technique is also amenable to be used as an online tool via front face fluorescence measurements done concurrently with product concentration determination by UV. © 2009 American Institute of Chemical Engineers Biotechnol. Prog., 2009     

Case study and application of process analytical technology (PAT) towards bioprocessing: II. Use of ultra-performance liquid chromatography (UPLC) for making real-time pooling decisions for process chromatography

Process analytical technology (PAT) has been gaining a lot of momentum in the biopharmaceutical community due to the potential for continuous real-time quality assurance resulting in improved operational control and compliance. Two of the key goals that have been outlined for PAT are "variability is managed by the process" and "product quality attributes can be accurately and reliably predicted over the design space established for materials used, process parameters, manufacturing, environmental, and other conditions". Recently, we have been examining the feasibility of applying different analytical tools for designing PAT applications for bioprocessing. We have previously shown that a commercially available online high performance liquid chromatography (HPLC) system can be used for analysis that can facilitate real-time decisions for column pooling based on product quality attributes (Rathore et al., 2008). In this article we test the feasibility of using a commercially available ultra- performance liquid chromatography (UPLC) system for real-time pooling of process chromatography columns. It is demonstrated that the UPLC system offers a feasible approach and meets the requirements of a PAT application. While the application presented here is of a reversed phase assay, the approach and the hardware can be easily applied to other modes of liquid chromatography.     

A novel and fully scalable Agrobacterium spray‐based process for manufacturing cellulases and other cost‐sensitive proteins in plants

Transient transfection of plants by vacuum infiltration of Agrobacterium vectors represents the state of the art in plant‐based protein manufacturing; however, the complexity and cost of this approach restrict it to pharmaceutical proteins. We demonstrated that simple spraying of Nicotiana plants with Agrobacterium vectors in the presence of a surfactant can substitute for vacuum inoculation. When the T‐DNA of Agrobacterium encodes viral replicons capable of cell‐to‐cell movement, up to 90% of the leaf cells can be transfected and express a recombinant protein at levels up to 50% of total soluble protein. This simple, fast and indefinitely scalable process was successfully applied to produce cellulases, one of the most volume‐ and cost‐sensitive biotechnology products. We demonstrate here for the first time that representatives of all hydrolase classes necessary for cellulosic biomass decomposition can be expressed at high levels, stored as silage without significant loss of activity and then used directly as enzyme additives. This process enables production of cellulases, and other potential high‐volume products such as noncaloric sweetener thaumatin and antiviral protein griffithsin, at commodity agricultural prices and could find broad applicability in the large‐scale production of many other cost‐sensitive proteins.     

An enzymatic process for the production of the pharmacologically active glycoside desglucodesrhamnoruscin from Ruscus aculeatus L.

The pharmacological properties of the extract of Ruscus aculeatus L. have been well established for many years now. The compounds which possess these properties are the steroid glycosides ruscin and ruscoside and their hydrolysis products desglucoruscin, desglucodesrhamnoruscin and desglucoruscoside. As the pharmacological action increases with the decrease of the amount of the sugar molecules, the plant extracts must be submitted to chemical or enzyme hydrolysis in order to obtain the most active compounds.

In our laboratory, a bioconversion process to produce the monoglycoside desglucodesrhamnoruscin from dry extracts of the rhizome of R. aculeatus has been developed using enzyme preparations containing a β-glucopyranosidase and an -rhamnopyranosidase. Identifying the concentrations of substrate, enzyme and ethanol that are most advantageous for the bioconversion has optimized the process. The developed process gave a final product containing 19% of desglucodesrhamnoruscin.     

Chemometrics applications in biotech processes: assessing process comparability

A typical biotech process starts with the vial of the cell bank, ends with the final product and has anywhere from 15 to 30 unit operations in series. The total number of process variables (input and output parameters) and other variables (raw materials) can add up to several hundred variables. As the manufacturing process is widely accepted to have significant impact on the quality of the product, the regulatory agencies require an assessment of process comparability across different phases of manufacturing (Phase I vs. Phase II vs. Phase III vs. Commercial) as well as other key activities during product commercialization (process scale-up, technology transfer, and process improvement). However, assessing comparability for a process with such a large number of variables is nontrivial and often companies resort to qualitative comparisons. In this article, we present a quantitative approach for assessing process comparability via use of chemometrics. To our knowledge this is the first time that such an approach has been published for biotech processing. The approach has been applied to an industrial case study involving evaluation of two processes that are being used for commercial manufacturing of a major biosimilar product. It has been demonstrated that the proposed approach is able to successfully identify the unit operations in the two processes that are operating differently. We expect this approach, which can also be applied toward assessing product comparability, to be of great use to both the regulators and the industry which otherwise struggle to assess comparability.     

黄土丘陵半干旱区柠条林株高生长过程新模型

黄土丘陵半干旱区柠条林的株高生长不随时间单调增加,在生长末期因生长动力小于生长阻力,株高随时间小幅度减小。采用宁夏固原上黄生态站柠条林的生长观测资料,以经典Logistic方程为基础,添加了生长阻力因素,建立了柠条林生长的改进模型,使得生长速率在生长末期出现负值;并以高密度柠条成林多年生长观测数据为依据,建立了连年生长模型。用数学建模和统计检验的方法对数据进行处理,其结果表明,改进模型较Logistic方程具有更高的拟合度和相关系数。建立的模型与传统生长方程不同,由于微分方程中引入了阻力因子,故生长曲线中存在极值坐标且不具有严格单调性。将多年的株高生长曲线综合到一个坐标系内后,新模型中位置参数a与内禀生长率b的比值随着生长呈现逐渐增大的趋势。改进模型的生长顶点出现在8月,与柠条林株高的实际生长过程吻合;计算了新模型的生长顶点与生长期结束时的株高的差值,并将该值记为生长损失。由于柠条林的灌丛较为矮小,在越冬时干梢现象对株高的影响不可忽略,该过程导致生长方程中第二年初始点小于第一年最末点;在考虑了该现象后所建立的连年生长模型中,2002年和2003年干稍现象的终止点位于2月,与植物生长的节律吻合。本研究为描述半干旱区灌木林生长过程提供了依据。     

Evolution and current status of the phytochemistry of nitrogenous compounds

Nitrogen-containing and other secondary plant products have evolved as a consequence of the struggle between the plant and the animal kingdoms, the latter directly or indirectly thriving on plants. During evolution plants developed bioactive and exceedingly complicated chemical structures that serve the purpose of plant defense. It is this property of those plants that has been exploited by mankind as medicines, poisons and recreational drugs. Three classes of nitrogen-containing plant products are being reviewed in this article: the alkaloids, the cyanogenic glucosides/glucosinolates and the nonprotein amino acids. It is the interplay of different scientific disciplines such as chemistry, pharmacognosy, medicine, analytics, cell biology, molecular biology, botany and chemotaxonomy that form a new and exciting area called "phytochemistry". It is foreseeable that this integration of disciplines across traditional borders will bring new achievements in phytochemistry, as history has taught us already.     

LCA Case Study of zinc hydro and pyro-metallurgical process in China

Goal, Scope and Background  China is one of the main producers of metallic zinc and its annual production has been becoming the largest in the world since the year 2000. To improve the environmental situation of zinc production in China, a life cycle assessment was performed for hydro and pyro-metallurgical processes, based on the case study of Zhuzhou Smelter and Shaoguan metallurgical plant, respectively. Methods  The system is modeled into several sub-modules so as to identify the source of environmental impacts. Results and Discussion  The main results of LCA study are summarized as follows: (1) Hydro-metallurgical process is superior to pyro-metallurgical process in GWP and inferior to pyro-metallurgical process in GER and ACP. (2) Compared with the advanced foreign zinc metallurgical process, the GWP, ACP and HME of the zinc metallurgical process in China are much higher. (3) In hydro-metallurgical processes, residue treatment and auxiliary processes are the main contributors of ACP and GWP, which are the key sub-modules, and should be improved. In pyro-metallurgical processes, the main sub-modules needing improvement are smelting, power and electricity generation. (4) Electricity is the main energy consumption in the hydro-metallurgical processes, accounting for 60% of GER. In pyro-metallurgical process, main energy sources are metallurgical coke and anthracite, both also accounting for 60% of GER. Conclusions  According to the discovery of LCA study, three main measures to improve the environmental performance of zinc products were proposed: 1) Regulating the structure of energy sources of Shaoguan Smelter, 2) removing SO^b2 in low concentration from flue gas by absorption with zinc oxide, and 3) adjusting the material structure of Walze rotary furnace.     

Computer-aided process analysis and economic evaluation for biosynthetic human insulin production-A case study

Human insulin was the first mammalian protein produced in bacteria using recombinant DNA technology. Two technologies were developed; the first based on the separate expression of precursors of chains A and B of insulin, and the second based on the expression of a precursor of proinsulin as a Trp-E fusion protein. Both technologies utilized Escherichia coli as an expression system. Later, a third technology was developed based on a strain of yeast that can secrete a precursor of insulin. The second E. coli process, a variation of which has been commercialized by Eli Lilly and Co., is analyzed in this article from a process design and economic evaluation viewpoint. The objective of this work is to elucidate the technical complexity and high cost associated with the manufacturing of biopharmaceuticals. Human insulin is a good example of a protein-based biopharmaceutical produced in large quantities (a fex tons per year) that requires large scale equipment and presents a multitude of scale-up challenges. Based onthe analysis, a number of conclusions are drawn regarding the cost breakdown and cost dependency on process parameters. Recommendations are made for cost reduction and environmental impact minimization. This analysis was performed using a software tool for computer-aided bioprocess design. (c) 1995 John Wiley & Sons, Inc.     

Plant species potentially useful in the phytostabilization process for the abandoned CMC mining site in northern Cyprus

The Cupper Mining Company (CMC)'s site located in Lefke-Gemikonagi, Northern Cyprus has been a continuous source of highly dangerous contamination for the surrounding environment, the Lefke region, and the neighboring ecosystems and settlements. Rehabilitation and reuse possibilities of the CMC site due to its vital importance have kept its place in the agenda of Northern Cyprus. Phytostabilization appears to be a convenient and less expensive method that can immediately be used for reducing the negative impacts of the mining site on the region. The main purpose of this study is to identify potential candidate plant species, adapted to grow on polluted sites, for revegetation in the CMC site. Within this context, the method of the study can be summarized as follows: literature review for examining potential candidate plant species for pyhtostabilization in arid and semiarid regions, especially the ones suitable both for the existing ecological and present conditions of Cyprus; identification of native and/or cultural plant species survived in the heavily polluted mining site, and definition of a number of candidate plant species for the study site. The result of sampling revealed that 23 plant species thrive well in the contaminated site. As a result of the literature review and considering drought, metal, salt tolerant features of semiarid environment in the region, 5 tree, 4 shrub, and 23 herbaceous plant species were proposed for starting revegetation with the purpose of phytostabilization on the CMC mining site.     

Startup of anaerobic fluidized bed reactors with acetic acid as the substrate

The startup of anaerobic fluidized bed reactors, which use Manville R-633 beads as the growth support media, acetate enriched bacterial culture as the inoculum, and acetic acid as the sole substrate, is studied. Tow startup strategies are evaluated: one based on maximum and stable substrate utilization and another based on maximum substrate loading controlled by reactor pH. The startup process is characterized using a number of operational parameters.The reactors again excellent total organic carbon (TOC) removal (i.e., > 97% at a feed concentration of 5000 mg TOC/L) and stable methane production (i.e., 0.90 L CH(4)/g TOC, where TOC(r) is TOC removed) at a early stage of the startup process, regardless of the strategies applied. The loading can be increased rapidly without the danger of being overloaded. Significant losses of growth support media and biomass caused by gas effervescence at higher loadings limits the maximum loading that can be safely applied during startup process.A high reactor immobilized biomass inventory is achievable using the porous growth support media (e.g., Manville 633 beads). A rapid increase in loading creates a substrate rich environment that yields more viable reactor biomass. Both substrate utilization rate (batch and continuous) and immobilized biomass inventory stabilize concomitantly at the late stage of the startup process, indicating the attainment of steady-state conditions in reactors. Therefore, they are better parameters that TOC removal and methane production for characterizing the entire startup process of aerobic fluidized bed reactor.The strategy based on maximum substrate loading controlled by reactor pH significantly shortens the startup time. In this case, the reactor attains steady-state conditions approximately 140 days after startup. On the other hand, a startup time of 200 days is required when the strategy based maximum substrate utilization is adopted. (c) 1993 John Wiley & Sons, Inc.     

A Genomic and Molecular View of Wood Formation

Wood formation is a process derived from plant secondary growth. Different from primary growth, plant secondary growth is derived from cambium meristem cells in the vascular and cork cambia and leads to the girth increase of the plant trunk. In the secondary growth process, plants convert most of photosynthesized products into various biopolymers for use in the formation of woody tissues. This article summarizes the new developments of genomic and genetic characterization of wood formation in herbaceous model plant and tree plant systems. Genomic studies have categorized a collection of the genes for which expression is associated with secondary growth. During wood formation, the expression of many genes is regulated in a stage-specific manner. The function of many genes involved in wood biosyntheses and xylem differentiation has been characterized. Although great progress has been achieved in the molecular and genomic understanding of plant secondary growth in recent years, the profound genetic mechanisms underlying this plant development remain to be investigated. Completion of the first tree genome sequence (Populus genome) provides a valuable genomic resource for characterization of plant secondary growth.     

Acclimation Strategy of a Biohydrogen Producing Population in a Continuous‐Flow Reactor with Carbohydrate Fermentation

Poor startup of biological hydrogen production systems can cause an ineffective hydrogen production rate and poor biomass growth at a high hydraulic retention time (HRT), or cause a prolonged period of acclimation. In this paper a new startup strategy was developed in order to improve the enrichment of the hydrogen‐producing population and the efficiency of hydrogen production. A continuously‐stirred tank reactor (CSTR) and molasses were used to evaluate the hydrogen productivity of the sewage sludge microflora at a temperature of 35 °C. The experimental results indicated that the feed to microorganism ratio (F/M ratio) was a key parameter for the enrichment of hydrogen producing sludge in a continuous‐flow reactor. When the initial biomass was inoculated with 6.24 g of volatile suspended solids (VSS)/L, an HRT of 6 h, an initial organic loading rate (OLR) of 7.0 kg chemical oxygen demand (COD)/(m³ × d) and an feed to microorganism ratio (F/M) ratio of about 2–3 g COD/(g of volatile suspended solids (VSS) per day) were maintained during startup. Under these conditions, a hydrogen producing population at an equilibrium state could be established within 30 days. The main liquid fermentation products were acetate and ethanol. Biogas was composed of H₂ and CO₂. The hydrogen content in the biogas amounted to 47.5 %. The average hydrogen yield was 2.01 mol/mol hexose consumed. It was also observed that a special hydrogen producing population was formed when this startup strategy was used. It is supposed that the population may have had some special metabolic pathways to produce hydrogen along with ethanol as the main fermentation products.     

Application of Raman spectroscopy in monoclonal antibody producing continuous systems for downstream process intensification

Monoclonal antibodies (mAbs) are biopharmaceuticals produced by mammalian cell lines in bioreactors at a variety of scales. Cell engineering, media optimization, process monitoring, and control strategies for in vitro production have become crucial subjects to meet increasing demand for these high value pharmaceuticals. Raman Spectroscopy has gained great attention in the pharmaceutical industry for process monitoring and control to maintain quality assurance. For the first time, this article demonstrated the possibility of subclass independent quantitative mAb prediction by Raman spectroscopy in real time. The developed model estimated the concentrations of different mAb isotypes with average prediction errors of 0.2 (g/L) over the course of cell culture. In situ Raman spectroscopy combined with chemometric methods showed to be a useful predictive tool for monitoring of real time mAb concentrations in a permeate stream without sample removal. Raman spectroscopy can, therefore, be considered as a reliable process analytical technology tool for process monitor, control, and intensification of downstream continuous manufacturing. The presented results provide useful information for pharmaceutical industries to choose the most appropriate spectroscopic technology for their continuous processes.     

Electrofusion of cells: principles and industrial potential

Short electric field pulses of high intensity can be used for cell manipulation, genetic engineering and cell fusion. Animal, plant and microbial cells have been fused by this process. The technique may also come to be employed to increase the permeability of membranes to specific products, thus facilitating their recovery from fermentation media.