一种新型助滤剂在血液制品生产中的应用研究

目的:探讨新型硅藻土用于血液制品组份分离过滤的适用性。方法:对比新型硅藻土与传统硅藻土的电镜扫描物理结构、金属离子含量、比表面积、离心湿密度等物理表征数据,并考察其在血浆蛋白分离阶段各组份过滤效果及最终产品的质量。结果:新型硅藻土与传统硅藻土比较,具有颗粒孔隙致密、金属离子含量低、比表面积大和离心湿密度小的特点;在血浆蛋白分离阶段的过滤过程中,按照传统硅藻土用量的70%左右使用新型硅藻土时,过滤时可得到理想的滤液浊度、较快的过滤速率、更小的过滤压力和均匀的滤饼分布;所得最终产品的质量符合《中国药典》及公司内控标准。结论:新型硅藻土可替代传统硅藻土用于血液制品的规模化生产,同时降低使用量。该应用研究对于降低血液制品的生产成本和提高产品质量具有一定的实际应用价值和参考意义。     

Development of a novel disposable filter bag for separation of biomolecules with functionalized magnetic particles

The integration of disposable magnetic filters in combination with functionalized magnetic particles represents a fast and cost‐effective alternative for enzyme purification in comparison to solid/liquid separation by means of centrifugation followed by chromatographic purification. The main advantage of the particle‐based process is the solid/solid/liquid separation in one step combined with disposable equipment. Furthermore this combination provides the possibility to also process biocatalytic reactions in cell‐containing media into disposable equipment with preimmobilized enzymes onto the magnetic particles. The focus of the presented study is on the design and performance of a disposable filtration unit consisting of a plastic bag with an inlet and outlet and a stainless steel filter matrix. During magnetic separation, the magnetic particles selectively retard at the filter matrix due to the magnetic force, which counteracts the drag force. It was found that the length of a lengthwise aligned filter matrix should be longer than the magnetic pole surfaces in fluid flow direction. Hereby, a filtration capacity of 5.6 g magnetic particles was measured with a loss of below 0.5%. Introducing a two‐phase flow optimizes the cleaning of the bag after a magnetic filtration. The procedure offered a high cleaning efficiency. Herewith, the cleaned filter unit could be discarded with minimum losses of product and magnet particles.     

A new method for yeast recovery in batch ethanol fermentations: Filter aid filtration followed by separation of yeast from filter aid using hydrocyclones

In the Melle-Boinot process for alcohol production, centrifuges are normally used for yeast recovery at the end of a batch fermentation. Centrifuges are expensive equipment and represent an impressive part of the equipment costs in alcohol industries. In the present work, an alternative method for yeast recovery using less expensive equipment was studied. Instead of using centrifuges, yeast was separated from the fermented broth by filter aid filtration, followed by separation of yeast from the filter aid using hydrocyclones. A stainless steel plate-and-frame filter of filtration area 1.14 m² and two 30 mm hydrocyclones, which followed the Bradley and Rietema recommended proportions, were used in this work. The filter aid was perlite. Tests of direct separation of yeast from the fermented broth using the Bradley hydrocyclone proved to be completely unfeasible, since the maximal reduced total efficiency obtained was only 1%. When the hydrocyclones were used to separate perlite from the resuspended filtration cake, the perlite total separation efficiency obtained in the underflow was as high as 95% when using the Bradley hydrocyclone with an underflow diameter of 3 mm. To show the feasibility of the proposed new method of yeast recovery, a complete cycle of experiments, which included fermentation, yeast separation, and new fermentation using the recycled cells, was performed with good results.     

Scale-down of continuous filtration for rapid bioprocess design: Recovery and dewatering of protein precipitate suspensions

The early specification of bioprocesses often has to be achieved with small (tens of millilitres) quantities of process material. If extensive process discovery is to be avoided at pilot or industrial scale, it is necessary that scale-down methods be created that not only examine the conditions of process stages but also allows production of realistic output streams (i.e., streams truly representative of the large scale). These output streams can then be used in the development of subsequent purification operations. The traditional approach to predicting filtration operations is via a bench-scale pressure filter using constant pressure tests to examine the effect of pressure on the filtrate flux rate and filter cake dewatering. Interpretation of the results into cake resistance at unit applied pressure (alpha) and compressibility (n) is used to predict the pressure profile required to maintain the filtrate flux rate at a constant predetermined value. This article reports on the operation of a continuous mode laboratory filter in such a way as to prepare filter cakes and filtrate similar to what may be achieved at the industrial scale. Analysis of the filtration rate profile indicated the filter cake to have changing properties (compressibility) with time. Using the insight gained from the new scale-down methodology gave predictions of the flux profile in a pilot-scale candle filter superior to those obtained from the traditional batch filter used for laboratory development.     

Protein fouling during constant-flux virus filtration: Mechanisms and modeling

As biomanufacturers consider the transition from batch to continuous processing, it will be necessary to re-examine the design and operating conditions for many downstream processes. For example, the integration of virus removal filtration in continuous biomanufacturing will likely require operation at low and constant filtrate flux instead of the high (constant) transmembrane pressures (TMPs) currently employed in traditional batch processing. The objective of this study was to examine the effect of low operating filtrate flux (5–100 L/m²/h) on protein fouling during normal flow filtration of human serum Immunoglobulin G (hIgG) through the Viresolve® Pro membrane, including a direct comparison of the fouling behavior during constant-flux and constant-pressure operation. The filter capacity, defined as the volumetric throughput of hIgG solution at which the TMP increased to 30 psi, showed a distinct minimum at intermediate filtrate flux (around 20–30 L/m²/h). The fouling data were well-described using a previously-developed mechanistic model based on sequential pore blockage and cake filtration, suitably modified for operation at constant flux. Simple analytical expressions for the pressure profiles were developed in the limits of very low and high filtrate flux, enabling rapid estimation of the filter performance and capacity. The model calculations highlight the importance of both the pressure-dependent rate of pore blockage and the compressibility of the protein cake to the fouling behavior. These results provide important insights into the overall impact of constant-flux operation on the protein fouling behavior and filter capacity during virus removal filtration using the Viresolve® Pro membrane.     

Filtration of a yeast suspension using an enclosed microporous metal filter

Summary A microporous (3 m) metal filter was very efficient for the recovery of Saccharomyces cerevisiae from a suspension. The filtration could be described by a cake filtration model, the cake resistance being dependent on the pressure drop applied and the concentration of bodyfeed added. The mean filtration capacity was 0.4 m³/m² h.     

Artificial neural network (ANN)‐based prediction of depth filter loading capacity for filter sizing

This article presents an application of artificial neural network (ANN) modelling towards prediction of depth filter loading capacity for clarification of a monoclonal antibody (mAb) product during commercial manufacturing. The effect of operating parameters on filter loading capacity was evaluated based on the analysis of change in the differential pressure (DP) as a function of time. The proposed ANN model uses inlet stream properties (feed turbidity, feed cell count, feed cell viability), flux, and time to predict the corresponding DP. The ANN contained a single output layer with ten neurons in hidden layer and employed a sigmoidal activation function. This network was trained with 174 training points, 37 validation points, and 37 test points. Further, a pressure cut‐off of 1.1 bar was used for sizing the filter area required under each operating condition. The modelling results showed that there was excellent agreement between the predicted and experimental data with a regression coefficient (R²) of 0.98. The developed ANN model was used for performing variable depth filter sizing for different clarification lots. Monte‐Carlo simulation was performed to estimate the cost savings by using different filter areas for different clarification lots rather than using the same filter area. A 10% saving in cost of goods was obtained for this operation. © 2016 American Institute of Chemical Engineers Biotechnol. Prog., 32:1436–1443, 2016     

Comparison of different options for harvest of a therapeutic protein product from high cell density yeast fermentation broth

Recovery of therapeutic protein from high cell density yeast fermentations at commercial scale is a challenging task. In this study, we investigate and compare three different harvest approaches, namely centrifugation followed by depth filtration, centrifugation followed by filter-aid enhanced depth filtration, and microfiltration. This is achieved by presenting a case study involving recovery of a therapeutic protein from Pichia pastoris fermentation broth. The focus of this study is on performance of the depth filtration and the microfiltration steps. The experimental data has been fitted to the conventional models for cake filtration to evaluate specific cake resistance and cake compressibility. In the case of microfiltration, the experimental data agrees well with flux predicted by shear induced diffusion model. It is shown that, under optimal conditions, all three options can deliver the desired product recovery ( >80%), harvest time ( <15 h including sequential concentration/diafiltration step), and clarification ( <6 NTU). However, the three options differ in terms of process development time required, capital cost, consumable cost, ease of scale-ability and process robustness. It is recommended that these be kept under consideration when making a final decision on a harvesting approach.     

Stability of fatty acid monolayers and the relationship between equilibrium spreading pressure, phase transformations, and polymorphic crystal forms

Force-area isotherms were obtained for hexadecanoic, octadecanoic, eicosanoic, and docosanoic acid monolayers at different compression rates. Equilibrium spreading pressures were determined both by monolayer collapse and by spreading from the bulk phase. Monolayers formed metastable phases at all pressures above their equilibrium spreading pressures and at all surface areas smaller than the surface areas at their equilibrium spreading pressures. These metastable phases collapsed to stable phases at the equilibrium spreading pressures of the fatty acids. Collapse phenomena and compression experiments at very slow compression rates suggested that a previously unrecognized phase transformation occurred at the equilibrium spreading pressure. The surface area at this phase transformation corresponded to the cross-sectional area of the C-form of the fatty acid crystal. Fatty acid monolayers at the phase transformations previously described by other workers had surface areas which were closely related to molecular areas in their A and B polymorphic crystal forms. These correlations indicated that molecular structure in saturated fatty acid monolayers was similar to molecular structure in fatty acid crystals.     

Automated fast filtration and on‐filter quenching improve the intracellular metabolite analysis of microorganisms

To reliably determine intracellular metabolite concentrations in microorganisms, accurate sampling and sample inactivation strategies are crucial. Here, we present a method for automated fast filtration and on‐filter quenching of microbial samples to overcome metabolite leakage induced by cold shock and significantly reduce the sampling and treatment time compared to manual filtration methods. The whole process of sampling, sample filtration, filter wash, and quenching of the filter with liquid nitrogen was finished in less than 6–15 s, depending on the experimental setup. By integration into an automated fast sampling device, we compared our method to the conventional methanol quenching method and showed that intracellular amino acid contents in Escherichia coli were significantly increased (≥75%) with our fast filtration and on‐filter quenching method. Furthermore, we investigated different filter types for the fast filtration and the efficiency of metabolite extraction from cells held on filters. Additionally, we found that the fast filtration behaves considerably different during exponential and nonexponential growth, probably due to variations of cell morphologies. Overall, we demonstrated that the automation of the fast filtration method significantly reduces the time for filtration and quenching and hence enlarge the number of metabolites that can be quantified with this leakage‐free sampling method.     

Sphingomyelin interfacial behavior: the impact of changing acyl chain composition

Sphingomyelins (SMs) containing homogeneous acyl chains with 12, 14, 16, 18, 24, or 26 carbons were synthesized and characterized using an automated Langmuir-type film balance. Surface pressure was monitored as a function of lipid molecular area at constant temperatures between 10 degrees C and 30 degrees C. SM containing lauroyl (12:0) acyl chains displayed only liquid-expanded behavior. Increasing the length of the saturated acyl chain (e.g., 14:0, 16:0, or 18:0) resulted in liquid-expanded to condensed two-dimensional phase transitions at many temperatures in the 10-30 degrees C range. Similar behavior was observed for SMs with lignoceroyl (24:0) or (cerotoyl) 26:0 acyl chains, but isotherms showed only condensed behavior at 10 and 15 degrees C. Insights into the physico-mechanical in-plane interactions occurring within the different SM phases and accompanying changes in SM phase state were provided by analyzing the interfacial area compressibility moduli. At similar surface pressures, SM fluid phases were less compressible than those of phosphatidylcholines with similar chain structures. The area per molecule and compressibility of SM condensed phases depended upon the length of the saturated acyl chain and upon spreading temperature. Spreading of SMs with very long saturated acyl chains at temperatures 30-35 degrees below T(m) resulted in condensed films with lower in-plane compressibilities, but consistently larger cross-sectional molecular areas than the condensed phases achieved by spreading at temperatures only 10-20 degrees below T(m). This behavior is discussed in terms of the enhancement of SM lateral aggregation by temperature reduction, a common approach used during domain isolation from biomembranes.     

Co-composting of filter cake and bagasse; by-products from a sugar mill

Thailand has nearly 2 million tonnes of filter cake waste containing 1.8% total N from the sugar cane industry to dispose of annually. Compost studies were conducted to determine how rapidly this material can be converted to a stable product that may be useful in crop production, and to characterize the N transformations. Two kinds of sugar mill by-products were composted, filter cake and filter cake mixed with bagasse, at a 2:1 ratio to reduce the C:N ratio in an attempt to reduce N loss during composting. Materials were mixed manually at 3-5 day intervals during the composting process. Both composts were analyzed at least weekly to measure temperature, pH, NH4+, NO3-, total N content, C loss, and germination index. For both mixtures, the thermophilic stage lasted 15-20 days and was higher than ambient for nearly 80 days. The degradation of organic matter (OM) was rapid in both mixtures to approximately 40 days, after which it began to stabilize. Both mixtures achieved maturity at approximately 90 days as indicated by a stable C/N, low NH4+/NO3-, lack of heat production and a germination index higher than 80%. Mixing filter cake with bagasse helped conserve N during composting. Because N was in excess, approximately 12-15% was lost from the composts. Mixing more bagasse with the filter cake may result in further reduction in N losses. Both composts have potential for use in crop production.     

膜前助滤预处理对高藻水微滤膜污染的影响研究

研究采用添加硅藻土、植物棉、活性炭等3种不同预处理手段来过滤铜绿微囊藻,并考察未预处理及预处理后的藻液过滤过程中的过滤特性、有机物分布及膜污染特性。结果表明, 3种预处理手段对过滤通量均有所提高并减缓膜污染。其中,硅藻土预处理提高平均过滤通量达915%,明显优于其他助滤手段。活性炭预处理能够有效吸附芳香族蛋白质类荧光污染物,显著降低污染膜的不可逆化学污染阻力。通过OCT及SEM分析可知未预处理的高藻水直接过滤造成的膜污染最严重,饼层结构的粗糙度最低并且厚度也最小,而硅藻土通过优化饼层结构以达到缓解膜污染的效果。最后基于XDLVO理论结果也进一步证实硅藻土预处理手段对改善膜污染效果最好。研究结果对未来蓝藻水华膜处理技术的预处理手段研发具有指导意义。     

The validity of the cholesterol nucleation assay.

The validity of the cholesterol nucleation assay rests on the assumption that all cholesterol crystals are removed at the start of the assay so that de novo formation of crystals can be studied. In this paper we have tested the validity of this assumption. Cholesterol crystals were added to supersaturated model bile. Subsequently the mixtures were either filtered over a 0.22 micron filter or centrifuged at 37 degrees C for 2 h at 100,000 x g. After ultracentrifugation the isotropic interphase was collected. Using polarized light microscopy no crystals could be visualized in this fraction. However, the nucleation time of the isotropic interphase decreased from 6.8 +/- 1.1 days to 1.8 +/- 0.2 days (mean +/- S.E., P less than 0.01, n = 5) when 10-100 micrograms/ml crystals were added prior to centrifugation. Similar results were observed when instead of centrifugation the mixtures containing crystals were filtered. After filtration over a 0.22 micron filter no crystals could be detected in the filtrate. Yet the nucleation time of the filtrate decreased from 6.4 +/- 0.7 days to 3.1 +/- 0.5 days (mean +/- S.E.) when 10 micrograms/ml cholesterol crystals were added before filtration (n = 10, P less than 0.01). Since no cholesterol crystals could be detected at the start of the assay the reduction in nucleation time must have been brought about by cholesterol microcrystals that passed through the filter. Supplementation of cholesterol crystals to model bile did not accelerate the nucleation time when the samples were passed over a 0.02 micron filter, indicating that the size of the microcrystals was larger than 20 nm. The effect of addition of cholesterol crystals prior to filtration over a 0.22 micron filter was also tested in the crystal growth assay recently developed by Busch et al. ((1990) J. Lipid Res. 31, 1903-1909). Addition of crystals had only a minor effect on the assay. In conclusion, the reduced nucleation time of biles from gallstone patients is probably not only due to the presence of promoting or the absence of inhibiting proteins, but can be caused by the presence of small cholesterol crystals in these biles.     

Robust depth filter sizing for centrate clarification

Cellulosic depth filters embedded with diatomaceous earth are widely used to remove colloidal cell debris from centrate as a secondary clarification step during the harvest of mammalian cell culture fluid. The high cost associated with process failure in a GMP (Good Manufacturing Practice) environment highlights the need for a robust process scale depth filter sizing that allows for (1) stochastic batch‐to‐batch variations from filter media, bioreactor feed and operation, and (2) systematic scaling differences in average performance between filter sizes and formats. Matched‐lot depth filter media tested at the same conditions with consecutive batches of the same molecule were used to assess the sources and magnitudes of process variability. Depth filter sizing safety factors of 1.2–1.6 allow a filtration process to compensate for random batch‐to‐batch process variations. Matched‐lot depth filter media in four different devices tested simultaneously at the same conditions was used with a common feed to assess scaling effects. All filter devices showed <11% capacity difference and the Pod format devices showed no statistically different capacity differences. © 2015 American Institute of Chemical Engineers Biotechnol. Prog., 31:1542–1550, 2015     

Robust scale-up of dead end filtration: impact of filter fouling mechanisms and flow distribution

Robust design of a dead end filtration step and the resulting performance at manufacturing scale relies on laboratory data collected with small filter units. During process development it is important to characterize and understand the filter fouling mechanisms of the process streams so that an accurate assessment can be made of the filter area required at manufacturing scale. Successful scale-up also requires integration of the lab-scale filtration data with an understanding of flow characteristics in the full-scale filtration equipment. A case study is presented on the development and scale-up of a depth filtration step used in a 2nd generation polysaccharide vaccine manufacturing process. The effect of operating parameters on filter performance was experimentally characterized for a diverse set of process streams. Filter capacity was significantly reduced when operating at low fluxes, caused by both low filtration pressure and high stream viscosity. The effect of flux on filter capacity could be explained for a variety of diverse streams by a single mechanistic model of filter fouling. To complement the laboratory filtration data, the fluid flow and distribution characteristics in manufacturing-scale filtration equipment were carefully evaluated. This analysis identified the need for additional scale-up factors to account for non-uniform filter area usage in large-scale filter housings. This understanding proved critical to the final equipment design and depth filtration step definition, resulting in robust process performance at manufacturing scale.     

Dewatering of algal suspension using microfiltration with cross flow in the presence of magnetite as a filter aid

Dewatering algal suspensions is an important step in the extraction of oil and other useful substances from algae. In this study, spherical Nannochloropsis sp. and ellipsoidal Monoraphidium sp. suspensions were dewatered in the presence of different amounts of 350-nm magnetite particles using a microfiltration membrane with 360-nm pores in cross-flow mode. Magnetite functions as a filter aid by reducing the deformation of the cake of filtered algae on the membrane and providing paths for water to flow through the filtration cake of algae. In the case of Nannochloropsis sp., the highest dewatering rate was obtained when the number ratio, defined based on the size and ideal density, between Nannochloropsis sp. and magnetite was 1:12.5, but the addition of magnetite had no observable effect on the filtration of ellipsoidal Monoraphidium sp. suspensions through the membrane. After dewatering, magnetite was effectively separated from the concentrated algal suspension by the application of a magnetic field in an open flow system. Magnetite has the potential to enhance dewatering performance using a cross-flow membrane system.     

Consolidation of Soybean Protein Coagulate

The process of dehydration of soybean protein coagulate in expression involves two mechanisms, filtration and consolidation. The filtration process was explained by Ruth’s filtration model. The consolidation process, except for secondary consolidation, was analyzed by the modified consolidation model of Shirato et al., taking into account the compressibility of cake. The modified coefficient of consolidation was not affected significantly by the pressure applied. Evaluation of the modified coefficient of consolidation is of importance for an attempt to improve the current production of soybean protein.     

Drum filter performance in a recirculating eel culture unit

The performance of a drum filter of a recirculating eel culture unit was studied. Electron microscopy scanning micrographs of drum filter panels showed a high degree of clogging of the filter mesh (after 4 months of operation). Mean removal efficiency for Total Suspended Solids (TSS) fluctuated considerably between subsequent sampling periods (9.6–18.4%). Drum filtration changed the particle size distribution of fish tank drainage water, resulting in increasing amounts (from 56 to 67% of dry weight, before and after filter passage) of the smaller particle fractions (< 20 μm), thereby indicating a partial breakdown of larger particles during the filtration process. Possible reasons for rapid filter clogging and suggestions for improvements in filter performance are discussed.     

The validity of the cholesterol nucleation assay

The validity of the cholesterol nucleation assay rests on the assumption that all cholesterol crystals are removed at the start of the assay so that de novo formation of crystals can be studied. In this paper we have tested the validity of this assumption. Cholesterol crystals were added to supersaturated model bile. Subsequently the mixtures were either filtered over a 0.22 μm filter or centrifuged at 37°C for 2 h at 100 000 × g. After ultracentrifugation the isotropic interphase was collected. Using polarized light microscopy no crystals could be visualized in this fraction. However, the nucleation time of the isotropic interphase decreased from 6.8 ± 1.1 days to 1.8 ± 0.2 days (mean ± S.E., P < 0.01, n = 5) when 10–100 μg/ml crystals were added prior to centrifugation. Similar results were observed when instead of centrifugation the mixtures containing crystals were filtered. After filtration over a 0.22 μm filter no crystals could be detected in the filtrate. Yet the nucleation time of the filtrate decreased from 6.4 ± 0.7 days to 3.1 ± 0.5 days (mean ± S.E.) when 10 μg/ml cholesterol crystals were added before filtration (n = 10, P < 0.01). Since no cholesterol crystals could be detected at the start of the assay the reduction in nucleation time must have been brought about by cholesterol microcrystals that passed through the filter. Supplementation of cholesterol crystals to model bile did not accelerate the nucleation time when the samples were passed over a 0.02 μm filter, indicating that the size of the microcrystals was larger than 20 nm. The effect of addition of cholesterol crystals prior to filtration over a 0.22 μm filter was also tested in the crystal growth assay recently developed by Busch et al. ((1990) J. Lipid Res. 31, 1903–1909). Addition of crystals had only a minor effect on the assay. In conclusion, the reduced nucleation time of biles from gallstone patients is probably not only due to the presence of promoting or the absence of inhibiting proteins, but can be caused by the presence of small cholesterol crystals in these biles.