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1.
This paper demonstrates a simple graphical approach for the design and analysis of a bioprocess flowsheet in which process interactions are significant. Results are presented showing how the feasible space for operation can be simulated and used both to address key design and operating decisions and to identify suitable trade-offs between operating variables, such as fermentation growth rate and disruption conditions, in order to achieve prespecified levels of process performance. Using verified models to describe the production and isolation of an intracellular protein alcohol dehydrogenase (ADH) in yeast as a test bed, a series of so-called "windows of operation" are developed at growth rates in the range of 0.06-0.28 h(-1) and for a range of overall process specifications. The effects of altering the process design performance specification as defined by the level of cell debris removal and the overall process productivity on the size and position of the feasible space were investigated to demonstrate the sensitivity of the flowsheet to changes in process objectives. Using the approach it has been possible to visualise the processing trade-offs required to increase performance in terms of the level of cell debris removal by 50% and the overall process productivity by 400% from a defined base level. The approach provides a convenient tool when designing integrated bioprocesses by enabling process options to be compared visually and can help in achieving better process designs and accelerating process development for the biological process industry. 相似文献
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This article describes how a combination of an ultra scale‐down (USD) shear device feeding a microwell centrifugation plate may be used to provide a prediction of how mammalian cell broth will clarify at scale. In particular a method is described that is inherently adaptable to a robotic platform and may be used to predict how the flow rate and capacity (equivalent settling area) of a centrifuge and the choice of feed zone configuration may affect the solids carry over in the supernatant. This is an important consideration as the extent of solids carry over will determine the required size and lifetime of a subsequent filtration stage or the passage of fine particulates and colloidal material affecting the performance and lifetime of chromatography stages. The extent of solids removal observed in individual wells of a microwell plate during centrifugation is shown to correlate with the vertical and horizontal location of the well on the plate. Geometric adjustments to the evaluation of the equivalent settling area of individual wells (ΣM) results in an improved prediction of solids removal as a function of centrifuge capacity. The USD centrifuge settling characteristics need to be as for a range of equivalent flow rates as may be experienced at an industrial scale for a machine of different shear characteristics in the entry feed zone. This was shown to be achievable with two microwell‐plate based measurements and the use of varying fill volumes in the microwells to allow the rapid study of a fivefold range of equivalent flow rates (i.e., at full scale for a particular industrial centrifuge) and the effect of a range of feed configurations. The microwell based USD method was used to examine the recovery of CHO‐S cells, prepared in a 5 L reactor, at different points of growth and for different levels of exposure to shear post reactor. The combination of particle size distribution measurements of the cells before and after shear and the effect of shear on the solids remaining after centrifugation rate provide insight into the state of the cells throughout the fermentation and the ease with which they and accumulated debris may be removed by continuous centrifugation. Hence bioprocess data are more readily available to help better integrate cell culture and cell removal stages and resolve key bioprocess design issues such as choice of time of harvesting and the impact on product yield and contaminant carry over. Operation at microwell scale allows data acquisition and bioprocess understanding over a wide range of operating conditions that might not normally be achieved during bioprocess development. Biotechnol. Bioeng. 2009; 104: 321–331 © 2009 Wiley Periodicals, Inc. 相似文献
4.
The selection of appropriate operating conditions for bioprocessing is complex due to the large number of interacting stages
and variables. Bioprocesses also operate under tight regulation and therefore tools to assist bioprocess design are of significant
utility. Conventional approaches for the analysis of variable sensitivities are inadequate. We propose the use of global sensitivity
analysis to determine the level of importance of each variable and their interactions. Once key variables have been determined,
the designer may focus on the most significant subset. Two case studies are used to demonstrate the applicability of the approach.
Each is based on centrifugation and determines the impact of flow-rate, feed viscosity, density difference and particle size,
while performance is assessed by supernatant clarification. Significant differences in sensitivities were found between the
two studies due to the different feed material properties. Variable sensitivities were found to be system-specific and provide
insight for potential operating strategies. 相似文献
5.
In order to provide sufficient pharmaceutical-grade plasmid DNA material, it is essential to gain a comprehensive knowledge
of the bioprocesses involved; so, the development of protocols and techniques that allow a fast monitoring of process performance
is a valuable tool for bioprocess design. Regarding plasmid DNA production, the metabolic stress of the host strain as well
as plasmid stability have been identified as two of the key parameters that greatly influence plasmid DNA yields. The present
work describes the impact of batch and fed-batch fermentations using different C/N ratios and different feeding profiles on
cell physiology and plasmid stability, investigating the potential of these two monitoring techniques as valuable tools for
bioprocess development and design. The results obtained in batch fermentations showed that plasmid copy number values suffered
a pronounced increase at the end of almost all fermentation conditions tested. Regarding fed-batch fermentations, the strategies
with exponential feeding profiles, in contrast with those with constant feeding, showed higher biomass and plasmid yields,
the maximum values obtained for these two parameters being 95.64 OD600 and 344.3 mg plasmid DNA (pDNA)/L, respectively, when using an exponential feed rate of 0.2 h−1. Despite the results obtained, cell physiology and plasmid stability monitoring revealed that, although higher pDNA overall
yields were obtained, this fermentation exhibited lower plasmid stability and percentage of viable cells. In conclusion, this
study allowed clarifying the bioprocess performance based on cell physiology and plasmid stability assessment, allowing improvement
of the overall process and not only plasmid DNA yield and cell growth. 相似文献
6.
Dr. Maria C. Cuellar Joseph J. Heijnen Luuk A. M. van der Wielen 《Biotechnology journal》2013,8(6):682-689
Industrial biotechnology is playing an important role in the transition to a bio-based economy. Currently, however, industrial implementation is still modest, despite the advances made in microorganism development. Given that the fuels and commodity chemicals sectors are characterized by tight economic margins, we propose to address overall process design and efficiency at the start of bioprocess development. While current microorganism development is targeted at product formation and product yield, addressing process design at the start of bioprocess development means that microorganism selection can also be extended to other critical targets for process technology and process scale implementation, such as enhancing cell separation or increasing cell robustness at operating conditions that favor the overall process. In this paper we follow this approach for the microbial production of diesel-like biofuels. We review current microbial routes with both oleaginous and engineered microorganisms. For the routes leading to extracellular production, we identify the process conditions for large scale operation. The process conditions identified are finally translated to microorganism development targets. We show that microorganism development should be directed at anaerobic production, increasing robustness at extreme process conditions and tailoring cell surface properties. All the same time, novel process configurations integrating fermentation and product recovery, cell reuse and low-cost technologies for product separation are mandatory. This review provides a state-of-the-art summary of the latest challenges in large-scale production of diesel-like biofuels. 相似文献
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Purification of glucose oxidase from Aspergillus niger by liquid-liquid cationic reversed micelles extraction 总被引:1,自引:0,他引:1
The aim of this work was to select the operating conditions for the extraction and recovery of glucose oxidase (GOX) by reversed micelles from mixtures of commercial enzyme and Aspergillus niger homogenates. For this purpose, the influence of the main operating parameters (pH, surfactant concentration, and presence of cell debris or not) on GOX extraction was investigated at 25 degrees C. Without cell debris, the highest yield of GOX activity recovery (90.8%) was obtained performing (a) the forward extraction in isooctane as solvent and hexanol and butanol as cosolvents at 76/6/18 ratio, pH 7.0, 0.2 M cetyl trimethylammonium bromide as cationic surfactant, and electric conductivity of 5.0 mS cm(-1) and (b) the backward extraction at pH 5.5. Forward and backward extractions furnished comparable results when using raw homogenate, which demonstrates a negligible impact of the presence of cell debris on the process. The highest extraction yield (94%) was obtained under the same forward and backward conditions adopted without cell debris. The promising results of this work suggest that the proposed methodology could be profitably exploited at an industrial level. 相似文献
9.
Eduardo C. Lau Simyee Kong Shaun McNulty Claire Entwisle Ann Mcilgorm Kate A. Dalton Mike Hoare 《Biotechnology and bioengineering》2013,110(7):1973-1983
Fusion proteins offer the prospect of new therapeutic products with multiple functions. The primary recovery is investigated of a fusion protein consisting of modified E2 protein from hepatitis C virus fused to human IgG1 Fc and expressed in a Chinese hamster ovary (CHO) cell line. Fusion protein products inevitably pose increased challenge in preparation and purification. Of particular concerns are: (i) the impact of shear stress on product integrity and (ii) the presence of product‐related contaminants which could prove challenging to remove during the high resolution purification steps. This paper addresses the use of microwell‐based ultra scale‐down (USD) methods to develop a bioprocess strategy focused on the integration of cell culture and cell removal operations and where the focus is on the use of operations which impart low shear stress levels even when applied at eventual manufacturing scale. An USD shear device was used to demonstrate that cells exposed to high process stresses such as those that occur in the feed zone of a continuous non‐hermetic centrifuge resulted in the reduction of the fusion protein and also the release of glycosylated intracellular variants. In addition, extended cell culture resulted in release of such variants. USD mimics of low shear stress, hydrohermetic feed zone centrifugation and of depth filtration were used to demonstrate little to no release during recovery of these variants with both results verified at pilot scale. Furthermore, the USD studies were used to predict removal of contaminants such as lipids, nucleic acids, and cell debris with, for example, depth filtration delivering greater removal than for centrifugation but a small (~10%) decrease in yield of the fusion protein. These USD observations of product recovery and carryover of contaminants were also confirmed at pilot scale as was also the capacity or throughput achievable for continuous centrifugation or for depth filtration. The advantages are discussed of operating a lower yield cell culture and a low shear stress recovery process in return for a considerably less challenging purification demand. Biotechnol. Bioeng. 2013; 110: 1973–1983. © 2013 Wiley Periodicals, Inc. 相似文献
10.
Ungrin MD Clarke G Yin T Niebrugge S Nostro MC Sarangi F Wood G Keller G Zandstra PW 《Biotechnology and bioengineering》2012,109(4):853-866
We present a predictive bioprocess design strategy employing cell- and molecular-level analysis of rate-limiting steps in human pluripotent stem cell (hPSC) expansion and differentiation, and apply it to produce definitive endoderm (DE) progenitors using a scalable directed-differentiation technology. We define a bioprocess optimization parameter (L; targeted cell Loss) and, with quantitative cell division tracking and fate monitoring, identify and overcome key suspension bioprocess bottlenecks. Adapting process operating conditions to pivotal parameters (single cell survival and growth rate) in a cell-line-specific manner enabled adherent-equivalent expansion of hPSCs in feeder- and matrix-free defined-medium suspension culture. Predominantly instructive differentiation mechanisms were found to underlie a subsequent 18-fold expansion, during directed differentiation, to high-purity DE competent for further commitment along pancreatic and hepatic lineages. This study demonstrates that iPSC expansion and differentiation conditions can be prospectively specified to guide the enhanced production of target cells in a scale-free directed differentiation system. 相似文献
11.
Salte H King JM Baganz F Hoare M Titchener-Hooker NJ 《Biotechnology and bioengineering》2006,95(6):1218-1227
Expression systems capable of growing to high cell densities are now readily available and are popular due to the benefits of increased product concentration. However, such high solids density cultures pose a major challenge for bioprocess engineers as choosing the right separation equipment and operating it at optimal conditions is crucial for efficient recovery. This study proposes a methodology for the rapid determination of suitable operating conditions for the centrifugal recovery of high cell density fermentation broths. An ultra scale-down (USD) approach for the prediction of clarification and dewatering levels achieved in a range of typical high-speed centrifuges is presented. Together with a visualisation tool, a Window of Operation, this provides for the rapid analysis of separation performance and evaluation of the available operating conditions, as an aid in the selection of the centrifuge equipment most appropriate for a given process duty. A case study examining centrifuge selection for the processing of a high cell density Pichia pastoris culture demonstrates the method. The study examines semi-continuous disc-stack centrifuges and batch-operated machines such as multi-chamber bowls and Carr Powerfuges. Performance is assessed based on the variables of clarification, dewatering and product yield. Inclusion of limits imposed by the centrifuge type and design, and operation itself, serve to constrain the process and to define the Windows of Operation. The insight gained from the case study provides a useful indication of the utility of the methodology presented and illustrates the challenges of centrifuge selection for the demanding case of high solids concentration feed streams. 相似文献
12.
This article investigates the integrated application of ultra scale‐down (USD) techniques and economic modeling as a means for identifying optimal bioprocess operating conditions. The benefits of the approach are illustrated for the recovery of lactoperoxidase (LPO) from bovine milk. In the process, milk is skimmed to deplete its lipid content, before being subjected to low pH incubation with acetic acid in order to precipitate the primary impurity (casein). Following removal of the solids by disk stack centrifugation, pH adjustment and filtration, cation exchange chromatography is used as a positive mode column step to bind the LPO before it is polished and freeze dried. An economic model of this process was used to identify where greatest product loss occurs and hence where the largest opportunity cost was being incurred. Scale‐down analysis was used to characterize the influence of the critical steps, identified as precipitation and centrifugation, upon LPO recovery. A mathematical model was used to relate the centrifuge feed flowrate and discharge interval to the supernatant yield, and it was shown that increasing the centrifugal solids residence time achieved superior solids de‐watering and so higher product yield, although this also increased the overall processing time. To resolve this conflict, scale‐down data were used again in conjunction with an economic model to determine the most suitable conditions that maximized annual profit and minimized operating costs. The results demonstrate the power of combining USD data with models of economic and process performance in order to establish the best overall operating strategies for biopharmaceutical manufacture. © 2011 American Institute of Chemical Engineers Biotechnol. Prog., 2011 相似文献
13.
A method for using a bench-top centrifuge is described in order to mimic the recovery performance of an industrial-scale centrifuge, in this case a continuous-flow disc stack separator. Recovery performance was determined for polyvinyl acetate particles and for biological process streams of yeast cell debris and protein precipitates. Recovery of polyvinyl acetate particles was found to be well predicted for these robust particles. The laboratory centrifugation scale-down technique again predicted the performance of the disc stack centrifuge for the recovery of yeast cell debris particles although there was some suggestion of over-prediction at high levels of debris recovery due to the nature of any cell debris aggregates present. The laboratory centrifuge scale-down technique also proved to be an important investigative probe into the extent of shear-induced breakup of shear-sensitive protein precipitate aggregates during recovery in continuous high speed centrifuges. Such breakup can lead to over 10-fold reduction in separator capacity. 相似文献
14.
C.Q. Reid A. Tait H. Baldascini A. Mohindra A. Racher S. Bilsborough C.M. Smales M. Hoare 《Biotechnology and bioengineering》2010,107(1):85-95
With the trend towards the generation and production of increasing numbers of complex biopharmaceutical (protein based) products, there is an increased need and requirement to characterize both the product and production process in terms of robustness and reproducibility. This is of particular importance for products from mammalian cell culture which have large molecular structures and more often than not complex post‐translational modifications (PTMs) that can impact the efficacy, stability and ultimately the safety of the final product. It is therefore vital to understand how the operating conditions of a bioprocess affect the distribution and make up of these PTMs to ensure a consistent quality and activity in the final product. Here we have characterized a typical bioprocess and determined (a) how the time of harvest from a mammalian cell culture and, (b) through the use of an ultra scale‐down mimic how the nature of the primary recovery stages, affect the distribution and make up of the PTMs observed on a recombinant IgG4 monoclonal antibody. In particular we describe the use of rapid whole antibody analysis by mass spectrometry to analyze simultaneously the changes that occur to the cleavage of heavy chain C‐terminal lysine residues and the glycosylation pattern, as well as the presence of HL dimers. The time of harvest was found to have a large impact upon the range of glycosylation patterns observed, but not upon C‐terminal lysine cleavage. The culture age had a profound impact on the ratio of different glycan moieties found on antibody molecules. The proportion of short glycans increased (e.g., (G0F)2 20–35%), with an associated decrease in the proportion of long glycans with culture age (e.g., (G2F)2 7–4%, and G1F/G2F from 15.2% to 7.8%). Ultra scale‐down mimics showed that subsequent processing of these cultures did not change the post‐translational modifications investigated, but did increase the proportion of half antibodies present in the process stream. The combination of ultra scale‐down methodology and whole antibody analysis by mass spectrometry has demonstrated that the effects of processing on the detailed molecular structure of a monoclonal antibody can be rapidly determined early in the development process. In this study we have demonstrated this analysis to be applicable to critical process design decisions (e.g., time of harvest) in terms of achieving a desired molecular structure, but this approach could also be applied as a selection criterion as to the suitability of a platform process for the preparation of a new drug candidate. Also the methodology provides means for bioprocess engineers to predict at the discovery phase how a bioprocess will impact upon the quality of the final product. Biotechnol. Bioeng. 2010;107: 85–95. © 2010 Wiley Periodicals, Inc. 相似文献
15.
Verena Nold Lisa Junghans Lorenzo Bisgen Raphael Drerup Beate Presser Ingo Gorr Thomas Schwab Bettina Knapp Stefan Wieschalka 《Engineering in Life Science》2022,22(12):784
The analysis of data collected using design of experiments (DoE) is the current gold standard to determine the influence of input parameters and their interactions on process performance and product quality. In early development, knowledge on the bioprocess of a new product is limited. Many input parameters need to be investigated for a thorough investigation. For eukaryotic cell cultures, intensified DoE (iDoE) has been proposed as efficient tool, requiring fewer bioreactor runs by introducing setpoint changes during the bioprocess. We report the first successful application of iDoE to mammalian cell culture, performing sequential setpoint changes in the growth phase for the selected input parameters temperature and dissolved oxygen. The process performance data were analyzed using ordinary least squares regression. Our results indicate iDoE to be applicable to mammalian bioprocesses and to be a cost‐efficient option to inform modeling early on during process development. Even though only half the number of bioreactor runs were used in comparison to a classical DoE approach, the resulting models revealed comparable input‐output relations. Being able to examine several setpoint levels within one bioreactor run, we confirm iDoE to be a promising tool to speed up biopharmaceutical process development. 相似文献
16.
Apoptosis is a form of programmed and controlled cell death that accounts for the majority of cellular death in bioprocesses. Cell death affects culture longevity and product quality; it is instigated by several stresses experienced by the cells within a bioreactor. Understanding the factors that cause apoptosis as well as developing strategies that can protect cells is crucial for robust bioprocess development. This review aims to a) address apoptosis from a bioprocess perspective; b) describe the significant apoptotic mechanisms linking them to the most relevant stresses encountered in bioreactors; c) discuss the design of operating conditions in order to avoid cell death; d) focus on industrially relevant cell lines; and e) present anti-apoptosis strategies including cell engineering and model-based optimization of bioprocesses. In addition, the importance of apoptosis in quality-by-design bioprocess development from clone screening to production scale are highlighted. 相似文献
17.
M. Bulmer A. I. Clarkson N. J. Titchener-Hooker P. Dunnill 《Bioprocess and biosystems engineering》1996,15(6):331-337
Accurate and reliable models are required for a range of unit operations if simulations are to be used for accelerating the
design and optimisation of bioprocesses. This paper presents results of pilot-plant studies that have been used to verify
process simulations for a sequence of operations comprising of cell disruption, fractional protein precipitation and centrifugal
separation. These have been tested using the purification of the enzyme alcohol dehydrogenase (ADH) from Saccharomyces cerevisiae
as being representative of the recovery of a labile intracellular enzyme. Comparison of pilot-plant against simulated data
highlights where improvements to the models are required and has resulted in increased confidence in the simulations for a
wide range of conditions including the operational scale and the nature of the starting material. Results demonstrate the
effectiveness of the verification approach for the development of reliable predictive models to assess the feasibility of
process designs and performance of a train of bioprocess operations.
UCL is the Biotechnology and Biological Sciences Research Council's sponsored Advanced Centre for Biochemical Engineering
and the Council's support is gratefully acknowledged. The authors would like to thank I Ms. N. Abidi for technical assistance. 相似文献
18.
Joseph Newton Reinhard Oeggl Nils H. Janzen Sandra Abad Daniela Reinisch 《Engineering in Life Science》2020,20(8):331-337
Miniaturization and automation have become increasingly popular in bioprocess development in recent years, enabling rapid high‐throughput screening and optimization of process conditions. In addition, advances in the bioprocessing industry have led to increasingly complex process designs, such as pH and temperature shifts, in microbial fed‐batch fermentations for optimal soluble protein expression in a range of hosts. However, in order to develop an accurate scale‐down model for bioprocess screening and optimization, small‐scale bioreactors must be able to accurately reproduce these complex process designs. Monitoring methods, such as fluorometric‐based pH sensors, provide elegant solutions for the miniaturization of bioreactors, however, previous research suggests that the intrinsic fluorescence of biomass alters the sigmoidal calibration curve of fluorometric pH sensors, leading to inaccurate pH control. In this article, we present results investigating the impact of biomass on the accuracy of a commercially available fluorometric pH sensor. Subsequently, we present our calibration methodology for more precise online measurement and provide recommendations for improved pH control in sophisticated fermentation processes. 相似文献
19.
Quality by design (QbD) is a current structured approach to design processes yielding a quality product. Knowledge and process understanding cannot be achieved without proper experimental data; hence requirements for measurement error and frequency of measurement of bioprocess variables have to be defined. In this contribution, a model-based approach is used to investigate impact factors on calculated rates to predict the obtainable information from real-time measurements (= signal quality). Measurement error, biological activity, and averaging window (= period of observation) were identified as biggest impact factors on signal quality. Moreover, signal quality has been set in context with a quantifiable measure using statistical error testing, which can be used as a benchmark for process analytics and exploitation of data. Results have been validated with data from an E. coli batch process. This approach is useful to get an idea which process dynamics can be observed with a given bioprocess setup and sampling strategy beforehand. 相似文献
20.
Influence of the extent of disruption of Bakers' yeast on protein adsorption in expanded beds 总被引:2,自引:0,他引:2
Expanded bed adsorption chromatography is used to capture the protein product of interest from a crude biological suspension directly, thereby eliminating the need for the removal of the cell debris. While this technique may replace three or four unit operations in a typical downstream process for biological product recovery, the adsorption process is influenced by the interaction between the microbial cells or cell debris and the adsorbent as well as the presence of contaminating solutes. The influence of the extent and nature of disruption of Bakers' yeast on the adsorption of the total soluble protein and alpha-glucosidase was investigated in this study. Two different techniques were used for cell disruption: high pressure homogenisation and hydrodynamic cavitation. Two different adsorbents were chosen: anionic Streamline DEAE and cationic Streamline SP. The settled bed height and the superficial velocity were constant across all experiments. The feedstock was characterised in terms of viscosity, pH, conductivity, particle size distribution of the cell debris and the extent of protein and alpha-glucosidase released. The performance of the adsorption process was found to be influenced by the electrostatic interactions of cell debris with the anionic adsorbent Streamline DEAE and the intraparticle diffusional resistance inside the pores of the adsorbent matrix. The increase in the intensity of disruption resulted in an increase in the dynamic binding capacity (10% feed) of both the total soluble protein and the alpha-glucosidase. However, the increase in the DBC of protein and alpha-glucosidase were not proportional. The amount of protein that could be adsorbed per ml of adsorbent from the samples subjected to a lower intensity of disruption was found to exceed that obtained at a higher disruption intensity on increasing the volume of feed suggesting multilayer adsorption. In this case, selective adsorption of the model protein alpha-glucosidase was reduced, illustrating the compromise of maximising protein recovery through non-specific binding. The study illustrates the need for an interrogation of the intensity of disruption needed and a rigorous understanding of the influence of cell debris and adsorbent-protein interaction, in optimising the selective recovery of intracellular products by EBA. 相似文献