Antibody production by a hybridoma cell line at high cell density is limited by two independent mechanisms

Our previous attempt to model the stationary phase of production-scale hollow-fiber bioreactors using a scaled-down micro hollow-fiber bioreactor resulted in a predicted antibody production rate that was three- to fourfold lower than the actual value (Gramer and Poeschl, 2000). Medium limitations were suspected as the reason for the discrepancy. In this study, various increases in medium feed rate were implemented in the micro bioreactor by increasing the diameter of the silicone tubing that houses the hollow fibers. Because larger diameter tubing may induce oxygen limitations, we also explored the effect of medium recirculation to enhance oxygenation. Antibody production in the micro bioreactor increased both as a result of increased medium supply and due to medium recirculation. However, these parameters increased antibody production through two independent mechanisms. The increased medium supply resulted in a higher cell-specific antibody production rate, but not a higher viable cell density. Medium circulation resulted in the support of a higher viable cell density, but had little effect on the cell-specific secretion rate. The two mechanisms of enhanced antibody production were additive, demonstrating that simultaneous parameters can limit antibody production by this cell line in a hollow-fiber system. When the medium feed and circulation rates were increased to a volumetrically proportional scale, scale-up predictions from the micro bioreactor matched the actual data from the production-scale system to within 15%. These data demonstrate the usefulness of the micro bioreactor for characterizing cell growth and limiting mechanisms at high cell densities.     

A novel centrifugal impeller bioreactor. I. Fluid circulation, mixing, and liquid velocity profiles

A novel centrifugal impeller bioreactor for shear-sensitive biological systems was designed by installing a centrifugal-pumplike impeller in a stirred vessel. The fluid circulation, mixing, and liquid velocity profiles in the new bioreactor (5-L) were assessed as functions of the principal impeller designing and bioreactor operating parameters. The performances of the centrifugal impeller bioreactor were compared with those of a widely used cell-lift bioreactor. The newly developed bioreactor showed higher liquid lift capacity and shorter mixing time than the cell lift with comparable dimensions. Furthermore, the experiments of the liquid velocity profiles around an impeller region indicated that the centrifugal impeller bioreactor produced lower shear stress than the cell lift. This conclusion was also supported by evaluating the changes in size distributions of granulated agar particles that were sheared with those two types of impeller.     

New miniaturized hollow-fiber bioreactor for in vivo like cell culture, cell expansion, and production of cell-derived products

We have developed a miniaturized hollow-fiber bioreactor system for mammalian cell culture with a volume of 1 mL. Cell and medium compartments of the bioreactor are separated by a semipermeable membrane, and oxygenation of the cell compartment is accomplished using an oxygenation membrane. As a result of the geometry of the transparent housing, cells can be observed by microscopy during culture. The leukemic cell lines CCRF-CEM, HL-60, and REH were cultivated up to densities of 3.5 x 10(7)/mL without medium change or manipulation of the cells. As shown using CCRF-CEM cells, growth in the bioreactor was strongly influenced and could be controlled by the medium flow rate. As a consequence, consumption of glucose and generation of lactate varied with flow rate. Depending on the molecular size cutoff of the membranes used, added growth factors such as GM-CSF, as well as factors secreted from the cells, are retained in the cell compartment for up to 1 week. This new miniaturized hollow-fiber bioreactor offers advantages in tissue engineering by continuous nutrient supply for cells in high density, retention of added or autocrine produced factors, and undisturbed long-term culture in a closed system.     

A comparison of oxygenation methods fro high-density perfusion culture of animal cells

A perfusion culture system was developed to investigate the oxygenation of high-density hybridoma cell cultures. The culture system was composed of a stirred-tank bioreactor and an external microfiltration hollow fiber cartridge for medium perfusion. Cell growth and antibody production were examined with large bubble ( approximately 5 mm in diameter), micron-sized bubble ( approximately 80 mum in diameter), and silicone tubing oxygenation techniques. Comparable cell growth and monoclonal antibody (MAb) production were found for both the micron-sized and large oxygenation methods, provided that large bubbles were enriched with pure oxygen. Relatively low cell growth and MAb production were attained with the bubble-free silicone tubing oxygenation. It is concluded that direct bubble oxygenation can be applied successfully in high-density animal cell cultures, provided that the culture medium is supplemented with Pluronic F-68. The accumulation of ammonia in the culture medium rather than oxygen limitation was found to be one of the possible problems that eventually inhibited cell growth. This and the fouling of the filtration cartridge during long-term cultivation were found to be more problematic than simple bubble oxygenation of high-density cell culture. The micron-sized bubble oxygenation method is highly recommended for high-density animal cell cultures, provided that Pluronic F-68 is supplemented into the culture medium. (c) 1993 John Wiley & Sons, Inc.     

Microfabricated grooved substrates as platforms for bioartificial liver reactors

An extracorporeal bioartificial liver device has the potential to provide temporary hepatic support for patients with liver failure. Our goal was to optimize the flow environment for the cultured hepatocytes in a flat-plate bioreactor, specifically focusing on oxygen delivery using high medium flow rates while reducing the detrimental effects of the resulting shear stresses. We used photolithographic techniques to fabricate microgrooves onto the underlying glass substrate. The microgrooves, perpendicular to the axial flow direction, protected the hepatocytes from the shear stress induced by the flowing medium. Using finite element analysis, we found that the velocity gradient change near the cell surface (i.e., bottom of the grooves) was smaller than that near the top surface of the flow channel, indicating that the grooves would provide protection to the attached cells from the mechanical effects of the flowing medium. We also determined that the shear stress at the cell surface could be reduced by as much as 30 times (channel height of 100 microm) in the grooved-substrate (0.5 dyn/cm(2)) bioreactor compared to the flat-substrate (15 dyn/cm(2)) bioreactor for a medium flow rate of 4.0 mL/min. Albumin and urea synthesis rates of hepatocytes cocultured with 3T3-J2 fibroblasts remained stable over 5 days of perfusion in the grooved-substrate bioreactor, whereas in the flat-substrate bioreactor they decreased over the same time period. These studies indicate that under "high" flow conditions the microgrooved-substrate in the bioreactor can decrease the detrimental effects of shear stress on the hepatocytes while providing adequate oxygenation, thereby resulting in stable liver-specific function.     

Engineering select physical properties of cross-linked red blood cells and a simple a priori estimation of their efficacy as an oxygen delivery vehicle within the context of a hepatic hollow fiber bioreactor

Bovine red blood cells (bRBCs) can potentially provide a simplistic and economic means of improving oxygenation within hollow fiber (HF) bioreactor cell cultures. Bovine RBCs are also interesting since many of their physical properties can be altered as a result of glutaraldehyde (G) cross-linking. Cross-linking bRBCs produces an oxygen carrier that is expected to be beneficial under specific circumstances (i.e., delivery of oxygen to cells that are sensitive to free hemoglobin (Hb) and cells that require low inlet oxygen tensions). We have examined the osmotic stability and electrophoretic mobility of cross-linked bRBCs and observed that cross-linking improves osmotic stability while minimally impacting electrophoretic mobility. The oxygen binding/dissociation properties (P(50) and n) of cross-linked bRBCs were also measured, and under the reported reaction conditions, cross-linking increased the oxygen affinity and reduced the cooperativity of bRBCs. A basic Krogh tissue cylinder model was then utilized to provide a quick a priori estimate of oxygen delivery and release to hepatocytes housed within a HF bioreactor in order to demonstrate potential oxygenation benefits arising with both normal and cross-linked bRBC media supplementation. This model showed that bRBCs generally improved oxygen delivery and release to HF cell cultures and that cross-linked bRBCs are particularly beneficial in specifically targeting oxygen delivery to cells maintained at low inlet oxygen tensions. Additionally, the model showed that bRBC supplementation can significantly improve oxygen delivery without requiring extreme bRBC concentrations.     

A fiber-bed bioreactor for anchorage-dependent animal cell cultures: part I. Bioreactor design and operations

A concentric-cylinder airlift reactor, in which the annulus is a packed bed of glass fibers, has been developed in order to facilitate the scaleup and enhance the volumetric productivity of anchorage-dependent animal cell cultures. In this bio-reactor, oxygen-containing gas is sparged through the inner draft tube, causing bubble-free medium to flow through the fiber bed in the outer cylinder and providing both oxygenation and convective nutrient transfer to the cells. Several other desirable features for reactor operation are also provided by this design. Cell cultivations in this bioreactor have been successfully carried out and provide data for the feasibility of the large-scale cell cultivation.     

动植物细胞或组织生物反应器悬浮培养过程中的通气方式

通气在动植物细胞或组织生物反应器培养过程中起着至关重要的作用,而同时通气过程所产生的机械损伤力亦可对细胞造成直接的伤害,因此,通气方式是动植物细胞或组织生物反应器培养过程设计与工程放大的关键技术之一。本文综述了动植物细胞或组织生物反应器悬浮培养过程中三种主要通气(异养培养时又称供氧)方式的结构特点,及其对气液传质、生物量、代谢产物量和细胞损伤的影响,以及改进的新型通气方式和几种通气方式的融合并用。     

A thin‐walled polydimethylsiloxane bioreactor for high‐density hepatocyte sandwich culture

In vitro drug testing requires long‐term maintenance of hepatocyte liver specific functions. Hepatocytes cultured at a higher seeding density in a sandwich configuration exhibit an increased level of liver specific functions when compared to low density cultures due to the better cell to cell contacts that promote long term maintenance of polarity and liver specific functions. However, culturing hepatocytes at high seeding densities in a standard 24‐well plate poses problems in terms of the mass transport of nutrients and oxygen to the cells. In view of this drawback, we have developed a polydimethylsiloxane (PDMS) bioreactor that was able to maintain the long‐term liver specific functions of a hepatocyte sandwich culture at a high seeding density. The bioreactor was fabricated with PDMS, an oxygen permeable material, which allowed direct oxygenation and perfusion to take place simultaneously. The mass transport of oxygen and the level of shear stress acting on the cells were analyzed by computational fluid dynamics (CFD). The combination of both direct oxygenation and perfusion has a synergistic effect on the liver specific function of a high density hepatocyte sandwich culture over a period of 9 days. Biotechnol. Bioeng. 2013; 110: 1663–1673. © 2012 Wiley Periodicals, Inc.     

Effect of agitation rate and impeller design on oxygen transfer coefficients in small bioreactors using surface aeration

The effects of agitation rate and impeller type on the combined oxygen mass-transfer coefficient (kL a) in four different benchtop bioreactors have been examined. Surface oxygenation of a cell culture medium supplemented with fetal bovine serum and distilled deionized water has been studied by passing air through the bioreactor headspace at approximately one headspace volume per minute. A new ribbon-type impeller design using strips of Teflon has been shown to be superior to conventional impeller designs for oxygen transfer.     

A radial flow hollow fiber bioreactor for the large-scale culture of mammalian cells

A radial flow hollow fiber bioreactor has been developed that maximizes the utilization of fiber surface for cell growth while eliminating nutrient and metabolic gradients inherent in conventional hollow fiber cartridges. The reactor consists of a central flow distributor tube surrounded by an annular bed of hollow fibers. The central flow distributor tube ensures an axially uniform radial convective flow of nutrients across the fiber bed. Cells attach and proliferate on the outer surface of the fibers. The fibers are pretreated with polylysine to facilitate cell attachment and long-term maintenance of tissuelike densities of cell mass. A mixture of air and CO(2) is fed through the tube side of the hollow fibers, ensuring direct oxygenation of the cells and maintenance of pH. Spent medium diffuses across the cell layer into the tube side of the fibers and is convected away along with the spent gas stream. The bioreactor was run as a recycle reactor to permit maximum utilization of nutrient medium. A bioreactor with a membrane surface area of 1150 cm(2) was developed and H1 cells were grown to a density of 7.3 x 10(6) cells/cm(2).     

Hemoglobin regulates the metabolic and synthetic function of rat insulinoma cells cultured in a hollow fiber bioreactor

Pancreatic islet transplantation continues to benefit patients with type 1 diabetes by normalizing glucose metabolism and improving other complications of diabetes. However, islet transplantation therapy is limited by the inadequate availability of pancreatic islets. In order to address this concern, this work investigated the expansion of rat insulinoma cells (INS‐1) and their ability to generate insulin in a hollow fiber bioreactor (HFB). The long‐term goal of this project is to develop a bioartificial pancreas. HFBs were incubated at two different oxygenation conditions (10% and 19% O₂) to determine the best scenario for O₂ transport to cultured cells. Also, bovine hemoglobin (BvHb) was supplemented in the cell culture media of the HFBs in order to increase O₂ transport under both oxygenation conditions. Our results show that INS‐1 cells expanded under all oxygenation conditions after 2 weeks of culture, with a slightly higher cell expansion under normoxic oxygenation (19% O₂) for both control HFBs and BvHb HFBs. In addition, cellular insulin production remained steady throughout the study for normoxic control HFBs and BvHb HFBs, while it increased under hypoxic oxygenation (10% O₂) for both types of HFBs but to different extents. Under the two different oxygenation conditions, cellular insulin production was more uniform with time in BvHb HFBs versus control HFBs. These results, along with qRT‐PCR analysis, suggest a possible dysregulation of the insulin‐signaling pathway under hypoxic culture conditions. In conclusion, the HFB culture system is an environment capable of expanding insulinomas while maintaining their viability and insulin production capabilities. Biotechnol. Bioeng. 2010;107: 582–592. © 2010 Wiley Periodicals, Inc.     

Next-generation polymerized human hemoglobins in hepatic bioreactor simulations

Hepatic hollow fiber (HF) bioreactors can be used to provide temporary support to patients experiencing liver failure. Before being connected to the patient's circulation, cells in the bioreactor must be exposed to a range of physiological O₂ concentrations as observed in the liver sinusoid to ensure proper performance. This zonation in cellular oxygenation promotes differences in hepatocyte phenotype and may better approximate the performance of a real liver within the bioreactor. Polymerized human hemoglobin (PolyhHb) locked in the tense quaternary state (T-state) has the potential to both supply and regulate O₂ transport to cultured hepatocytes in the bioreactor due to its low O₂ affinity. In this study, T-state PolyhHb production and purification processes were optimized to minimize the concentration of low-molecular-weight PolyhHb species in solution. Deconvolution of size-exclusion chromatography spectra was performed to calculate the distribution of polymeric Hb species in the final product. Fluid flow and mass transport within a single fiber of a hepatic HF bioreactor was computationally modeled with finite element methods to simulate the effects of employing T-state PolyhHb to facilitate O₂ transport in a hepatic bioreactor system. Optimal bioreactor performance was defined as having a combined hypoxic and hyperoxic volume fraction in the extracapillary space of less than 0.05 where multiple zones were observed. The Damköhler number and Sherwood number had strong inverse relationships at each cell density and fiber thickness combination. These results suggest that targeting a specific Damköhler number may be beneficial for optimal hepatic HF bioreactor operation.     

Rotating versus perfusion bioreactor for the culture of engineered vascular constructs based on hyaluronic acid

It is generally accepted that dynamic culture conditions are required for vascular tissue engineering. We compared the effects of two dynamic culture systems, a perfusion and a rotating bioreactor, using tubular constructs based on hyaluronic acid seeded with porcine aortic smooth muscle cells (SMC), that we recently showed to be adequate for the generation of vascular tissue. In perfused constructs mechanical stimulation importantly affected cell morphology, increased the incidence of cell proliferation and reduced apoptosis. However, extracellular matrix deposition, cytoskeletal organization and mechanical properties were poor. In rotated constructs cell proliferation was also higher and apoptosis lower than in static controls. Rotated constructs showed the highest ultimate stress and the lowest elastic modulus. Our data indicate that the rotating bioreactor is more efficient than the perfusion bioreactor and we then suggest that this method can be considered a valid alternative to complex bioreactor systems described in the literature.     

Three-dimensional co-culture of primary human liver cells in bioreactors for in vitro drug studies: effects of the initial cell quality on the long-term maintenance of hepatocyte-specific functions

In vitro culture models that employ human liver cells could be potent tools for predictive studies on drug toxicity and metabolism in the pharmaceutical industry. A bioreactor culture model was developed that permits the three-dimensional co-culture of liver cells under continuous medium perfusion with decentralised mass exchange and integral oxygenation. We tested the ability of the system to support the long-term maintenance and differentiation of primary human liver cells. The effects of the initial cell quality were investigated by comparing cultures from resected, non-preserved liver with cultures from liver graft tissue damaged by long-term preservation. In cultures originating from non-preserved liver, protein and urea synthesis, glucose metabolism, and cytochrome (CYP450) activities were stable over the 2-week culture period, with maximal activities at the end of the first week in culture. Enzyme induction led to increased 7-ethoxyresorufin O-deethylase activities of up to 20 times the basal value. In cultures from preservation-damaged liver, recovery of metabolic activities was detected during bioreactor culture. After two weeks, most biochemical parameters approached those of cultures from non-preserved human liver. Light microscopy demonstrated the three-dimensional reorganisation of hepatocytes and non-parenchymal cells in co-culture. Long-term maintenance, and even the regeneration of specific functional activities of human liver cells, can be achieved in the bioreactor. This could facilitate the introduction into the pharmaceutical industry of in vitro drug testing with primary human liver cells.     

Sparging and agitation-induced injury of cultured animals cells: Do cell-to-bubble interactions in the bulk liquid injure cells?

It has been established that the forces resulting from bubbles rupturing at the free air (gas)/liquid surface injure animal cells in agitated and/or sparged bioreactors. Although it has been suggested that bubble coalescence and breakup within agitated and sparged bioreactors (i.e., away from the free liquid surface) can be a source of cell injury as well, the evidence has been indirect. We have carried out experiments to examine this issue. The free air/liquid surface in a sparged and agitated bioractor was eliminated by completely filling the 2-L reactor and allowing sparged bubbles to escape through an outlet tube. Two identical bioreactors were run in parallel to make comparisons between cultures that were oxygenated via direct air sparging and the control culture in which silicone tubing was used for bubble-free oxygenation. Thus, cell damage from cell-to-bubble interactions due to processes (bubble coalescence and breakup) occurring in the bulk liquid could be isolated by eliminating damage due to bubbles rupturing at the free air/liquid surface of the bioreactor. We found that Chinese hamster ovary (CHO) cells grown in medium that does not contain shear-protecting additives can be agitated at rates up to 600 rpm without being damaged extensively by cell-to bubble interactions in the bulk of the bioreactor. We verified this using both batch and high-density perfusion cultures. We tested two impeller designs (pitched blade and Rushton) and found them not to affect cell damage under similar operational conditions. Sparger location (above vs. below the impeller) had no effect on cell damage at higher agitation rates but may affect the injury process at lower agitation intensities (here, below 250 rpm). In the absence of a headspace, we found less cell damage at higher agitation intensities (400 and 600 rpm), and we suggest that this nonintuitive finding derives from the important effect of bubble size and foam stability on the cell damage process. (c) 1996 John Wiley & Sons, Inc.     

A NMR-compatible and reduced gravity simulation based (NRG) bioreactor for on-line monitoring cell culture metabolism

We developed a NMR-compatible microgravity-based bioreactor (NRG[R]) that offers the advantage of an analytical non-invasive approach associated to the effects of an optimized suspension culture. The simulated microgravity conditions reached in the bioreactor are analogous to those of commercial apparatus like the Rotating Wall Vessel (RWV) system. The faster proliferation of endothelial cells cultured in the NRG bioreactor (doubling time : 28 +/- 1.7 vs. 43 +/- 5.6 h of the control grown in RWV) are attributed to different oxygenation conditions and medium wash out.     

Large-scale production of murine bone marrow cells in an airlift packed bed bioreactor

Large-scale cultivation of murine bone marrow cells was accomplished in an airlift packed bed bioreactor system designed to mimic the in vivo bone marrow environment. The attachment-dependent stromal cell population, which provides the necessary microenvironment, including growth factors for subsequent hematopoietic activity, was first established within the bioreactor. This attachment-dependent cell growth occurred on the fiber-glass matrix packed in the annular region of the bioreactor. Once the stromal cell layer was established, fresh bone marrow cells were inoculated to initiate hematopoiesis. However, traditional culture medium was found to be inadequate for the initiation of hematopoiesis, but the use of stromal cell "conditioned" medium (with no exogenously added growth factors) yielded sustained cell production. The extent of stromal cell subculturing prior to inoculation into the bioreactor and the inoculation density were also important factors for the successful initiation of hematopoietic activity. A 500-mL perfusion culture experiment resulted in the production and harvest of 3.6 x 10(8) suspended bone marrow cells over the course of 11 weeks. (c) 1996 John Wiley & Sons, Inc.     

Bi-zonal cartilaginous tissues engineered in a rotary cell culture system

In this study, we aimed at validating a rotary cell culture system (RCCS) bioreactor with medium recirculation and external oxygenation, for cartilage tissue engineering. Primary bovine and human culture-expanded chondrocytes were seeded into non-woven meshes of esterified hyaluronan (HYAFF-11), and the resulting constructs were cultured statically or in the RCCS, in the presence of insulin and TGFbeta3, for up to 4 weeks. Culture in the RCCS did not induce significant differences in the contents of glycosaminoglycans (GAG) and collagen deposited, but markedly affected their distribution. In contrast to statically grown tissues, engineered cartilage cultured in the RCCS had a bi-zonal structure, consisting of an outgrowing fibrous capsule deficient in GAG and rich in collagen, and an inner region more positively stained for GAG. Structurally, trends were similar using primary bovine or expanded human chondrocytes, although the human cells deposited inferior amounts of matrix. The use of the presented RCCS, in conjunction with the described medium composition, has the potential to generate bi-zonal tissues with features qualitatively resembling the native meniscus.     

Analysis of an upflow bioreactor system for nitrogen removal via autotrophic nitrification and denitrification

The upflow bioreactor system without biomass-liquid separation unit was evaluated for its efficacy in sustaining autotrophic nitrification and denitrification (AND). The bioreactor system was capable of sustaining AND by means of carefully controlled oxygenation to achieve the maximum NH(4)(+)-N removal rate of 0.054 g N gVSS(-1) day(-1) (38% removal efficiency) at the oxygen influx and nitrogen loading rate of 3.68 mg O(2) h(-1) L-bioreactor(-1) and 182 mg N day(-1) L-bioreactor(-1), respectively. Additional nitrogen removal was achieved in a two-stage bioreactor configuration due to endogenous denitrification under long mean cell residence time. Quiescent conditions maintained in the bioreactor provided stable hydrodynamic environments for the chemoautotrophic biomass matrix, which revealed porous, loosely-structured, and mat-like architecture. More than 95% of the total biomass holdup (1.3-1.5 g VSS) was retained, thereby producing low biomass washout rate ( approximately 40 mg VSS day(-1)) with VSS < 11 mg VSSL(-1) in the effluent.