The performance of a scaled down industrial disc stack centrifuge with a reduced feed material requirement

A method is described for the scale-down of a disc stack centrifuge which reduces the number of separating discs and also the liquid and solid hold-up of the centrifuge bowl. This is to enable a reduced volume of process material to be used for study of clarification. Scale-down is achieved in stages using a series of interlocking inserts to suit particular applications. Maximum scale-down gives a 76% reduction in the separation area and a bowl volume reduction of 70%. Separation performance of the full stack machine and scale-down variants is compared using the grade efficiency concept. Polyvinyl acetate and bakers' yeast homogenate particle suspensions are used for the comparison. The grade efficiency curves produced by the scale-down variants closely follow the curves for the full stack machine. This resulted in supernatants of the same volume size distribution and concentration when using scale-down methodology to mimic the full scale operation.

     

Assessment of a disc stack centrifuge for use in mammalian cell separation

A prototype disc stack centrifuge was tested for the separation of mammalian cell cultures from 80- and 2000-L fermentations. The clarification capacity for mammalian cells was excellent, but some smaller particles remained in the supernatant and reduced its usefulness for downstream processing. In order to identify the source of such particle formation, several parameters were assessed and minimum particle size for separation was calculated. An analysis of particle distribution was performed. Temperature and pressure effects inside the centrifuge bowl were measured. Some modifications of mechanical engineering can be suggested for the improvement of the use of standard disc stack centrifuges for mammalian cells. (c) 1995 John Wiley & Sons, Inc.     

Shear stress analysis of mammalian cell suspensions for prediction of industrial centrifugation and its verification

This article describes the use of ultra scale-down studies requiring milliliter quantities of process material to study the clarification of mammalian cell culture broths using industrial-scale continuous centrifuges during the manufacture of a monoclonal antibody for therapeutic use. Samples were pretreated in a small high-speed rotating-disc device in order to mimic the effect on the cells of shear stresses in the feed zone of the industrial scale centrifuges. The use of this feed mimic was shown to predict a reduction of the clarification efficiency by significantly reducing the particle size distribution of the mammalian cells. The combined use of the rotating-disc device and a laboratory-scale test tube centrifuge successfully predicted the separation characteristics of industrial-scale, disc stack centrifuges operating with different feed zones. A 70% reduction in flow rate in the industrial-scale centrifuge was shown to arise from shear effects. A predicted 2.5-fold increase in throughput for the same clarification performance, achieved by the change to a centrifuge using a feed zone designed to give gentler acceleration of the bioprocess fluid, was also verified at large-scale.     

Evaluation of a single-use disk stack centrifuge for improved efficiency and sustainability at 1000 L GMP manufacturing scale

Direct depth filtration is an established technology for single-use harvest operation. Advantages of direct depth filtration include familiarity with depth filtration in downstream processes and simplicity of the operation. Drawbacks include low capacity, large footprint, labor-intensive set-up, high water use, and high waste in the form of discarded filters. Single-use centrifugation is emerging as an alternative to depth filtration for the single-use harvest step. Within the single-use centrifugation space, disc stack centrifugation represents the newest entrant. In this study, we evaluated the performance of the GEA kytero single-use disc stack centrifuge to clarify two monoclonal antibody-producing cell culture fluids. The separation performance of the GEA kytero centrifuge varied between the two cell culture fluids, with differences in centrate turbidity and centrate filterability measured. A comparison was then performed to determine resource savings, compared to direct two-stage depth filtration, when using a GEA kytero centrifuge to harvest a 1000 L bioreactor. The analysis concluded that replacement of the first stage of depth filters with a GEA kytero centrifuge has the potential to decrease the required second stage depth filtration area by up to 80%. The decrease in depth filter area resulting from the use of the GEA kytero would result in a decrease in the harvest step footprint, a decrease in buffer volume required to prime and rinse depth filters, and a decrease in the volume of plastic waste. An economic comparison of the GEA kytero single-use centrifuge against a direct depth filtration step found that for a 1000 L harvest step, the GEA kytero centrifuge may reduce costs by up to 20% compared with two-stage direct depth filtration.     

The use of laboratory centrifugation studies to predict performance of industrial machines: studies of shear-insensitive and shear-sensitive materials

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.     

Lysis-free separation of hybridoma cells by continuous disc stack centrifugation

The non-destructive removal of hybridoma cells from fermentation broth with an improved disc stack centrifuge (CSA1, Westfalia Separator AG, Oelde, Germany) was investigated. The centrifuge was equipped with a hydrohermetic feed system, which allowed a gentle, shearless acceleration of the cells inside the bowl. No significant cell damage was observed during the separation of hybridoma cells from repeated batch fermentation in 100 liter scale. In the clarified liquid phase there was no increase in Lactate-Dehydrogenase (LDH) activity. Consequently, there was no increased exposure of the product to intracellular components.Due to continuous operation with a periodic and automatic discharge of sediment, a high throughput was achieved without any considerable loss of product. The clarification for mammalian cells was in the range of 99% to 99.9%, depending on the operating conditions. The content of cell debris and other small particles decreased about 30 to 50%, depending on the particle load in the feed stream. The centrifuge was fully contained; cleaning and sterilizing in place possible. Therefore, the decice could be integrated easily into the fermentation process.     

Clarification of animal cell cultures on a large scale by continuous centrifugation

Summary Animal cells from 80-L and 2000-L fed batch fermentations were removed by a prototype disc stack centrifuge in order to achieve a fast and reliable separation of solids from large quantities of cell culture fluids. The clarification capacity was excellent for animal cells but particles remained in the liquid phase and affected further downstream processing of the cell-free harvest fluid. No significant loss of product was observed. A number of parameters were monitored to optimize process conditions for use with animal cells.     

Computational pharmacokinetics of solute penetration into human intervertebral discs-Effects of endplate permeability, solute molecular weight and disc size

A finite element model is developed to predict the penetration time-history of three different solutes into the human lumbar disc following intravenous injection. Antibiotics are routinely administered intravenously in spinal surgery to prevent disc infection. Successful prophylaxis requires antibiotics to reach adequate inhibitory levels. Here, the transient diffusion of cephazolin is investigated over 10h post-injection in a human disc model subject to reported concentrations in the blood stream as the prescribed boundary sources. Post-injection variation of cephazolin concentrations in the disc adjacent to supply sources closely followed the decay curve in the blood stream and fell sharply with time. Much lower concentrations were computed in the inner annulus and nucleus; much of the disc (80% at 1h and 49% at 4h) experienced concentrations below required inhibitory level of 1mg/L in agreement with measurements. Changes in endplate permeability, disc size, and solute molecular weight had profound effects on concentration profiles at all times and regions, especially in the disc centre, demonstrating their crucial roles on the adequate delivery of drugs. Larger solutes markedly slow transport into the disc. The failure to reach critical therapeutic levels in the central disc regions, especially when endplates calcify and in larger discs, raises concerns and calls for caution in attempts to extrapolate findings of studies on animals with much smaller and non degenerate discs to the human discs. The current study also demonstrates the capability of computational models in predicting the transport of intravenously injected solutes into the disc.     

Monitoring recombinant inclusion body recovery in an industrial disc stack centrifuge

A simple and rapid spectrophotometric method for measuring recombinant inclusion body concentrations in the presence of Escherichia coli cell debris has been applied to monitoring the performance of an industrial disc stack centrifuge. Turbidimetric measurements were made at two wavelengths, i.e., 600 nm and 420 nm, and the ratios of OD(600nm)/OD(420nm) related to the particle composition in suspension. The principle behind the technique is that inclusion body particles scatter light at 600 nm more effectively than do smaller cell debris particles when compared with the degree of light scatter at 420 nm. This technique may have broad potential application in developing an automatic monitoring and control system for industrial-scale inclusion body recovery. (c) 1994 John Wiley & Sons, Inc.     

Performance prediction of industrial centrifuges using scale-down models

Computational fluid dynamics was used to model the high flow forces found in the feed zone of a multichamber-bowl centrifuge and reproduce these in a small, high-speed rotating disc device. Linking the device to scale-down centrifugation, permitted good estimation of the performance of various continuous-flow centrifuges (disc stack, multichamber bowl, CARR Powerfuge) for shear-sensitive protein precipitates. Critically, the ultra scale-down centrifugation process proved to be a much more accurate predictor of production multichamber-bowl performance than was the pilot centrifuge.     

Step change in the efficiency of centrifugation through cell engineering: co‐expression of Staphylococcal nuclease to reduce the viscosity of the bioprocess feedstock

Cell engineering to enable step change improvements in bioprocessing can be directed at targets other than increasing product titer. The physical properties of the process suspension such as viscosity, for example, have a major impact on various downstream processing unit operations. The release of chromosomal DNA during homogenization of Escherichia coli and its influence on viscosity is well‐recognized. In this current article we demonstrate co‐expression of Staphylococcus aureus nuclease in E. coli to reduce viscosity through auto‐hydrolysis of nucleic acids. Viscosity reduction of up to 75% was achieved while the particle size distribution of cell debris was maintained approximately constant (d₅₀ = 0.5–0.6 µm). Critically, resultant step change improvements to the clarification performance under disc‐stack centrifugation conditions are shown. The cell‐engineered nuclease matched or exceeded the viscosity reduction performance seen with the addition of exogenous nuclease removing the expense and validation issues associated with such additions to a bioprocess. The resultant material dramatically altered performance in scale‐down mimics of continuous disc‐stack centrifugation. Laboratory scale data indicated that a fourfold reduction in the settling area of a disc‐stack centrifuge can be expected due to a less viscous process stream achieved through nuclease co‐expression with a recombinant protein. Biotechnol. Bioeng. 2009; 104: 134–142 © 2009 Wiley Periodicals, Inc.     

Computer analysis of cell division in Drosophila imaginal discs: Model revision and extension to simulate leg disc growth

Extension of a computer model designed by the author to simulate clone growth in the Drosophila head disc allows modelling of growth in the leg disc. A fault of the earlier model, namely break-up of clones caused by cells being pushed away from their neighbours is rectified by reducing the amount of separation allowed between recently divided daughter cells. A geometrical method is used to convert sectorial clones in the leg disc to the parallel sided clones seen in the adult leg.It is suggested here that clone growth in leg and head discs occurs in similar ways, based on the random division of cells in a two dimensional plane, the radial growth in the leg disc being due to lack of external constraints like those present in the head disc, for example the larval brain to head disc linkage. Several parameters of growth, including differential mitotic activity over the growing disc, and relative orientations of individual cell divisions are investigated, and the relevance of these data to experiments on real discs is discussed. In particular, the accuracy of information about cell division orientations gleaned from twin spot studies is questioned.     

Prediction of the pilot-scale recovery of a recombinant yeast enzyme using integrated models

This article describes the rapid prediction of recovery process performance for a new recombinant enzyme product on the basis of a broad portfolio of computer models and highly targeted experimentation. A process model for the recombinant system was generated by linking unit operation models in an integrated fashion, with required parameter estimation and physical property determination accomplished using data from scale-down studies. This enabled the generic modeling framework established for processing of a natural enzyme from bakers' yeast to be applied. An experimental study of the same operations at the pilot scale showed that the process model gave a conservative prediction of recombinant enzyme recovery. The model successfully captured interactions leading to a low overall product yield and indicated the need for further study of precipitate breakage in the feed zone of a disc stack centrifuge in order to improve performance. The utility of scale-down units as an aid to fast model generation and the advantage of integrating computer modeling and scale-down studies to accelerate bioprocess development are highlighted.     

Increased IL-17 expression in degenerated human discs and increased production in cultured annulus cells exposed to IL-1ß and TNF-α

Abstract

IL-17 is expressed in a number of tissues including the intervertebral disc, where it exerts strong inflammatory properties. We evaluated IL-17 using immunolocalization in herniated and non-herniated human discs, IL-17 gene expression, and the production of IL-17 by annulus cells cultured in three dimensions in the presence of IL-1ß or TNF-α. There was no difference in the percentage of IL-17 positive cells in annulus or nucleus in herniated vs. non-herniated disc specimens. Molecular studies confirmed expression of IL-17 in disc tissue, with significantly increased expression in more degenerated discs; there was no difference in expression between herniated vs. non-herniated discs. Exposure to IL-1ß or TNF-α resulted in significantly greater production of IL-17. Our findings expand understanding of IL-17 production by disc cells and reveal the importance of non-canonical IL-17 production in the disc. Significantly greater expression of IL-17 in more degenerated discs adds to our understanding of the changes in disc cell function with advancing stages of disc degeneration.     

Particle interaction effects on blood cell sedimentation and separations

Experiments with a continuous centrifuge reveal that the separation of leukocytes (WBCs) and platelets from erythrocytes (RBCs) is maximized at a lower than normal RBC concentration or hematocrit (HCT). Conventional hindered settling models are unsatisfactory in the explanation of this behavior because they do not adequately account for differences in cell size, density, deformability and electrical charge on the membrane surface. In this paper a new approach is taken where an effective porosity is used to account for the differences in the micro-environment of each particle type. Introduction of effective porosities into various sedimentation equations is useful in allowing better prediction of the optimum separation conditions observed in experimental data. Further adjustment of parameters is necessary for some models to shift optimums in settling curves to align with experimental trends.     

A method for estimating the number of blastoderm cells which give rise to Drosophila imaginal discs

Summary A mathematical method for calculating the number of blastoderm cells whose descendants form the various imaginal discs is described. The method differs from available approaches in two respects: (1) It is based only upon the frequency of mosaicism of the adult derivatives of a given imaginal disc and ignores the relative surface area of the two genetically marked cell populations which comprise these derivatives. (2) The method estimates the average number of cells at the blastoderm stage which give rise to a particular imaginal disc and not at the developmental stage at which restriction of the pool of cells which will form this imaginal disc occurs. Despite their methodological differences the estimates obtained from this method and from other approaches are of the same order of magnitude and thus provide further support to the currently available estimates and to the notion that restriction of whole imaginal discs occurs at the blastoderm stage. The proposed method also provides a quantitative approximation of the non-linear relationship that exists between the frequencies of mosaicism of different imaginal discs and the number of cells which comprise these discs.     

Near-Field Imaging of Surface Plasmon Polaritons Excited by Chains of Gold Nanodiscs

We present a study of the near-field pattern created by chains of gold nanodiscs situated on a gold thin film and illuminated at oblique incidence. Each disc generates surface plasmon polaritons that propagate on the gold surface. The created waves interfere between them and with the illuminating beam. We observed that when the discs are separated by a distance smaller than the half wavelength, the chain behaves like a continuous ridge. When the discs separation increases, a complex periodic pattern appears and extends up to several wavelengths from the chain. For some specific separation distances, a directional emission of surface plasmon is also observed. The experimental results are in good agreement with numerical simulations performed by considering each disk as an independent dipole-like surface plasmon source.     

Modeling industrial centrifugation of mammalian cell culture using a capillary based scale-down system

Continuous-flow centrifugation is widely utilized as the primary clarification step in the recovery of biopharmaceuticals from cell culture. However, it is a challenging operation to develop and characterize due to the lack of easy to use, small-scale, systems that can be used to model industrial processes. As a result, pilot-scale continuous centrifugation is typically employed to model large-scale systems requiring a significant amount of resources. In an effort to reduce resource requirements and create a system which is easy to construct and utilize, a capillary shear device, capable of producing energy dissipation rates equivalent to those present in the feed zones of industrial disk stack centrifuges, was developed and evaluated. When coupled to a bench-top, batch centrifuge, the capillary device reduced centrate turbidity prediction error from 37% to 4% compared to using a bench-top centrifuge alone. Laboratory-scale parameters that are analogous to those routinely varied during industrial-scale continuous centrifugation were identified and evaluated for their utility in emulating disk stack centrifuge performance. The resulting relationships enable bench-scale process modeling of continuous disk stack centrifuges using an easily constructed, scalable, capillary shear device coupled to a typical bench-top centrifuge.     

A mechanical model for the human intervertebral disc

Stress relaxation experiments were performed on specimens from a human intervertebral disc. Specimens were made from the nucleus pulposus and from the external lamellae of the anulus fibrosus in two different orientations. Tests were run with varying moisture content so as to develop a relaxation master curve. A model was developed based on the experimental data. It was found that the short term master curve for the lamellae of the anulus and nucleus are similar, whereas the long term rubbery plateau is different between the lamellae and the nucleus. It was also established that the master curves for different lamellae and the nucleus were shifted relative to each other in the time domain due to changes in water content. The average relaxation modulus of the whole disc was obtained by averaging the properties between the anulus and nucleus. This model was then used for studies of Schmorl's nodes, of degenerated discs and for circumstances in which hydration is considered to be important.     

Transdetermination: Drosophila imaginal disc cells exhibit stem cell-like potency

Drosophila imaginal discs, the primordia of the adult fly appendages, are an excellent system for studying developmental plasticity. Cells in the imaginal discs are determined for their disc-specific fate (wingness, legness) during embryogenesis. Disc cells maintain their determination during larval development, a time of extensive growth and proliferation. Only when prompted to regenerate do disc cells exhibit lability in their determined identity. Regeneration in the disc is mediated by a localized region of cell division, known as the regeneration blastema. Most regenerating disc cells strictly adhere to their disc-specific identity; some cells however, switch fate in a phenomenon known as transdetermination. Similar regeneration and transdetermination events can be induced in situ by misexpression of the signaling molecule wingless. Recent studies indicate that the plasticity of disc cells during regeneration is associated with high morphogen activity and the reorganization of chromatin structure. Here we provide both a historical perspective of imaginal disc transdetermination, as well as discuss recent findings on how imaginal disc cells acquire developmental plasticity and multipotency. We also highlight how an understanding of imaginal disc transdetermination can enhance an understanding of developmental potency exhibited by stem cells.