Very high density of CHO cells in perfusion by ATF or TFF in WAVE bioreactor™. Part I. Effect of the cell density on the process

High cell density perfusion process of antibody producing CHO cells was developed in disposable WAVE Bioreactor? using external hollow fiber filter as cell separation device. Both “classical” tangential flow filtration (TFF) and alternating tangential flow system (ATF) equipment were used and compared. Consistency of both TFF‐ and ATF‐based cultures was shown at 20–35 × 10⁶ cells/mL density stabilized by cell bleeds. To minimize the nutrients deprivation and by‐product accumulation, a perfusion rate correlated to the cell density was applied. The cells were maintained by cell bleeds at density 0.9–1.3 × 10⁸ cells/mL in growing state and at high viability for more than 2 weeks. Finally, with the present settings, maximal cell densities of 2.14 × 10⁸ cells/mL, achieved for the first time in a wave‐induced bioreactor, and 1.32 × 10⁸ cells/mL were reached using TFF and ATF systems, respectively. Using TFF, the cell density was limited by the membrane capacity for the encountered high viscosity and by the pCO₂ level. Using ATF, the cell density was limited by the vacuum capacity failing to pull the highly viscous fluid. Thus, the TFF system allowed reaching higher cell densities. The TFF inlet pressure was highly correlated to the viscosity leading to the development of a model of this pressure, which is a useful tool for hollow fiber design of TFF and ATF. At very high cell density, the viscosity introduced physical limitations. This led us to recommend cell densities under 1.46 × 10⁸ cell/mL based on the analysis of the theoretical distance between the cells for the present cell line. © 2013 American Institute of Chemical Engineers Biotechnol. Prog., 29:754–767, 2013     

Understanding and modeling alternating tangential flow filtration for perfusion cell culture

Alternating tangential flow (ATF) filtration has been used with success in the Biopharmaceutical industry as a lower shear technology for cell retention with perfusion cultures. The ATF system is different than tangential flow filtration; however, in that reverse flow is used once per cycle as a means to minimize fouling. Few studies have been reported in the literature that evaluates ATF and how key system variables affect the rate at which ATF filters foul. In this study, an experimental setup was devised that allowed for determination of the time it took for fouling to occur for given mammalian (PER.C6) cell culture cell densities and viabilities as permeate flow rate and antifoam concentration was varied. The experimental results indicate, in accordance with D'Arcy's law, that the average resistance to permeate flow (across a cycle of operation) increases as biological material deposits on the membrane. Scanning electron microscope images of the post‐run filtration surface indicated that both cells and antifoam micelles deposit on the membrane. A unique mathematical model, based on the assumption that fouling was due to pore blockage from the cells and micelles in combination, was devised that allowed for estimation of sticking factors for the cells and the micelles on the membrane. This model was then used to accurately predict the increase in transmembane pressure during constant flux operation for an ATF cartridge used for perfusion cell culture. © 2014 American Institute of Chemical Engineers Biotechnol. Prog., 30:1291–1300, 2014     

Large-scale preparation of bacterial cell membranes by tangential flow filtration

The preparation of cell membranes by ultracentrifugation of bacterial cell lysates, a pre-requisite for the purification of over-expressed membrane proteins, is both time-consuming and difficult to perform on a large scale. To overcome this bottleneck in the structural investigation of such proteins in the UK Membrane Protein Structure Initiative, we have investigated the alternative use of tangential flow filtration for preparation of membranes from Escherichia coli. This method proved to be superior to the conventional use of ultracentrifuges both in speed and in yield of membrane protein. Moreover, it could more readily be scaled up to process larger quantities of bacterial cells. Comparison of the purity and monodispersity of an over-expressed membrane protein purified from conventionally-prepared membranes and from membranes prepared by filtration revealed no substantial differences. The approach described should therefore be of general use for membrane protein preparation for a wide range of applications, including both structural and functional studies.     

Properties of microfiltration membranes: flux loss during constant pressure permeation of bovine serum albumin

An experimental study of permeation of dilute BSA solutions (filtration) at microfiltration membranes has been carried out. Most measurements were made with capillary pore aluminum oxide membranes, with some comparative measurements with tortuous and capillary pore polymeric membranes. In all cases, a continuous and substantial decrease in the rate of permeation with time was observed. This decrease in permeation with time was observed. This decrease in permeation rate was due neither to concentration polarization nor to protein adsorption alone. However, it could be quantified using the standard blocking filtration law, which describes a decrease in pore volume due to deposition of protein on the walls of the pore. The maximum calculated thickness of the deposited layers was 55nm on the walls of 200-nm diameter pores. This phenomenon is quite different to adsorption of protein at such surfaces, this latter giving only sub-monolayer or monolayer protein coverage under the conditions studied.     

提高成纤维细胞生长因子-21产率和纯度

成纤维细胞生长因子-21(FGF-21)作为近期发现的新型代谢调节因子,因其具有独立于胰岛素调节糖脂代谢、增加胰岛素敏感性等作用,有望成为治疗糖尿病的新型药物。包涵体形式表达外源蛋白表达量及纯度高,但是以pET载体表达时,FGF-21以包涵体形式表达,且复性率及产率低,蛋白活性降低[1]。针对这一瓶颈问题,用SUMO载体首次以包涵体形式表达带有SUMO标签的hFGF-21,通过优化培养条件,并应用中空纤维柱膜过滤技术对菌体进行富集,对包涵体进行洗涤、变性及复性,经过亲和层析、凝胶过滤层析的纯化方法,得到了成熟的hFGF-21,在保证蛋白活性的同时增加了蛋白的产量及纯度。通过检测HepG2细胞葡萄糖吸收及2型糖尿病db/db小鼠短期及长期血糖变化鉴定其降糖生物学活性。结果表明,以包涵体形式表达hFGF-21(ihFGF-21)的表达量是可溶形式表达的hFGF-21(shFGF-21)的3倍,最终ihFGF-21的收率为20 mg/L,而shFGF-21的收率仅为6 mg/L。ihFGF-21的纯度可达到95%以上,而shFGF-21仅能达到90%左右;在细胞水平和动物水平上两者的降糖生物学活性一致。在保证hFGF-21生物学活性的前提下,与传统包涵体途径提取目的蛋白的方法相比,应用中空纤维柱膜过滤技术使hFGF-21的生产周期缩短了约1/3左右。综上所述,此法为FGF-21中试及工业化生产提供了高效、经济的策略。     

Virus filtration of high‐concentration monoclonal antibody solutions

The ability to process high‐concentration monoclonal antibody solutions (> 10 g/L) through small‐pore membranes typically used for virus removal can improve current antibody purification processes by eliminating the need for feed stream dilution, and by reducing filter area, cycle‐time, and costs. In this work, we present the screening of virus filters of varying configurations and materials of construction using MAb solutions with a concentration range of 4–20 g/L. For our MAbs of interest—two different humanized IgG1s—flux decay was not observed up to a filter loading of 200 L/m² with a regenerated cellulose hollow fiber virus removal filter. In contrast, PVDF and PES flat sheet disc membranes were plugged by solutions of these same MAbs with concentrations >4 g/L well before 50 L/m². These results were obtained with purified feed streams containing <2% aggregates, as measured by size exclusion chromatography, where the majority of the aggregate likely was composed of dimers. Differences in filtration flux performance between the two MAbs under similar operating conditions indicate the sensitivity of the system to small differences in protein structure, presumably due to the impact of these differences on nonspecific interactions between the protein and the membrane; these differences cannot be anticipated based on protein pI alone. Virus clearance data with two model viruses (XMuLV and MMV) confirm the ability of hollow fiber membranes with 19 ± 2 nm pore size to achieve at least 3–4 LRV, independent of MAb concentration, over the range examined. © 2009 American Institute of Chemical Engineers Biotechnol. Prog., 2009     

哺乳动物细胞灌流培养工艺开发与优化

近年来生物药市场需求量激增,高产量、高质量、低成本的哺乳动物细胞灌流培养工艺顺势成为工业界和学术界普遍关注的热点。文中围绕灌流培养工艺特有的操作环节及工艺优化应着重关注的细节展开论述,综述了近年来在灌流培养工艺开发和优化上取得的进步和提出的策略,以期为哺乳动物细胞灌流培养技术的开发提供参考。     

Effects of ammonium ion removal on growth and MAb production of hybridoma cells

Production of monoclonal antibody against hepatitis B surface antigen was carried out by perfusion culture coupled with a selective removal system for ammonium ion. The removal system is composed of three sub-systems namely, cell separation by cross-flow ceramic filter, dialysis by hollow fiber module and ion-exchange by zeolite A-3 packed bed column. The ammonium ion concentration in the culture broth was effectively maintained below the inhibitory level, and the viable cell density reached 2.5×10⁷ cells ml^–1 which was three times that of conventional perfusion cultures. The monoclonal antibody accumulated to a concentration as high as 26.3×10⁵ mIU^–1. This is already almost half of the amount producedin vivo. The numerical investigation of the ammonium ion removal system showed the possibility to improve much more the performance of this perfusion cultivation system.