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.     

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.     

Downscaling cake filtration—Correlations between compressibility of lysozyme crystal filter cakes and filter area

Crystallization is a commonly used method for the purification and formulation of proteins. In order to harmonize crystallization with the mechanical separation process, it is necessary to estimate early the separation conditions of protein crystals. To fulfill this requirement, the feed material for filtration is minimized by reducing the filter area. The filtration behavior of lysozyme crystals in pressure filters with two different filter areas was compared. Crystal slurries with different mean crystal sizes and shapes were produced and the influence of the size and shape on the scalability of filtration data was examined. It was found that for different aggregated crystal structures and isometric crystals, the larger the compressibility of the cake was, the larger were the deviations for the two considered filter areas. For needle‐shaped crystals, the compressibility was not subject to deviations, but the absolute filter cake resistance was. Furthermore, the deviations of the cake resistances increased with higher pressures for all product systems. It was indicated that upscaling from the small filter area is possible for low compressible product systems and at low pressures. With high compressible products and for needle‐like crystals, the filtration time is underestimated with the small filter area.     

Modeling the influence of slurry concentration on Saccharomyces cerevisiae cake porosity and resistance during microfiltration

Filtration of an isotonic suspension of baker's yeast through a 0.45‐μm membrane was studied at two different pressures, 40 and 80 kPa, for yeast concentrations ranging from 0.14 to 51 kg/m³ (dry weight). For a yeast volume fraction above 0.06 (～21.8 kg/m³), the porosity of the yeast cake is less dependent on the suspension concentration. For highly diluted suspensions, the specific cake resistance approaches a minimum that depends on the filtration pressure. Correlation functions of cake porosity and specific cake resistance were obtained for the concentration range investigated showing that the Kozeny–Carman coefficient increases when the applied pressure increases. Both filtration pressure and slurry concentration can be process controlled. In the range of moderate yeast concentration, the filtrate flux may be increased by manipulating the filtration pressure and the slurry concentration, thereby improving the overall process efficiency. The complex behavior of yeast cakes at high slurry concentration can be described by a conventional model as long as part of yeast cells are assumed to form aggregates, which behave as single bigger particles. The aggregation effect may be accounted for using a binary mixture model. © 2012 American Institute of Chemical Engineers Biotechnol. Prog., 2012     

A new sensor-the "filtration Probe"- for quantitative characterization of penicillin fermentation. III. An automatically operating probe

The filtration characteristics of the penicillin broth can be monitored semicontinuously using an automatic filtration probe. This probe operates aseptically and the broth samples (filtrate and filter cake) are recycled to the fermentor after each filtration. The collected data-filtrate volume and filter cake volume versus filtration time-can be related to the total biomass concentration in the fermentor.     

Prefiltration enhances performance of sterile filtration for glycoconjugate vaccines

Recent studies have reported very low capacity during sterile filtration of glycoconjugate vaccines due to rapid fouling of the sterile filter. The objective of this study was to explore the potential for significantly increasing the capacity of the sterile filter through the use of an appropriate prefilter. Data were obtained using prefilters with different pore size and chemistry, with the sterile filtration performed at constant filtrate flux using 0.22 μm nominal pore size Durapore® polyvinylidene difluoride membranes. Prefiltration through 5 μm pore size Durapore® or Nylon prefilters nearly eliminated the fouling of the sterile filter, leading to more than a 100-fold reduction in the rate of pressure increase for the sterile filter. This dramatic improvement in sterile filter performance was due to the removal of large components (greater than 1 μm in size) as confirmed by dynamic light scattering. These results demonstrate the potential of using large pore size prefilters to significantly enhance the performance of the sterile filtration process for the production of important glycoconjugate vaccines.     

A two-compartment bioreactor system made of commercial parts for bioprocess scale-down studies: impact of oscillations on Bacillus subtilis fed-batch cultivations

This study describes an advanced version of a two-compartment scale-down bioreactor that simulates inhomogeneities present in large-scale industrial bioreactors on the laboratory scale. The system is made of commercially available parts and is suitable for sterilization with steam. The scale-down bioreactor consists of a usual stirred tank bioreactor (STR) and a plug flow reactor (PFR) equipped with static mixer modules. The PFR module with a working volume of 1.2 L is equipped with five sample ports, and pH and dissolved oxygen (DO) sensors. The concept was applied using the non-sporulating Bacillus subtilis mutant strain AS3, characterized by a SpoIIGA gene knockout. In a fed-batch process with a constant feed rate, it is found that oscillating substrate and DO concentration led to diminished glucose uptake, ethanol formation and an altered amino acid synthesis. Sampling at the PFR module allowed the detection of dynamics at different concentrations of intermediates, such as pyruvic acid, lactic acid and amino acids. Results indicate that the carbon flux at excess glucose and low DO concentrations is shifted towards ethanol formation. As a result, the reduced carbon flux entering the tricarboxylic acid cycle is not sufficient to support amino acid synthesis following the oxaloacetic acid branch point.     

In situ filtration of Anchusa officinalis culture in a cell-retention stirred tank bioreactor

Summary The effect of agitation and aeration on filtration of Anchusa officinalis culture in a stirred tank bioreactor integrated with an internal filter unit was investigated. Increases in suction head of the pump that drove the filtration process were measured at impeller speeds of 100 and 200 rpm. Surprisingly, suction head attained at 200 rpm was about 40% higher than at 100 rpm. Direct observation of the cake deposition process in the reactor using a dilute cell suspension revealed that the filter cake formed at 100 rpm was thicker, but less compact. Aeration at 0.4 vvm was shown to have little effect on the filtration rate, since the bulk fluid flow was dominated by the impeller hydrodynamics. The initial flux can be recovered by filter backwashing with compressed air at a flow rate of 0.6 vvm for a duration of 5 minutes.     

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.     

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。     

Microfiltration of recombinant yeast cells using a rotating disk dynamic filtration system

To develop a highly efficient cell harvest step under time constraint, a novel rotating disk dynamic filtration system was studied on the laboratory scale (0.147-ft.(2) nylon membrane) for concentrating recombinant yeast cells containing an intracellular product. The existing cross-flow microfiltration method yielded pseudo-steady state flux values below 25 LMH (L/m(2). h) even at low membrane loadings (10 L/ft.(2)). By creating high shear rates (up to 120,000(-1)) on the membrane surface using a rotating solid disk, this dynamic filter has demonstrated dramatically improved performance, presumably due to minimal cake buildup and reduced membrane fouling. Among the many factors investigated, disk rotating speed, which determines shear rates and flow patterns, was found to be the most important adjustable parameter. Our experimental results have shown that the flux increases with disk rotating speed, increases with transmembrane pressure at higher cell concentrations, and can be sustained at high levels under constant flux mode. At a certain membrane loading level, there was a critical speed below which it behaved similarly to a flat sheet system with equivalent shear. Average flux greater than 200 LMH has been demonstrated at 37-L/ft.(2) loading at maximum speed to complete sixfold concentration and 15-volume diafiltration for less than 100 min. An order of magnitude improvement over the crossflow microfiltration control was projected for large scale production. This superior performance, however, would be achieved at the expense of additional power input and heat dissipation, especially when cell concentration reaches above 80 g dry cell weight (DCW)/L. Although a positive linear relationship between power input and dynamic flux at a certain concentration factor has been established, high cell density associated with high viscosity impacted adversely on effective average shear rates and, eventually, severe membrane fouling, rather than cake formation, would limit the performance of this novel system. (c) 1995 John Wiley & Sons, Inc.     

Clarification of yeast cell suspensions by depth filtration

Depth filtration can be very attractive for initial clarification because of low capital costs and ease of operation. However, there is currently no fundamental understanding of the effects of the filter pore size and morphology on the overall capacity and filtrate quality. The objective of this study was to examine the flux, capacity, and filtrate turbidity of a series of depth filters with different pore size ratings and multilayer structures for the filtration of yeast cell suspensions. Data were analyzed using available fouling models to obtain insights into the flux decline mechanisms. Filters with small pore size provide high filtrate quality at low capacity, with the reverse being true for the larger pore sizes. The multilayer structure of commercial depth filters leads to improved performance, although the choice of layer properties is critical. The highest capacity was achieved using a multilayer filter in which the upper layer allows significant yeast cell penetration into the filter matrix but still protects the retentive layer that is needed for a high quality filtrate.     

Protein fouling of virus filtration membranes: effects of membrane orientation and operating conditions

The capacity of virus filters used in the purification of therapeutic proteins is determined by the rate and extent of membrane fouling. Current virus filtration membranes have a complex multilayer structure that can be used with either the skin-side up or with the skin-side facing away from the feed, but there is currently no quantitative understanding of the effects of membrane orientation or operating conditions on the filtration performance. Experiments were performed using Millipore's Viresolve 180 membrane under both constant pressure and constant flux operation with sulfhydryl-modified BSA used as a model protein. The capacity with the skin-side up was greater during operation with constant flux and at low transmembrane pressures, with the flux decline or pressure rise due primarily to osmotic pressure effects. In contrast, data obtained with the skin-side down showed a slower, steady increase in total resistance with the cumulative filtrate volume, with minimal contribution from osmotic pressure. The capacity with the skin-side down was significantly greater than that with the skin-side up, reflecting the different fouling mechanisms in the different membrane orientations. These results provide important insights for the design and operation of virus filtration membranes.     

Separation of yeast by cross-flow filtration with backwashing

The following results were obtained at the separation of yeast by cross-flow filtration from fermentation broth or yeast suspensions with or without backwashing by the filtrate, using micro-porous membranes: 1) the first stage of the filtration process was described by the standard blocking filtration model, 2) the mean filtration flux in one filtration cycle was kept almost constant for at least 3 h by backwashing, 3) the mean filtration flux with backwashing was roughly estimated from the results of filtration without backwashing, and 4) the mean filtration flux at certain yeast concentration in concentrating the yeast was not so much affected by the previous concentration path, and almost agreed that in the filtration of a constant concentration at the same concentration.     

Streamlining process characterization efforts using the high throughput ambr® crossflow system for ultrafiltration and diafiltration processing of monoclonal antibodies

Commercial process development for biopharmaceuticals often involves process characterization (PC) studies to gain process knowledge and understanding in preparation for process validation. One common approach to conduct PC activities is by using design-of-experiment, which can help determine the impact process parameter deviations may have on product quality attributes. Qualified scale-down systems are typically used to conduct these studies. For an ultrafiltration/diafiltration (UF/DF) application, however, a traditional scale-down still requires hundreds of milliliters of material per run and can only conduct one experiment at a time. This poses a challenge in resources as there could be 20+ experiments required for a typical UF/DF PC study. One solution to circumvent this is the use of high-throughput systems, which enable parallel experimentation by only using a fraction of the resources. Sartorius Stedim Biotech has recently commercialized the ambr® crossflow high-throughput system to meet this need. In this study, the performance of this system during a monoclonal antibody UF/DF step was first compared with a pilot- and a manufacturing-scale tangential flow filtration (TFF) system at a single operating condition. Due to material limitations, it was then compared to only the pilot-scale TFF system across wider ranges of transmembrane pressure; crossflow rate; and diafiltration concentration in a PC study. Permeate flux, aggregate content, process yield, pH/conductivity traces, retentate concentration, axial pressure drop, and turbidity values were measured at both scales. A good agreement was attained across scales, further supporting its potential use as a scale-down system.     

Microfiltration of gluten processing streams from corn wet milling

In corn wet milling, dry matter can be separated from liquids in process streams with centrifuges or vacuum belt filtration (VBF). Because separations usually are not complete, dry matter can be lost in the liquid streams (overflow from the gluten thickener centrifuge and filtrate from VBF). This represents a loss of nutrients, especially protein, to low valued coproducts and reduces quality of water for recycling within the process. The objective was to compare microfiltration of light and heavy gluten process streams to conventional separation methods. Batches of light and heavy gluten were obtained from a wet mill plant and processed by microfiltration. Samples of permeate and concentrate from microfiltration were analyzed and compared to corresponding streams from wet milling. Microfiltration of light gluten resulted in concentrate and permeate streams similar in composition to conventionally processed light gluten using a centrifuge, suggesting that microfiltration is as effective as centrifugation in partitioning solids and water in light gluten. Dewatering of heavy gluten found that conventional VBF caused dry matter concentrations in gluten cake to be higher than concentrate from microfiltration. Permeate from microfiltration of heavy gluten had higher concentrations of ash and lower soluble nitrogen than filtrate from VBF. Microfiltration was able to remove more ash from concentrate, which may improve the value of wet milling coproducts. These data demonstrated microfiltration has potential for separation of light and heavy gluten streams, but more data are needed on effectiveness and practicality.     

Modulation of transmembrane pressure in manufacturing scale tangential flow filtration N-1 perfusion seed culture

Mammalian cells were grown to high density in a 3,000 L culture using perfusion with hollow fibers operated in a tangential flow filtration mode. The high-density culture was used to inoculate the production stage of a biomanufacturing process. At constant permeate flux operation, increased transmembrane pressures (TMPs) were observed on the final day of the manufacturing batches. Small scale studies suggested that the filters were not irreversibly fouled, but rather exposed to membrane concentration polarization that could be relieved by tangential sweeping of the hollow fibers. Studies were undertaken to analyze parameters that influence the hydrodynamic profile within hollow fibers; including filter area, cell density, recirculation flow rate, and permeate flow rate. Results indicated that permeate flow rate had the greatest influence on modulating TMP. Further evaluation showed a significant decrease in TMP when permeate flow was reduced, and this occurred without any negative effect on cell growth or viability. Hence, a 30% reduction of permeate flow rate was implemented at manufacturing scale. A stable operation was achieved as TMP was successfully reduced by 75% while preserving all critical factors for performance in the perfusion bioreactor.     

Role of membrane structure on the filtrate flux during monoclonal antibody filtration through virus retentive membranes

Virus removal filtration is a critical step in the manufacture of monoclonal antibody products, providing a robust size-based removal of both enveloped and non-enveloped viruses. Many monoclonal antibodies show very large reductions in filtrate flux during virus filtration, with the mechanisms governing this behavior and its dependence on the properties of the virus filter and antibody remaining largely unknown. Experiments were performed using the highly asymmetric Viresolve® Pro and the relatively homogeneous Pegasus™ SV4 virus filters using a highly purified monoclonal antibody. The filtrate flux for a 4 g/L antibody solution through the Viresolve® Pro decreased by about 10-fold when the filter was oriented with the skin side down but by more than 1000-fold when the asymmetric filter orientation was reversed and used with the skin side up. The very large flux decline observed with the skin side up could be eliminated by placing a large pore size prefilter directly on top of the virus filter; this improvement in filtrate flux was not seen when the prefilter was used inline or as a batch prefiltration step. The increase in flux due to the prefilter was not related to the removal of large protein aggregates or to an alteration in the extent of concentration polarization. Instead, the prefilter appears to transiently disrupt reversible associations of the antibodies caused by strong intermolecular attractions. These results provide important insights into the role of membrane morphology and antibody properties on the filtrate flux during virus filtration.     

Crossflow filtration of yeast broth cultivated in molasses

A broth of yeast cells cultivated in molasses was crossfiltered with a thin-channel module. The permeation flux gradually decreased at a constant cell concentration. The flux was much lower than that obtained for yeast broth cultivated in yeast extract, polypeptone, and dextrose (YPD) medium during the filtration. The flux did not depend on the membrane pore size (0.45 to 5 mum). The steady-state flux was one-twentieth that calculated for a cake filtration mode from the amount of cake per unit filtration area and the specific resistance of the cake measured in a dead-end filtration apparatus. The lower flux was due to small particles (most of which were less than 1 mum in diameter) in the molasses. The mehanism of crossflow filtration of broths of yeast cells cultivated in molasses was clarified by analysis of the change in flux with time and observations with scanning electron microscopy. At the initial stage of crossflow filtration the yeast cells and particles from the molasses were deposited on the membrane to form the molasses were deposited on the membrane to form a cake in a similar way to dead-end filtration. After the deposition of cells onto the membrane ceased, the fine particles from molasses formed a thin layer, which had higher resistance than the cake formed next to the membrane. The backwashing method was effective to increase the flux. The flux increased low when the pore size was 0.45 to 0.08 mum, but using larger pores of 3 to 5 mum it returned almost to the bases line. (c) 1994 John Wiley & Sons, Inc.     

Comparative testing of tangential microfiltration for microbial cultures

In an attempt to extend and intensify the productive periods of bioprocesses, a self-cleaning tangential filtration device was examined. Built into a special-design bioreactor, its cell retention was evaluated for continuous-flow operation with selected examples of bacteria (Escherichia coli), yeasts (Sacharomyces cerevisiae), and filamentous fungi (Aspergillus niger). Performance characteristics such as filtration rates and cell accumulation were assessed as a function of filter rotational speed, operating pressure, cultivation time, and microfilter type (i.e., membrane or porous metallic). The highest flux of cell-free filtrate for each culture type was achieved using a 0.45-micron membrane-covered microfilter. While the respective yeast (S. cerevisiae) and bacterial (E. coli) cell concentrations were enhanced by as much as 16- and 8-fold over the batch growth levels, the representative A. niger fungal cultivation was less satisfactory because of progressively declining filtration rates limited by hydraulically resistant layers of microbial surface growth quite resistant to in situ filter backflushing with gas. Maximum steady-state flux was independent of operating pressure, yet was enhanced at rotational speeds up to about 800 rpm. Higher speeds offered no further improvements. The overall fermentation process was limited by the moderate levels of attainable flux which restricted the feed and dilution rates. The maximum attainable stabilized fluxes were 26-40 L/m(2) x h.