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Preparative protein precipitation is known as a cost-efficient and easy-to-use alternative to chromatographic purification steps. This said, at the moment, there is no process for monoclonal antibodies (mAb) on the market, although especially polyethylene glycol-induced precipitation has shown great potential. One reason might be the highly complex behavior of each component of a crude feedstock during the precipitation process. For different investigated mAbs, significant variations in the host cell protein (HCP) reduction are observed. In contrast to the precipitation behavior of single components, the interactions and interplay in a complex feedstock are not fully understood yet. This work discusses the influence of contaminants on the precipitation behavior of two different mAbs, an IgG1, and an IgG2. By spiking the mAbs with mock solution, a complex feedstock could successfully be mimicked. Spiking contaminants influenced the yield and purity of the mAbs after the precipitation step, compared to the precipitation behavior of the single components. The mixture showed a decrease in the contaminant and mAb solubility. By re-buffering the mock solution prior to spiking, special salts, small molecules like amino acids, vitamins, or sugars could be depleted while larger ones like HCP or DNA were still present. Therefore, it was possible to distinguish the influence of small molecules and larger ones. Hence, mAb–macromolecular interaction could be identified as a possible reason for the observed higher precipitation propensity, while small molecules of the cell culture medium were identified as solubilisation factors during the precipitation process. [ABSTRACT FROM AUTHOR]

The continuous availability of cells with defined cell characteristics represents a crucial issue in the biopharmaceutical and cell therapy industry. Here, development of cell banks with a long-term stability is essential and ensured by a cryopreservation strategy. The strategy needs to be optimized for each cell application individually and usually comprises controlled freezing, storage at ultra-low temperature, and fast thawing of cells. This approach is implemented by the development of master and working cell banks. Currently, empirical cryopreservation strategy development is standard, but a knowledge-based approach would be highly advantageous. In this article, we report the development of a video-based tool for the characterisation of freezing and thawing behaviour in cryopreservation process to enable a more knowledge-based cryopreservation process development. A successful tool validation was performed with a model cryopreservation process for the β-cell line INS-1E. Performance was evaluated for two working volumes (1.0 mL and 2.0 mL), based on freezing-thawing rates (20 °C to − 80 °C) and cell recovery and increase of biomass, to determine tool flexibility and practicality. Evaluation confirmed flexibility by correctly identifying a delay in freezing and thawing for the larger working volume. Further more, a decrease in cell recovery from 0.94 (± 0.14) % using 1.0 mL working volume to 0.61 (± 0.05) % using a 2.0 mL working volume displays tool practicality. The video-based tool proposed in this study presents a powerful tool for cell-specific optimisation of cryopreservation protocols. This can facilitate faster and more knowledge-based cryopreservation process development In this study, a video-based analytical tool was developed for the characterisation of freezing and thawing behaviour in cryopreservation process development. Evaluation of the practicality and flexibility of the developed tool was done based on a scale-up case study with the cell line INS-1E. Here, the influence of sample working volume on process performance was investigated. Increasing the volume from 1to 2 mL led to a delay in freezing and thawing behaviour which caused cell recovery loss. We believe that the developed tool will facilitate more directed and systematic cryopreservation process development. [ABSTRACT FROM AUTHOR]

For the purification of biopharmaceutical proteins, liquid chromatography is still the gold standard. Especially with increasing product titers, drawbacks like slow volumetric throughput and high resin costs lead to an intensifying need for alternative technologies. Selective preparative protein precipitation is one promising alternative technique. Although the capability has been proven, there has been no precipitation process realized for large-scale monoclonal antibody (mAb) production yet. One reason might be that the mechanism behind protein phase behavior is not completely understood and the precipitation process development is still empirical. Mechanistic modeling can be a means for faster, material-saving process development and a better process understanding at the same time. In preparative chromatography, mechanistic modeling was successfully shown for a variety of applications. Lately, a new isotherm for hydrophobic interaction chromatography (HIC) under consideration of water molecules as participants was proposed, enabling an accurate description of HIC. In this work, based on similarities between protein precipitation and HIC, a new precipitation model was derived. In the proposed model, the formation of protein-protein interfaces is thought to be driven by hydrophobic effects, involving a reorganization of the well-ordered water structure on the hydrophobic surfaces of the protein-protein complex. To demonstrate model capability, high-throughput precipitation experiments with pure or prior to the experiments purified proteins lysozyme, myoglobin, bovine serum albumin, and one mAb were conducted at various pH values. Polyethylene glycol (PEG) 6000 was used as precipitant. The precipitant concentration as well as the initial protein concentration was varied systematically. For all investigated proteins, the initial protein concentrations were varied between 1.5 mg/mL and 12 mg/mL. The calibrated models were successfully validated with experimental data. This mechanistic description of protein precipitation process offers mathematical explanation of the precipitation behavior of proteins at PEG concentration, protein concentration, protein size, and pH. [ABSTRACT FROM AUTHOR]

Effective process development towards intensified processing for gene delivery applications using Hepatitis B core Antigen (HBcAg) virus-like particles (VLPs) relies on analytical methods for the absolute quantification of HBcAg VLP proteins and bound nucleic acids. We investigated a silica spin column (SC)-based extraction procedure, including proteinase K lysis and silica chromatography, for the absolute quantification of different species of nucleic acids bound to HBcAg VLPs analyzed by dye-based fluorescence assays. This revealed load-dependent nucleic acid recoveries of the silica-SC-based extraction. We also developed a reversed-phase high-performance liquid chromatography (RP-HPLC) method to separate and quantify the HBcAg proteins and the bound nucleic acids simultaneously without prior sample treatment by dissociation reagents. The method demonstrated sufficient linearity, accuracy, and precision coefficients and is suited for determining absolute protein and nucleic acid concentrations and HBcAg protein purities at various purification stages. Both the silica-SC-based extraction and the RP-based extraction presented overcome the limitations of analytical techniques, which are restricted to relative or qualitative analyses for HBcAg VLPs with bound nucleic acids. In combination with existing analytics, the methods for an absolute quantification of HBcAg VLPs and bound nucleic acids presented here are required to evaluate downstream purification steps, such as the removal of host cell-derived nucleic acids, concurrent protein loss, and efficient loading with therapeutic nucleic acids. Hence, the methods are key for effective process development when using HBcAg VLP as potential gene delivery vehicles. [ABSTRACT FROM AUTHOR]

Protein phase diagrams are a tool to investigate the cause and consequence of solution conditions on protein phase behavior. The effects are scored according to aggregation morphologies such as crystals or amorphous precipitates. Solution conditions affect morphologic features, such as crystal size, as well as kinetic features, such as crystal growth time. Commonly used data visualization techniques include individual line graphs or phase diagrams based on symbols. These techniques have limitations in terms of handling large data sets, comprehensiveness or completeness. To eliminate these limitations, morphologic and kinetic features obtained from crystallization images generated with high throughput microbatch experiments have been visualized with radar charts in combination with the empirical phase diagram method. Morphologic features (crystal size, shape, and number, as well as precipitate size) and kinetic features (crystal and precipitate onset and growth time) are extracted for 768 solutions with varying chicken egg white lysozyme concentration, salt type, ionic strength, and pH. Image-based aggregation morphology and kinetic features were compiled into a single and easily interpretable figure, thereby showing that the empirical phase diagram method can support high-throughput crystallization experiments in its data amount as well as its data complexity. [ABSTRACT FROM AUTHOR]

Abstract: BACKGROUND: 3D printing and bioprinting in particular are emerging technologies in the field of biotechnology. The developments of bioprinters and applications lie mostly in the highly observed working fields of tissue engineering and regenerative medicine. Until now only little attention has been paid to the application of 3D bioprinting for the investigation of hydrogel–liquid phase interactions in biotechnological applications. This can mostly be attributed to the need for complex and expensive equipment. RESULTS: In this work, an entry‐level bioprinter on the base of a commercially available Fused‐Filament‐Fabrication 3D printer and an easy to handle user interface was designed. This newly developed bioprinter allowed the structuring of bioinks and hydrogels in microwell plates and even complex models were printed. The applicability of the presented printer setup in the field of biotechnology was shown by the encapsulation of β‐galactosidase (EC 3.2.1.23) in poly(ethylene glycol) diacrylate based hydrogels. Subsequently, an automated screening of the biocatalytic conversion of the substrate ONPG by the encapsulated enzyme was executed on a liquid handling station. Under varied pH conditions in the surrounding liquid phase highest substrate turnover rates were detected at pH 3 and pH 5 which is in good accordance with previously reported pH optima of β‐galactosidase. CONCLUSION: This approach shows an easy access to 3D bioprinting in the field of biotechnology and the implementation of 3D printed hydrogels in high‐throughput experimentation. © 2017 Society of Chemical Industry [ABSTRACT FROM AUTHOR]

The biopharmaceutical industry is at a turning point moving toward a more customized and patient-oriented medicine (precision medicine). Straightforward routines such as the antibody platform process are extended to production processes for a new portfolio of molecules. As a consequence, individual and tailored productions require generic approaches for a fast and dedicated purification process development. In this article, different effective strategies in biopharmaceutical purification process development are reviewed that can analogously be used for the new generation of antibodies. Conventional approaches based on heuristics and high-throughput process development are discussed and compared to modern technologies such as multivariate calibration and mechanistic modeling tools. Such approaches constitute a good foundation for fast and effective process development for new products and processes, but their full potential becomes obvious in a correlated combination. Thus, different combinatorial approaches are presented, which might become future directions in the biopharmaceutical industry. [ABSTRACT FROM AUTHOR]

The protein A capture step is the main cost-driver in downstream processing, with high attrition costs especially when using protein A resin not until end of resin lifetime. Here we describe a feasibility study, transferring a batch downstream process to a hybrid process, aimed at replacing batch protein A capture chromatography with a continuous capture step, while leaving the polishing steps unchanged to minimize required process adaptations compared to a batch process. 35 g of antibody were purified using the hybrid approach, resulting in comparable product quality and step yield compared to the batch process. Productivity for the protein A step could be increased up to 420%, reducing buffer amounts by 30–40% and showing robustness for at least 48 h continuous run time. Additionally, to enable its potential application in a clinical trial manufacturing environment cost of goods were compared for the protein A step between hybrid process and batch process, showing a 300% cost reduction, depending on processed volumes and batch cycles. [ABSTRACT FROM AUTHOR]