David Pollard

A Review of Advanced Small-Scale Parallel Bioreactor Technology for Accelerated Process Development: Current State and Future Need

The pharmaceutical and biotech industries face continued pressure to reduce development costs and accelerate process development. This challenge occurs alongside the need for increased upstream experimentation to support quality by design initiatives and the pursuit of predictive models from systems biology. A small scale system enabling multiple reactions in parallel (n ≥ 20), with automated sampling and integrated to purification, would provide significant improvement (four to fivefold) to development timelines. State of the art attempts to pursue high throughput process development include shake flasks, microfluidic reactors, microtiter plates and small‐scale stirred reactors. The limitations of these systems are compared to desired criteria to mimic large scale commercial processes. The comparison shows that significant technological improvement is still required to provide automated solutions that can speed upstream process development.

Substrate supply for effective biocatalysis.

Using biocatalysis for some chemical synthesis steps has unique advantages such as achieving higher product selectivity under ambient process conditions. However, a common limitation with such systems is the inhibition or toxicity posed by the starting substrate as well as limited aqueous solubility in many cases. In this review, we discuss the supply of substrate to bioconversions. The delivery of substrate via an auxiliary, which may be water‐miscible, or a second phase such as a water‐immiscible organic solvent, adsorbing resin, or a gas, is examined through recent examples in the field. Finally, guidelines for experimental planning and process considerations are suggested to facilitate the choice of substrate delivery method and accelerate process development.

Optimization of a glycoengineered Pichia pastoris cultivation process for commercial antibody production

Glycoengineering enabled the production of proteins with human N‐linked glycans by Pichia pastoris. This study used a glycoengineered P. pastoris strain which is capable of producing humanized glycoprotein with terminal galactose for monoclonal antibody production. A design of experiments approach was used to optimize the process parameters. Followed by further optimization of the specific methanol feed rate, induction duration, and the initial induction biomass, the resulting process yielded up to 1.6 g/L of monoclonal antibody. This process was also scaled‐up to 1,200‐L scale, and the process profiles, productivity, and product quality were comparable with 30‐L scale. The successful scale‐up demonstrated that this glycoengineered P. pastoris fermentation process is a robust and commercially viable process.

Advanced near‐infrared monitor for stable real‐time measurement and control of Pichia pastoris bioprocesses

Near‐infrared spectroscopy is considered to be one of the most promising spectroscopic techniques for upstream bioprocess monitoring and control. Traditionally the nature of near‐infrared spectroscopy has demanded multivariate calibration models to relate spectral variance to analyte concentrations. The resulting analytical measurements have proven unreliable for the measurement of metabolic substrates for bioprocess batches performed outside the calibration process. This paper presents results of an innovative near‐infrared spectroscopic monitor designed to follow the concentrations of glycerol and methanol, as well as biomass, in real time and continuously during the production of a monoclonal antibody by a Pichia pastoris high cell density process. A solid state instrumental design overcomes the ruggedness limitations of conventional interferometer‐based spectrometers. Accurate monitoring of glycerol, methanol, and biomass is demonstrated over 274 days postcalibration. In addition, the first example of feedback control to maintain constant methanol concentrations, as low as 1 g/L, is presented. Postcalibration measurements over a 9‐month period illustrate a level of reliability and robustness that promises its adoption for online bioprocess monitoring throughout product development, from early laboratory research and development to pilot and manufacturing scale operation.

Advective hydrogel membrane chromatography for monoclonal antibody purification in bioprocessing.

Protein A chromatography is widely employed for the capture and purification of monoclonal antibodies (mAbs). Because of the high cost of protein A resins, there is a significant economic driving force to seek new downstream processing strategies. Membrane chromatography has emerged as a promising alternative to conventional resin based column chromatography. However, to date, the application has been limited to mostly ion exchange flow through (FT) mode. Recently, significant advances in Natrix hydrogel membrane has resulted in increased dynamic binding capacities for proteins, which makes membrane chromatography much more attractive for bind/elute operations. The dominantly advective mass transport property of the hydrogel membrane has also enabled Natrix membrane to be run at faster volumetric flow rates with high dynamic binding capacities. In this work, the potential of using Natrix weak cation exchange membrane as a mAb capture step is assessed. A series of cycle studies was also performed in the pilot scale device (> 30 cycles) with good reproducibility in terms of yield and product purities, suggesting potential for improved manufacturing flexibility and productivity. In addition, anion exchange (AEX) hydrogel membranes were also evaluated with multiple mAb programs in FT mode. Significantly higher binding capacity for impurities (support mAb loads up to 10Kg/L) and 40X faster processing speed were observed compared with traditional AEX column chromatography. A proposed protein A free mAb purification process platform could meet the demand of a downstream purification process with high purity, yield, and throughput.

The bioreduction of a β-tetralone to its corresponding alcohol by the yeast Trichosporon capitatum MY1890 and bacterium Rhodococcus erythropolis MA7213 in a range of ionic liquids

The stereospecific reduction of 6-Br-β-tetralone to its corresponding alcohol (S)-6-Br-β-tetralol was carried out by the yeast Trichosporon capitatum MY1890 and by the bacterium Rhodococcus erythropolis MA7213, using a range of ionic liquids chosen for the diversity of their composition. The decrease in cell viability of both types of cell upon exposure to ionic liquids was found to be between that determined for cells residing purely in fermentation media, and cells residing in a two-phase mixture of media and organic solvent (toluene). For T. capitatum MY1890 bioconversions, the water miscible hydrophilic ionic liquid [Emim][TOS] gave a reaction profile comparable to that observed in the previously studied water–ethanol (10% v/v) system, in terms of overall rate of reaction (0.2 g (prod) L−1 h−1) and conversion (100%). Of the hydrophobic ionic liquids evaluated, [Oc3MeN][BTA] gave the best conversion of 60%, but at a much reduced rate, suggesting solute mass transfer from the ionic liquid phase was rate limiting. For bioconversions carried out with R. erythropolis MA7213 employing 20% v/v [Emim][TOS] as a co-solvent, the conversion yield doubled, and a four-fold increase in initial rate was found compared to the standard ethanol co-solvent. This was attributed to improved cell viability and reduced aggregation of the R. erythropolis MA7213 compared to T. capitatum MY1890. Overall, this study demonstrates the feasibility of using ionic liquids for whole cell biocatalysis, however, no obvious link is apparent between the physico-chemical properties of ionic liquids, their influence on cell viability, and their efficacy as media for bioconversions.

On-Line Ion Exchange Liquid Chromatography as a Process Analytical Technology for Monoclonal Antibody Characterization in Continuous Bioprocessing

Combining process analytical technology (PAT) with continuous production provides a powerful tool to observe and control monoclonal antibody (mAb) fermentation and purification processes. This work demonstrates on-line liquid chromatography (on-line LC) as a PAT tool for monitoring a continuous biologics process and forced degradation studies. Specifically, this work focused on ion exchange chromatography (IEX), which is a critical separation technique to detect charge variants. Product-related impurities, including charge variants, that impact function are classified as critical quality attributes (CQAs). First, we confirmed no significant differences were observed in the charge heterogeneity profile of a mAb through both at-line and on-line sampling and that the on-line method has the ability to rapidly detect changes in protein quality over time. The robustness and versatility of the PAT methods were tested by sampling from two purification locations in a continuous mAb process. The PAT IEX methods used with on-line LC were a weak cation exchange (WCX) separation and a newly developed shorter strong cation exchange (SCX) assay. Both methods provided similar results with the distribution of percent acidic, main, and basic species remaining unchanged over a 2 week period. Second, a forced degradation study showed an increase in acidic species and a decrease in basic species when sampled on-line over 7 days. These applications further strengthen the use of on-line LC to monitor CQAs of a mAb continuously with various PAT IEX analytical methods. Implementation of on-line IEX will enable faster decision making during process development and could potentially be applied to control in biomanufacturing.

High‐throughput purification tools for rapid upstream process development are interchangeable for biologics

Upstream process development of biologics is not only productivity‐driven but also quality‐driven. Typically, most quality attributes are not directly measurable in cell culture samples due to low product concentration and purity, thus requiring some level of sample purification. As higher throughput upstream technologies become available, sample purification is becoming a bottleneck in limiting the number and types of cell culture samples that can be analyzed. The application of high‐throughput, microscale protein purification techniques has the potential to address and expand this capability. In this work, the affinity capture step of an IgG1 mAb was adapted to fit resin‐plate, resin‐tip, and mini‐column formats in an attempt to approximate the packed‐column performance by optimizing parameters such as contact time, liquid/resin ratio, and loading to produce a yield of ≥70% yield. A representative cell culture supernatant was purified using both the optimized microscale and conventional techniques, and analyzed using a comprehensive panel of product quality assays. This direct comparison demonstrated that each technique generates product of equivalent purity across a wide range of feed conditions. The analytical comparability suggests that any of the conventional and high‐throughput methods are interchangeable for biologics, allowing flexible development of an end‐to‐end integrated high‐throughput strategy.

Vent Gas Analysis

The monitoring of exhaust gas provides a universal method for fermentation characterization as most biological processes involve exchange or consumption of gases and volatile compounds. The monitoring of gas concentrations, such as carbon dioxide and oxygen, in the entry inlet and outlet gas streams and incorporation into liquid and gas balances makes it possible to quantify rates of gas utilization on production and respiratory quotient. This allows online real time monitoring of the physiological state of the fermentation, including growth kinetics and substrate consumption. A range of measuring methods for vent gas analysis are described including industrial application examples. Keywords: vent gas; fermentation profiling; online monitoring; sampling system; mass spectrometry; bioprocess; sensors