Michael Pohlscheidt

Optimizing capacity utilization by large scale 3000 L perfusion in seed train bioreactors

Increasing capacity utilization and lowering manufacturing costs are critical for pharmaceutical companies to improve their competitiveness in a challenging environment. Development of next generation cell lines, improved media formulations, application of mature technologies and innovative operational strategies have been deployed to improve yields and capacity utilization. This article describes a large‐scale perfusion strategy for the N‐1 seed train bioreactor that was successfully applied to achieve higher inoculation cell densities in the production culture. The N‐1 perfusion at 3,000‐L scale, utilizing a inclined settler, achieved cell densities of up to 158 × 105 cell mL−1 at perfusion rates of 2950 L day−1 and a retention efficiency of >85%. This approach increased inoculation cell densities and decreased cultivation times by ∼20% in a CHO‐based, fed‐batch antibody manufacturing process while providing comparable culture performance, productivity, and product quality. The strategy therefore yielded significant increase in capacity utilization and concomitant cost improvement in a large scale cGMP facility. Details of the strategy, the cell retention device, and the cell culture performance are described in this article.

Insights into large-scale cell-culture reactors: II. Gas-phase mixing and CO2 stripping

Most discussions about stirred tank bioreactors for cell cultures focus on liquid-phase motions and neglect the importance of the gas phase for mixing, power input and especially CO(2) stripping. Particularly in large production reactors, CO(2) removal from the culture is known to be a major problem. Here, we show that stripping is mainly affected by the change of the gas composition during the movement of the gas phase through the bioreactor from the sparger system towards the headspace. A mathematical model for CO(2)-stripping and O(2)-mass transfer is presented taking gas-residence times into account. The gas phase is not moving through the reactor in form of a plug flow as often assumed. The model is validated by measurement data. Further measurement results are presented that show how the gas is partly recirculated by the impellers, thus increasing the gas-residence time. The gas-residence times can be measured easily with stimulus-response techniques. The results offer further insights on the gas-residence time distributions in stirred tank reactors.

Insights into large-scale cell-culture reactors: I. Liquid mixing and oxygen supply

In the pharmaceutical industry, it is state of the art to produce recombinant proteins and antibodies with animal-cell cultures using bioreactors with volumes of up to 20 m(3) . Recent guidelines and position papers for the industry by the US FDA and the European Medicines Agency stress the necessity of mechanistic insights into large-scale bioreactors. A detailed mechanistic view of their practically relevant subsystems is required as well as their mutual interactions, i.e., mixing or homogenization of the culture broth and sufficient mass and heat transfer. In large-scale bioreactors for animal-cell cultures, different agitation systems are employed. Here, we discuss details of the flows induced in stirred tank reactors relevant for animal-cell cultures. In addition, solutions of the governing fluid dynamic equations obtained with the so-called computational fluid dynamics are presented. Experimental data obtained with improved measurement techniques are shown. The results are compared to previous studies and it is found that they support current hypotheses or models. Progress in improving insights requires continuous interactions between more accurate measurements and physical models. The paper aims at promoting the basic mechanistic understanding of transport phenomena that are crucial for large-scale animal-cell culture reactors.

Influence of pluronic F68 on oxygen mass transfer

Pluronic F68 is one of the most used shear protecting additives in cell culture cultivations. It is well known from literature that such surface‐active surfactants lower the surface tension at the gas‐liquid interface, which influences the mass transfer. In this study, the effect of Pluronic F68 on oxygen mass transfer in aqueous solutions was examined. Therefore, the gassing in/gassing out method and bubble size measurements were used. At low concentrations of 0.02 g/L, a 50% reduction on mass transfer was observed for all tested spargers and working conditions. An explanation of the observed effects by means of Higbies penetration or Dankwerts surface renewal theory was applied. It could be demonstrated that the suppressed movement of the bubble surface layer is the main cause for the significant drop down of the kLa‐values. For Pluronic F68 concentrations above 0.1 g/L, it was observed that it comes to changes in bubble appearance and bubble size strongly dependent on the sparger type. By using the bubble size measurement data, it could be shown that only small changes in mass transfer coefficient (kL) take place above the critical micelle concentration. Further changes on overall mass transfer at higher Pluronic F68 concentrations are mainly based on increasing of gas holdup and, more importantly, by increasing of the surface area available for mass transfer.

Bioreactor Fluid Dynamics

Flows are induced in bioreactors in order to mix the culture and to support mass transfer. These two tasks are addressed for the most important types of bioreactors, aerated stirred tanks and bubble columns. Insights into the basic mechanisms are provided by discussing several basic experimental results, for instance mixing time and flow velocity measurements, which consider the gas as well as the liquid phase. The experimental data show that the fluid flow velocity patterns usually shown in textbooks do not consider the flow properties essential for mixing and mass transfer. Also, computational fluid dynamic results are compared with experimental results to demonstrate that many aspects of the two-phase gas–liquid flows in bioreactors are mechanistically understood.

A test facility for fritted spargers of production-scale-bioreactors

The production of therapeutic proteins requires qualification of equipment components and appropriate validation procedures for all operations. Since protein productions are typically performed in bioreactors using aerobic cultivation processes air sparging is an essential factor. As recorded in literature, besides ring spargers and open pipe, sinter frits are often used as sparging elements in large scale bioreactors. Due to the manufacturing process these frits have a high lot-to-lot product variability. Experience shows this is a practical problem for use in production processes of therapeutic proteins, hence frits must be tested before they can be employed. The circumstance of checking quality and performance of frits as sparging elements was investigated and various possibilities have been compared. Criteria have been developed in order to evaluate the sparging performance under conditions comparable to those in production bioreactors. The oxygen mass transfer coefficient (kLa) was chosen as the evaluation criterion. It is well known as an essential performance measure for fermenters in the monoclonal antibody production. Therefore a test rig was constructed able to automatically test frit-spargers with respect to their kLa-values at various gas throughputs. Performance differences in the percent range could be detected.