Suzanne S. Farid

Fed-batch and perfusion culture processes: Economic, environmental, and operational feasibility under uncertainty.

This article evaluates the current and future potential of batch and continuous cell culture technologies via a case study based on the commercial manufacture of monoclonal antibodies. The case study compares fed‐batch culture to two perfusion technologies: spin‐filter perfusion and an emerging perfusion technology utilizing alternating tangential flow (ATF) perfusion. The operational, economic, and environmental feasibility of whole bioprocesses based on these systems was evaluated using a prototype dynamic decision‐support tool built at UCL encompassing process economics, discrete‐event simulation and uncertainty analysis, and combined with a multi‐attribute decision‐making technique so as to enable a holistic assessment. The strategies were compared across a range of scales and titres so as to visualize how their ranking changes in different industry scenarios. The deterministic analysis indicated that the ATF perfusion strategy has the potential to offer cost of goods savings of 20% when compared to conventional fed‐batch manufacturing processes when a fivefold increase in maximum viable cell densities was assumed. Savings were also seen when the ATF cell density dropped to a threefold increase over the fed‐batch strategy for most combinations of titres and production scales. In contrast, the fed‐batch strategy performed better in terms of environmental sustainability with a lower water and consumable usage profile. The impact of uncertainty and failure rates on the feasibility of the strategies was explored using Monte Carlo simulation. The risk analysis results demonstrated the enhanced robustness of the fed‐batch process but also highlighted that the ATF process was still the most cost‐effective option even under uncertainty. The multi‐attribute decision‐making analysis provided insight into the limited use of spin‐filter perfusion strategies in industry. The resulting sensitivity spider plots enabled identification of the critical ratio of weightings of economic and operational benefits that affect the choice between ATF perfusion and fed‐batch strategies. Biotechnol. Bioeng. 2013; 110: 206–219.

Decision-support tool for assessing biomanufacturing strategies under uncertainty: Stainless steel versus disposable equipment for clinical trial material preparation

This paper presents the application of a decision‐support tool, SimBiopharma, for assessing different manufacturing strategies under uncertainty for the production of biopharmaceuticals. SimBiopharma captures both the technical and business aspects of biopharmaceutical manufacture within a single tool that permits manufacturing alternatives to be evaluated in terms of cost, time, yield, project throughput, resource utilization, and risk. Its use for risk analysis is demonstrated through a hypothetical case study that uses the Monte Carlo simulation technique to imitate the randomness inherent in manufacturing subject to technical and market uncertainties. The case study addresses whether start‐up companies should invest in a stainless steel pilot plant or use disposable equipment for the production of early phase clinical trial material. The effects of fluctuating product demands and titers on the performance of a biopharmaceutical company manufacturing clinical trial material are analyzed. The analysis highlights the impact of different manufacturing options on the range in possible outcomes for the project throughput and cost of goods and the likelihood that these metrics exceed a critical threshold. The simulation studies highlight the benefits of incorporating uncertainties when evaluating manufacturing strategies. Methods of presenting and analyzing information generated by the simulations are suggested. These are used to help determine the ranking of alternatives under different scenarios. The example illustrates the benefits to companies of using such a tool to improve management of their R&D portfolios so as to control the cost of goods.

Allogeneic cell therapy bioprocess economics and optimization: Single‐use cell expansion technologies

For allogeneic cell therapies to reach their therapeutic potential, challenges related to achieving scalable and robust manufacturing processes will need to be addressed. A particular challenge is producing lot‐sizes capable of meeting commercial demands of up to 109 cells/dose for large patient numbers due to the current limitations of expansion technologies. This article describes the application of a decisional tool to identify the most cost‐effective expansion technologies for different scales of production as well as current gaps in the technology capabilities for allogeneic cell therapy manufacture. The tool integrates bioprocess economics with optimization to assess the economic competitiveness of planar and microcarrier‐based cell expansion technologies. Visualization methods were used to identify the production scales where planar technologies will cease to be cost‐effective and where microcarrier‐based bioreactors become the only option. The tool outputs also predict that for the industry to be sustainable for high demand scenarios, significant increases will likely be needed in the performance capabilities of microcarrier‐based systems. These data are presented using a technology S‐curve as well as windows of operation to identify the combination of cell productivities and scale of single‐use bioreactors required to meet future lot sizes. The modeling insights can be used to identify where future R&D investment should be focused to improve the performance of the most promising technologies so that they become a robust and scalable option that enables the cell therapy industry reach commercially relevant lot sizes. The tool outputs can facilitate decision‐making very early on in development and be used to predict, and better manage, the risk of process changes needed as products proceed through the development pathway. Biotechnol. Bioeng. 2014;111: 69–83.

Optimising the design and operation of semi-continuous affinity chromatography for clinical and commercial manufacture

This paper presents an integrated experimental and modelling approach to evaluate the potential of semi-continuous chromatography for the capture of monoclonal antibodies (mAb) in clinical and commercial manufacture. Small-scale single-column experimental breakthrough studies were used to derive design equations for the semi-continuous affinity chromatography system. Verification runs with the semi-continuous 3-column and 4-column periodic counter current (PCC) chromatography system indicated the robustness of the design approach. The product quality profiles and step yields (after wash step optimisation) achieved were comparable to the standard batch process. The experimentally-derived design equations were incorporated into a decisional tool comprising dynamic simulation, process economics and sizing optimisation. The decisional tool was used to evaluate the economic and operational feasibility of whole mAb bioprocesses employing PCC affinity capture chromatography versus standard batch chromatography across a products lifecycle from clinical to commercial manufacture. The tool predicted that PCC capture chromatography would offer more significant savings in direct costs for early-stage clinical manufacture (proof-of-concept) (∼30%) than for late-stage clinical (∼10-15%) or commercial (∼5%) manufacture. The evaluation also highlighted the potential facility fit issues that could arise with a capture resin (MabSelect) that experiences losses in binding capacity when operated in continuous mode over lengthy commercial campaigns. Consequently, the analysis explored the scenario of adopting the PCC system for clinical manufacture and switching to the standard batch process following product launch. The tool determined the PCC system design required to operate at commercial scale without facility fit issues and with similar costs to the standard batch process whilst pursuing a process change application. A retrofitting analysis established that the direct cost savings obtained by 8 proof-of-concept batches would be sufficient to pay back the investment cost of the pilot-scale semi-continuous chromatography system.

Established Bioprocesses for Producing Antibodies as a Basis for Future Planning

In the early years of monoclonal antibody production for human therapy and diagnosis the methods used were arrived at by individual organisations. However, there is now an accumulating body of information on antibodies and fragments that have been produced by processes approved for human use. This information is becoming available at a time when the number of potential antibody-based medicines is growing sharply. The review addresses the reported production routes, their scale and the titres achieved. It identifies the performances of fed-batch and perfusion culture versus batch culture, and compares processes for the production of antibodies for diagnosis and for antibody fragments. The analysis defines the likely routes of future production in a sector where demanding regulations constrain new technology. It also indicates what levels of performance new approaches will need to meet to be competitive.

Modelling biopharmaceutical manufacture: Design and implementation of SimBiopharma

Abstract This paper presents the implementation of a conceptual framework, for modelling a biopharmaceutical manufacturing plant, into a prototype decision-support tool, S im B iopharma . The tools scope covers the ability to evaluate manufacturing alternatives in terms of cost, time, yield, resource utilisation and risk. Incorporating uncertainty means that investment appraisal can be based on both the expected outputs and the likelihood of achieving them. A hierarchical approach to represent the key activities in a manufacturing process is introduced. Emphasis is placed on how a closer integration of bioprocess and business process modelling can be achieved by capturing common information in an object-oriented environment, G2 (Gensym Corporation, Cambridge, MA). The key features of S im B iopharma are highlighted; these include interactive graphics, task-oriented representation and dynamic simulation which create a much more flexible environment for modelling processes. Examples of typical outputs generated by S im B iopharma , when addressing the impact of manufacturing options on strategic operational and financial indicators, are given.

Human pluripotent stem cell-derived products: Advances towards robust, scalable and cost-effective manufacturing strategies

The ability to develop cost‐effective, scalable and robust bioprocesses for human pluripotent stem cells (hPSCs) will be key to their commercial success as cell therapies and tools for use in drug screening and disease modelling studies. This review outlines key process economic drivers for hPSCs and progress made on improving the economic and operational feasibility of hPSC bioprocesses. Factors influencing key cost metrics, namely capital investment and cost of goods, for hPSCs are discussed. Step efficiencies particularly for differentiation, media requirements and technology choice are amongst the key process economic drivers identified for hPSCs. Progress made to address these cost drivers in hPSC bioprocessing strategies is discussed. These include improving expansion and differentiation yields in planar and bioreactor technologies, the development of xeno‐free media and microcarrier coatings, identification of optimal bioprocess operating conditions to control cell fate and the development of directed differentiation protocols that reduce reliance on expensive morphogens such as growth factors and small molecules. These approaches offer methods to further optimise hPSC bioprocessing in terms of its commercial feasibility.

Application of a decision-support tool to assess pooling strategies in perfusion culture processes under uncertainty.

Biopharmaceutical manufacture is subject to numerous risk factors that may affect operational costs and throughput. This paper discusses the need for incorporating such uncertainties in decision‐making tools in order to reflect the inherent variability of process parameters during the operation of a biopharmaceutical plant. The functionalities of a risk‐based prototype tool to model cost summation, perform mass balance calculations, simulate resource handling, and incorporate uncertainties in order to evaluate the potential risk associated with different manufacturing strategies are demonstrated via a case study. The case study is based upon the assessment of pooling strategies in the perfusion culture of mammalian cells to deliver a therapeutic protein for commercial use. Monte Carlo simulations, which generate random sample behaviors for probabilistic factors so as to imitate the uncertainties inherent in any process, have been applied. This provides an indication of the range of possible output values and hence enables trends or anomalies in the expected performance of a process to be determined.

Modelling of the biopharmaceutical drug development pathway and portfolio management

Given the time, cost and risk associated with drug development, biopharmaceutical companies typically need to have a portfolio of drugs in development to be successful. Current pressures of cost and speed to market are driving the need for more effective means of assessing the value and risks of such drug portfolios. This paper presents research to generate a prototype computer tool developed to predict the process and business outcomes for portfolios of biopharmaceutical drugs proceeding through the development pathway. The tool incorporates the interactions between drug development activities and the available resources. In addition to the business and process issues, the risks involved in the process of drug development have also been incorporated into the model. A case study is presented to illustrate how the tool can be used to assist business decisions regarding biopharmaceutical portfolio management. The example addresses scenario analysis and the question of outsourcing versus in-house manufacture of material for clinical trials and the market under uncertainty. (c) 2005 Elsevier Ltd. All rights reserved.

Combining Multiple Quantitative and Qualitative Goals When Assessing Biomanufacturing Strategies under Uncertainty

This paper reports how financial and operational results from bioprocess simulations can be combined with other criteria pertinent to decision‐making predictions to provide a more holistic approach to the evaluation of biomanufacturing alternatives. The classical additive weighting method, which is a multiattribute decision‐making technique that can account for both the quantitative and qualitative parameters that ultimately need to be considered, is used. Its application is demonstrated through a case study that addresses whether start‐up companies should invest in a stainless steel pilot plant or use disposable equipment for the production of early phase clinical trial material. The technique is extended to allow for uncertainty in parameters. An illustration of its use to compare alternatives based on cumulative frequency curves of the aggregate scores is provided. For cases where it is difficult to discriminate between the options, plots of risk versus reward are shown to be useful for identifying the best alternative based on the risk preference of the companyapos;s management.