Sven Sommerfeld

Continuous purification of antibodies from cell culture supernatant with aqueous two-phase systems: From concept to process

An aqueous two-phase extraction (ATPE) process based on a PEG/phosphate system was developed for the capture of human immunoglobulin G and successfully applied to a Chinese hamster ovary and a PER.C6® cell supernatant. A continuous ATPE process incorporating three different steps (extraction, back-extraction, and washing) was set up and validated in a pump mixer-settler battery. Most of the higher molecular weight cell supernatant impurities were removed during the extraction step, while most of the lower molecular weight impurities were removed during the subsequent steps. A global recovery yield of 80% and a final protein purity of more than 99% were obtained for the IgG purification from a CHO cell supernatant, representing a 155-fold reduction in the protein/IgG ratio. For the purification of IgG from a PER.C6® cell supernatant, a global recovery yield of 100%, and a host cell protein purity were attained, representing a 22-fold reduction in the host cell protein/IgG ratio. These results, thus, open promising perspectives for the application of the developed ATPE process as a platform for the capture of antibodies. In fact, this new process has shown the ability to successfully recover and purify different antibodies from distinct cell culture supernatants. This technology can also overcome some of the limitations encountered using the typical chromatographic processes, besides inherent advantages of scalability, process integration, capability of continuous operation, and economic feasibility.

Continuous aqueous two-phase extraction of human antibodies using a packed column

The performance of a pilot scale packed differential contactor was evaluated for the continuous counter-current aqueous two-phase extraction (ATPE) of human immunoglobulin G (IgG) from a Chinese hamster ovary (CHO) cells supernatant (CS) enriched with pure protein. Preliminary studies have been firstly performed in order to select the dispersed phase (phosphate-rich or polyethylene glycol 3350 Da (PEG)-rich phase) and the column packing material. The PEG-rich phase has been selected as the dispersed phase and the stainless steel as the preferred material for the column packing bed since it was not wetted preferentially by the selected dispersed phase. Hydrodynamic studies have been also performed, and the experimental results were successfully adjusted to the Richardson-Zaki and Mísek equations, typically used for the conventional organic-aqueous two-phase systems. An experimental set-up combining the packed column with a pump mixer-settler stage showed to have the best performance and to be advantageous when compared to the IgG batch extraction. An IgG recovery yield of 85% could be obtained with about 50% of total contaminants and more than 85% of contaminant proteins removal. Mass transfer studies have revealed that the mass transfer was controlled by the PEG-rich phase. A higher efficiency could be obtained when using an extra pump mixer-settler stage and higher flow rates.

Downstream processing of antibodies: Single-stage versus multi-stage aqueous two-phase extraction

Single-stage and multi-stage strategies have been evaluated and compared for the purification of human antibodies using liquid-liquid extraction in aqueous two-phase systems (ATPSs) composed of polyethylene glycol 3350 (PEG 3350), dextran, and triethylene glycol diglutaric acid (TEG-COOH). The performance of single-stage extraction systems was firstly investigated by studying the effect of pH, TEG-COOH concentration and volume ratio on the partitioning of the different components of a Chinese hamster ovary (CHO) cells supernatant. It was observed that lower pH values and high TEG-COOH concentrations favoured the selective extraction of human immunoglobulin G (IgG) to the PEG-rich phase. Higher recovery yields, purities and percentage of contaminants removal were always achieved in the presence of the ligand, TEG-COOH. The extraction of IgG could be enhanced using higher volume ratios, however with a significant decrease in both purity and percentage of contaminants removal. The best single-stage extraction conditions were achieved for an ATPS containing 1.3% (w/w) TEG-COOH with a volume ratio of 2.2, which allowed the recovery of 96% of IgG in the PEG-rich phase with a final IgG concentration of 0.21mg/mL, a protein purity of 87% and a total purity of 43%. In order to enhance simultaneously both recovery yield and purity, a four stage cross-current operation was simulated and the corresponding liquid-liquid equilibrium (LLE) data determined. A predicted optimised scheme of a counter-current multi-stage aqueous two-phase extraction was hence described. IgG can be purified in the PEG-rich top phase with a final recovery yield of 95%, a final concentration of 1.04mg/mL and a protein purity of 93%, if a PEG/dextran ATPS containing 1.3% (w/w) TEG-COOH, 5 stages and volume ratio of 0.4 are used. Moreover, according to the LLE data of all CHO cells supernatant components, it was possible to observe that most of the cells supernatant contaminants can be removed during this extraction step leading to a final total purity of about 85%.

Phenomena and Modeling of Hydrophobic Interaction Chromatography

Comprehension of the mechanisms of hydrophobic interaction chromatography is not as deep as for other chromatographic steps. This article shows the combination of modeling and experimental model parameter determination. Original mammalian cell culture is applied for validation instead of often-used test systems with for example, three pure proteins. This approach can have a huge benefit for process development and optimization of production processes under project conditions. To simulate the separation by hydrophobic interaction chromatography, a distributed plug flow model with inner pore diffusion is applied. The needed model parameters are determined by small scale experiments on a 1 ml column to reduce feed amount consumption and experimental procedure. Effects caused by system setup are optimized in relation to the volume. Gradient experiments are performed for the determination of isotherm parameters. The model parameters determined are experimentally validated at different set-ups of operation parameters as well as scaled up to 10 ml columns. The practicability of the proposed stepwise procedure of physico-chemical modeling in combination with laboratory scale experiments for the prediction of separation performance of original mammalian cell culture is proved. A model parameter determination directly with fermentation mixture is as well feasible.

Computer-aided process design of affinity membrane adsorbers: a case study on antibodies capturing

Design of affinity membrane adsorbers for the purification of biomolecules requires a consideration of loading, washing, and elution. Modelling and simulation of membrane adsorbers in literature is, however, strongly focused on the loading step. Therefore, in this work, a complete process model which takes all the different steps into account was developed. Breakthrough experiments in which human IgG was captured onto and eluted from Sartobind Protein A downscale modules were used for model validation and for estimation of the required model parameters. The experimentally observed breakthrough curves were independent of the applied flow rate and from these results linear correlations between lumped kinetic parameters and linear velocity were determined. During elution, desorption was best described by an irreversible reaction of first order in H+ concentration. Applicability of the developed model to computer-aided design was illustrated through a process analysis study in which the influence of the amount of loaded protein per cycle on the process yield and productivity was investigated.