Process Development: Rapid Identification of Critical Process Variables

Process development is a key element in the creation of improved, more rapid and lower-cost methods for producing target products. Through feeding strategies, pH value optimization and the integration of various cultivation phases in a single process, DASGIP users can optimize growth, stability and productivity levels.

With up to 16 highly instrumented vessels, DASGIP systems allow users to rapidly establish reproducible and therefore comparable results on the basis of critical parameters. The wealth of information, parallel design and access to data mining tools permits the systematic analysis and comparison of process data. Process validation is thus having a greater impact on the subsequent approval process for the products under development. As part of its "Quality by Design" program for instance, the FDA promotes continuous improvements in development and production processes, thus shifting the focus further away from the analysis of already-manufactured foodstuffs and pharmaceuticals, to the process itself. By introducing process analysis technologies (PAT) in the development phase, the initial aim is to acquire a better understanding of the process, which ultimately leads to optimized production processes.

Please find information on the use of DASGIP Systems in process development e.g. for the process automationproduction of recombinant proteins, antibody production in mammalian cell cultures or development of biofuels here. 

Advanced Process Control and Automation

The integration of external analysis data into running production processes has attained major importance over the past few years. This is due not least to the process analytical technology (PAT) initiative launched by the U.S. FDA. Whether for the early detection of process deviations or for advanced process execution and optimization, external process values from analyzers, cell counting equipment and HPLC systems provide valuable supplemental information that can substantially benefit running processes. Even more important is access to this so-called at-line data for process development.

» Read more about the implementation of PAT by OPC-based implementation of an automated feed strategy at the MIT Institute in Boston.

The more additional data is considered in process development the more relevant intelligent design of experiments becomes. Users at Probiogen AG in Berlin integrate the Matlab numerical simulation software to develop an intelligent fed-batch feeding model for CHO cells.

 

DASGIP references

DASGIP references

Protein production

Modifying vaccines in response to changes by the respective virus or agent is a constant challenge for vaccine manufacturers. In this area, DASGIP parallel cultivation systems are used in a variety of ways in the field of research and development to produce acutely-modified proteins that can then be analyzed for other purposes. The parallel set-up of up to 16 bioreactors enables the preparation of different cultivations in a single experimental batch. After a production run, trigger functions can be used to automatically set the individual temperature in each reactor, which is necessary for the stability of each protein. This considerably simplifies the process of finding and selecting the suitable protein, which leads to the subsequent production process. Because the entire production procedure occurs under controlled conditions and since all relevant data is recorded, users have complete test documentation at their disposal at the push of a button. DASGIP cultivation systems can be used for protein production in microbial fermentation applications as well as cell cultivation applications. With increased protein yields and subsequent structure analyses, the way is thus paved for the biotechnological production of versatile, therapeutic proteins.

 

» Article "Proteinexpression with DASGIP Parallel Bioreactor Systems"; Bio Process International, 2006 (PDF)

DASGIP references

DASGIP references

Antibody production by mammalian cells

Antibodies are important in many respects, whether for therapeutic purposes or as part of analytical or diagnostic processes. In both cases, the aim is to develop quantitative as well as qualitative processes. The large working volumes in the final production process require the development and documentation of predefined, stable and reproducible cultivation conditions. The DASGIP cultivation system covers these requirements in research and development, which means prior to production. Apart from ensuring stable ratios for conditions such as pH value, dissolved oxygen and temperature, precise substrate feeding is achieved through the DASGIP MP8 and MP4 multipump feed modules. In addition to delivering flow rates up to 5 liters per hour, the precise speed control permits continuous flow rates as low as .3 liters per hour for even the smallest volumes. This ensures highly precise substrate feeding tailored especially for the successful production of antibodies and which through software can be adjusted via value tables, user-defined functions or even in conjunction with other process variables. 

 

» Article "Fed-batch process development for monoclonal antibody production"; Genetic Engineering News, 2002 (PDF)

» Application note "Statistically Designed Optimization for Monoclonal Antibody Production in CHO Fed-Batch Culture" (PDF)


» Application Note "Successful Transfer and 200-Fold Scale-Up of a r-CHO Cell Fed-Batch Process Using a New cGMP Compliant Basal and Feed Medium Combination" (PDF)

DASGIP references

DASGIP references

Biofuels

As an alternative to conventional energy sources such as oil and coal, biofuels derived from plant-based raw materials are increasingly gaining importance. For their production, biofuels are run through a series of mostly microbiological steps. Through advanced development, DASGIP now offers a parallel bioreactor system tailored specifically to applications in the field of biofuel production.  It can run processes with temperatures in the chilled low range or at extreme temperatures as high as 99° C. This provides extensive coverage of the wide temperature range in this segment, making it possible to carry out even temperature-based, multistage cultivations. Another special feature is the DASGIP MP4 multipump module, which through a suitable feeding hose can also dispense liquids with a high percentage of solids commonly found in the production of biofuels.


» E-Flyer "Biofuels" (PDF)

 

» Press release "Biofuels" (PDF)

 

» Article "Replacement of a phase-out technology: managing sophisticated processes with in-depth insight"; Biotech international, 2010 (PDF)

 

» Article "Biofuels - challenges & chances: How biofuel development can benefit from advanced process technology"; Engineering in Life Sciences, 2009 (PDF)

 

» Application Note "Isobutanol from Renewable Feedstock" (PDF)

 

DASGIP references

DASGIP references