Mab) Purification by Counter Current Chromatography (CCC

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Mab) Purification by Counter Current Chromatography (CCC Monoclonal antibody (mAb) purification by Counter Current Chromatography (CCC) A thesis submitted to Brunel University for the degree of Doctor of Philosophy by Samantha Fernando Institute for Bioengineering, Brunel University, London December 2011 Abstract Counter current chromatography (CCC) is a form of liquid liquid chromatography, which the Brunel Institute for Bioengineering (BIB) team have developed to process scale. In this thesis, its application has been successfully extended to the rapid, scalable purification of monoclonal antibodies (mAb) from mammalian cell culture, using aqueous two-phase systems (ATPS) of inorganic salts and polymer. A polyethylene glycol (PEG) and sodium citrate system was found to be the most appropriate by robotic phase system selection. The search for an economical alternative to protein A HPLC is a substantial bioprocessing concern; in this work CCC has been investigated. Initial studies showed that unpredictably, despite separation from impurities being achieved, some loss in the IgG‘s ability to bind to Protein A was seen, as confirmed by Protein A BiaCore analysis. CCC machines were seen to adversely affect IgG functionality. This led to a systematic investigation of the effect of CCC phase mixing on IgG functionality in a number of different CCC instruments, allowing direct comparisons of modes of CCC (hydrodynamic and hydrostatic CCC) and their associated mixing (wave- like and cascade, respectively). The varying g forces produced within the CCC column were determined using a recently developed model to calculate g force range. The effect of interfacial tension was also studied using a custom built ‗g‘ shaker. The optimum CCC mode was identified to be the non synchronous CCC, operated in a hydrodynamic mode but allowing bobbin to rotor speed (Pr ratio) to be controlled independently. In a normal synchronous J type centrifuge a Pr of 1 is fixed, this is where the bobbin and rotor speed are identical I.e. one bobbin rotation (where mixing occurs) to one rotor revolution (where settling occurs). Constraints were seen with this 1:1 ratio and the separation of mAb using ATPS. This work has shown with the use of the non synchronous CCC at a Pr of 0.33, mixing is reduced and rotor rotations increased. Consequently the associated g force range is decreased. Furthermore, by the extension of settling time, the clear separation of the mAb from impurities has been achieved with retention of biological activity. This thesis demonstrates the importance of settling time for ATPS in phase separation and documents the fundamental requirements for the successful separation of biologics. Purified non synchronous CCC samples have additionally undergone rigorous quality control testing at Lonza Biologics by their purification 1 scientists. This work has ultimately showed that with optimisation, the non synchronous CCC can be used to produce biological samples that are of industry standard. 2 Table of contents 1) Introduction and literature review 10 1.1.1 Monoclonal antibody (mAb) discovery 11 1.1.2 mAb cell culture production 12 1.1.3 mAb structure 14 1.1.4 Monoclonal antibody market 15 1.1.5 Modes of action 17 1.1.6 Upstream/downstream processing of mAbs 18 1.1.7 Protein A: Structure 19 1.1.8 Protein A chromatography 20 1.1.9 Protein A purification issues 21 1.2 Chromatographic alterative to Protein A 22 1.2.1 Cation exchange chromatography 22 1.2.2 Hydrophobic interaction chromatography 24 1.2.3 Affinity chromatography 25 1.3 Non chromatographic alternatives 27 1.3.1 Bulk separations 28 1.3.2 Field based separations 29 1.3.3 Absorptive separation 29 1.4 Aqueous two phase system (ATPS) extraction and Counter 30 current chromatography (CCC) 1.4.1 Monoclonal antibody purification by ATPS extraction 35 1.4.2 CCC machines for separation of proteins 42 1.4.3 CCC VS Protein A affinity chromatography 44 1.4.4 CCC column design for protein separation 44 1.5 Aims and objectives 57 2) Robotic solvent system selection 58 2.1 Summary 59 2.2 Introduction 60 2.3 Method and materials 61 2.3.1 Creation of solvent system table: obtained from Lukasz Grudzien 61 2.3.2 Preparation of solvents for the robot 64 2.3.3 Sample used 65 2.3.4 Stock solution preparation 65 2.3.5 Robot programming 66 2.3.6 Initial run with model proteins 67 2.3.7 Changes made to robotic handling due to the nature of the ATPSs 68 2.4 Results and discussion 69 2.4.1 Investigation of differing protein assays 69 2.4.2 Development of Protein A HPLC analytical method for two phase 76 samples 2.4.3 Robotic run using crude Cell Culture Supernatant (CCS), and 81 result analysis by developed protein A HPLC 2.5 Conclusions 89 3) Separation of monoclonal antibody from cell culture supernatant (CCS) using Centrifugal partitioning chromatography (CPC) 90 3.1 Summary 91 3.2 Introduction 92 3.3 Method and materials 94 3 3.3.1 Preparation of phase system 94 3.3.2 Sample preparation 94 3.3.3 CCC operation 95 3.4 Results and discussion 96 3.4.1 mAb separation from crude Cell Culture Supernatant (CCS) using CPC: CPC run 3-1 96 3.4.2 SDS PAGE results 99 3.4.3 Investigation of the formation Protein A non binding IgG 102 3.4.4 Study into specie interconversion 104 3.4.5 Sample loading capacity: CPC run 3-2 106 3.4.6 Stationary phase retention and stripping 107 3.4.7 Prediction of retention time 109 3.4.7 Precipitation issues associated with the ammonium sulphate system 109 3.4.8 Comparison of work with the Aires Barros group (Lisbon, Portugal): PEG 1000 14%/14% potassium phosphate system. 110 3.4.9 PEG 1000 17.5%/17.5% sodium citrate system vs. PEG 335011%/11% ammonium sulphate system 113 3.4.10 CPC run with the PEG 1000 17.5%/17.5% sodium citrate system 117 3.5 Conclusion 122 4) Separation of monoclonal antibody from cell culture supernatant (CCS) using toroidal coil CCC (TC CCC) centrifuge 123 4.1 Summary 124 4.2 Introduction 125 4.3 Method and materials 126 4.3.1 Preparation of phase system 126 4.3.2 TC CCC operation 126 4.4 Results and discussion 127 4.4.1 PEG 1000 17.5%/17.5% sodium citrate run on the TC CCC: Run 4-1 127 4.4.2 SDS PAGE results: silver stain 128 4.4.3 Determination of purity: host cell ELISA and concentration by stirred cell 130 4.4.4 Effect of flow rate, peak width and spin speed 133 4.4.5 Theoretical predictability: CCC2 modelling programme 135 4.4.6 Overview 136 4.5 Conclusions 138 5) Critical look at IgG functionality 140 5.1 Summary 141 5.2 Introduction 142 5.3 Method and materials 142 5.3.1 Aim of using Biacore from this work 142 5.3.2 Biacore theory: Surface Plasmon resonance 142 5.4 Results and discussion 143 5.4.1 Effect of phase system incubation on IgG functionality 145 5.4.2 Investigation of HPLC column saturation 148 5.4.3 Biacore analysis 149 5.4.4 Investigation of shaking vigour using a bench top centrifuge 154 5.4.5 Investigation of shaking vigour at one ‗g‘ using a custom built shaker 155 5.5 Conclusions 162 4 6) Separation of monoclonal antibodies using J-type CCC centrifuges: the need for gentler mixing 164 6.1 Summary 164 6.2 Introduction 165 6.3 Method and materials 166 6.3.1 Sample preparation 166 6.3.2 CCC processing 166 6.4 Results and discussion 167 6.4.1 Effect of rotational speed in IgG functionality 167 6.4.2 Investigation of IgG transit time of functionality 168 6.4.3 Investigation into sample loading capacity 169 6.4.4 Mini CCC separation using CCS 170 6.4.5 Investigation of model proteins 174 6.4.6 Conclusions drawn from the literature 177 6.4.7 Overview of results 178 6.5 Conclusions 182 7) Successful monoclonal antibody separation: Solution as provided by the non synchronous CCC 183 7.1 Summary 184 7.2 Introduction 185 7.3 Method and materials 189 7.4 Results and discussion 189 7.4.1 Investigation of differing Pr ratios using PA purified IgG: effect on recovery 189 7.4.2 Investigation of differing Pr ratios using CCS 191 7.4.3 Investigation of sample loading capacity using CCS 194 7.4.4 Increased fraction collection: effect on purity 196 7.4.5 Throughput: Studies into sample loading capacity 197 7.4.6 Effect of mass balance, purity and IgG recovery on throughput. 202 7.4.7 Investigation of associated g force with Non synchronous processing 204 7.5 Conclusions 207 8) Characterization of non synchronous CCC purified samples using Lonza quality control assays 209 8.1 Summary 210 8.2 Introduction 211 8.3 Method and materials 211 8.3.1 Investigation of sample clean up using PD 10 size exclusion columns 211 8.3.2 Investigation of ultrafiltration columns for sample clean up 213 8.3.3 Triplicate non synchronous CCC runs with sample clean up using a 5 kDa ultrafiltration column. 215 8.3.4 Child‘s assay for the removal of PEG from samples post ultrafiltration 218 8.3.5 QC assays conducted at Lonza by purification scientist Samit Patel 220 8.3.6 Summary of results 226 8.4 Conclusions 228 9) General discussion, conclusions and future work 231 5 Acknowledgements Firstly, I would like to acknowledge all my supervisors for giving me the opportunity to accomplish a personal ambition with the studying of a PhD.
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