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Chromatography Resin Characterisation to Analyse Lifetime and Performance During Biopharmaceutical Manufacture

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Chromatography Resin Characterisation to Analyse Lifetime and Performance During Biopharmaceutical Manufacture Chromatography Resin Characterisation to Analyse Lifetime and Performance During Biopharmaceutical Manufacture by Mauryn C. Nweke Department of Biochemical Engineering University College London Gower Street London WC1E 6BT A thesis submitted for the degree of DOCTOR OF PHILOSOPHY September 2017 1 DECLARATION I confirm that the work presented in this thesis is my own unless indicated otherwise. The work presented was carried out under the supervision of Prof Daniel G Bracewell at the Department of Biochemical Engineering, University College London and Dr R. Graham McCartney, Eli Lilly & Co., Ireland, between October 2013 and September 2017. This thesis has not been submitted, either in whole or in part, for another degree or another qualification at any other university. Mauryn C. Nweke London, September 2017 2 ACKNOWLEDGMENTS My acknowledgements extend as far back as when my time at UCL began in 2009. I would like to thank all the contributors to my academic career thus far, for without them, I would not have found myself here. I would especially like to thank my supervisor Prof Daniel G Bracewell, my industrial supervisor Dr Graham McCartney and my secondary supervisor Prof Nigel Titchener-Hooker for taking a chance on me and supporting me in my pursuit of this project. Your support has not been in vain! I also thank my Head of Department, Prof Gary J Lye and my mentor in many ways, Dr Sunny Bains, for helping me to develop my personal aspirations, I am grateful. I could never thank my loved ones enough. I thank you for your ability to believe in me in my darkest moments and your ability to continue to support me when I could hardly support myself. A special thank you to Dr Pierre Affaticati for inspiring me to take the leap and to Yasmine Cherry, Rawan Al-Ramahi, Eliane Rozanes and Estefani Daravina-Alvear for encouraging me to believe that I can, in any aspect of life. My mum and my brother are my world and everything I do and am is because of and thanks to their love. I love you, always and forever and words will never be enough to show my gratitude. Finally and most importantly, I thank Him. For listening to me and for hearing my every cry, no matter how petty it is. You do not let me cry in vain and every day, for the rest of my days, belongs to you. 3 ABSTRACT This thesis, completed in collaboration with Eli Lilly & Co., aims to understand and assess the structural and mechanical changes that occur as agarose-based chromatography resins are exposed to different bioprocessing conditions in an attempt to explore the mechanisms by which different resins age. By understanding this, there is significant potential for facilitating timely and improved decisions in large-scale chromatographic operations, maximising resin lifetime whist maintaining acceptable column performance. Scanning electron microscopy (SEM) was used to image the structural properties of nine widely used agarose-based chromatography resins before use while pressure- flow analysis was used to characterise the mechanical properties of the same fresh resins. The results showed that the Capto family had the highest critical velocities (Capto Adhere- 492, Capto Q- 477 cm/hr), whilst Sepharose CL-6B, Sepharose 4 Fast Flow and Sepharose CL-4B had the lowest critical velocity values (283, 204, 149 cm/hr respectively). There were practical limitations in using the pressure-flow technique alone to for mechanical characterisation, including the large quantity of chromatography resin and buffers and the stringent criteria required to pack a column. Dynamic mechanical analysis (DMA) was therefore developed as a novel technique in this field to address these limitations and allowed for further mechanical characterisation based on the viscoelastic properties using 1ml of resin. The technique was applied to the nine studied resins and correlated with the results obtained using the pressure-flow technique. The same trends were observed – The Capto family showed the highest resistance to deformation (Capto Adhere- 2.7, Capto Q- 1.92 1/%min-1) through to Sepharose CL-6B, Sepharose 4 Fast Flow and Sepharose CL-4B which exhibited the lowest slurry resistances (0.59, 0.4, 0.3 1/%min-1 respectively). These results indicate that DMA can be used as a small volume, high-throughput technique, relative to pressure-flow analysis, for the mechanical characterisation of chromatography media. 4 The structural imaging and mechanical testing tools developed in this study were then applied to measure changes in resins that had undergone lifetime studies. These studies expose the resins to repeated cycles of use to understand how they age in a particular bioprocess, enabling decision making about their use. The first set of experiments exposed the resins to the cleaning cycle only, whilst in the second set of experiments, the resins had been used for lifetime studies in the production of monoclonal antibodies (termed ‘aged’ resins). The results indicated that MabSelect (highly cross-linked protein A resin) and Q- Sepharose High Performance (anion exchange cross-linked resin) appeared to show similar mechanisms of aging. Their matrices showed agarose fibre breakage with increased exposure to process conditions. In the case of Capto Adhere (highly cross- linked multimodal anion exchange resin) and MabSelect Xtra (highly cross-linked protein A resin), the mechanism of aging appeared to be associated foulants coating the surface fibres. The results indicate that the interaction of CIP reagents and foulants (as opposed to CIP reagents alone) cause the greatest impact on the structural integrity of the resins. Pressure-flow and DMA characterisation were used to examine the mechanical properties of the cycled resins to provide the first systematic study of these issues. The results showed that fresh resins were consistently more robust than either of the cycled resins but the greatest mechanical differences were observed between fresh resins and aged resins, which corroborated the structural analysis data. Statistical analysis was performed with one way ANOVA to determine whether DMA could be independently used to assess the impact of process conditions on the mechanical properties of chromatography media and the results show a >80% certainty that DMA can be employed for this purpose. 5 IMPACT STATEMENT - Research relevance and Eli Lilly & Co.’s interest Large Scale chromatography is widely employed for the capture and purification of antibodies and other therapeutic proteins. Due to the high cost of most commercial use resins, there is a significant economic driving force to use these chromatographic materials for a large number of cycles. This however, needs to be balanced against the maintenance of acceptable column performance over the lifetime of the resin. Eli Lilly & Co. have observed that different matrices exhibit different limitations pertaining to column reuse. For example, sudden column collapse is particularly prevalent in hard bead support matrices, such as ceramic-based resins whereas agarose-based resins exhibit high back pressure symptoms. In both cases, the tools to understand the structural and mechanical implications are necessary and this research aims to provide advancements in this area (see figure 1 for Eli Lilly’s areas of interest). Eli Lilly’s interest Figure 1 – Flow diagram showing possible mechanisms of aging of chromatography resins related to loss of capacity and failure of the packed bed system. The figure pinpoints Eli Lilly’s interest for this research being associated with damage to the resins and the consequences of fouling. 6 Additionally, robust chromatographic performance is essential to meet regulatory expectations for biological products. It is a requirement to demonstrate the lifetime of the resin exceeds that of its intended use within the process and to establish procedures to monitor performance during operation. Hence there is a need to understand what the critical factors are in the aging process. Better process decisions can then be made to maximise resin usage by being able to better predict when mechanical column failure may occur. This project aims to address this by examining bead level events, which lead to mechanical failure of the column. 7 TABLE OF CONTENTS Page Acknowledgments………………………………………………………33 Abstract………………………………………………………………….44 Impact statement………………………………………………………..66 Table of contents………………………………………………...............88 List of figures…………………………………………………………..1111 List of tables……………………………………………………………2323 List of abbreviations and notations……………………………...........2727 List of publications…………………………………………………….2929 Introduction…………………………………………………………….3030 1. Literature review………………………………………………………33.33 1.1.Chromatography in bioprocessing………………………………….3535 1.2.Components of column chromatography…………………………..373737 1.3.The role of resins…………………………………………………..3939 1.3.1. Agarose-based resins………………………………………424242 1.4.Chromatographic operation: Packing………………………………444444 1.4.1. Structure-diffusion relationships……………………………4848 1.4.2. Adsorption…………………………………………………52..52 1.4.3. Resin lifetime and aging……………………………………5454 1.5.The importance of characterisation……………………………......5757 1.6.Mechanical and structural characterisation techniques…………...5960 1.6.1. Microscopy techniques…………………………………….60.59 1.6.2. Chromatographic techniques………………………………62.61 1.6.3. Other techniques……………………………………………6463 2. Materials and methods……………………………………………….6667 2.1.Scanning electron microscopy…………………………………......6869 2.1.1. Air drying……………………………………………….......6869 2.1.2.
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