Download - Asahi Kasei Bioprocess Europe 2016 02 1
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Virus Removal in Cell Culture Media
with PlanovaTM Nanofiltration
BioInnovation 2016
10 - 11 February 2016
Waldorf Astoria Hotel | Berlin | Germany
Konstantin AGOLLI
Technical Assistant
Asahi Kasei Bioprocess Europe
www.ak-bio.com
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Goal
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Goal
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1) Discussion about virus removal in media: Technologies available
How much virus reduction required ?
How to decrease cost of nanofiltration ?
2) PlanovaTM filters: Specifications
Filtration mechanisms
3) Case studies: Filterability & Cell growth
Virus spiking filtration studies
Cost calculation
Content
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Asahi Kasei Bioprocess
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Content
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Sepacell™ Bioprocess Division
Blood purification Blood transfusion
Asahi Kasei Corporation
Holding company
Core operating companies
Chemicals & fibers
Asahi Kasei Chemicals
Asahi Kasei Fibers
Homes &
Construction Materials
Asahi Kasei Homes
Asahi Kasei
Construction Materials
Electronics
Asahi Kasei Microdevices
Asahi Kasei E-materials
Asahi Kasei Pharma
Asahi Kasei FibersAsahi Kasei Medical
ZOLL Medical
Health Care
DialysisTherapeutic
Apheresis
Foundation: 1922; HQ: Tokyo; Employees: 25 000; Turnover: 19 B$
Innovative leader in various kind of business fields
Asahi Kasei Group
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PlanovaTM
Virus removal filters BioOptimalTM MF-SL
TFF microfilter
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… Asahi Kasei Bioprocess
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Systems & Equipment
CellufineTM
Cellulose Beads
Chromatography media(made by JMC Corporation)
BioCradleMicrocarriers for Cell Culture
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… Asahi Kasei Bioprocess
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1) Discussion about virus removal in media: Technologies available
How much virus reduction required ?
How to decrease cost of nanofiltration ?
Content
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Strict raw material testing & source control
Closed systems in the manufacturing process
Virus testing (traditional & new methods)
Etc…
Cell culture media ?
Despite a high level of Virus Safety Assurance, virus
contaminations occurred in the past
Current Approach To Virus Safety
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γ-irradiation
HTSTUV-treatment
Nanofiltration
Technologies for Virus Removal
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High volumes in short
time
Impact on media quality
Effectiveness on smallest virus ?
HTST: risk of precipitation
UV: Scalability ? Industrial reactor ?
Running costs ?
HTST
γ-irradiation
UV-treatment
Technologies for Virus Removal
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Nanofiltration
Effective vs “all“ viruses
(known and unknown)
No impact on media
composition
Easy to implement
(like sterile filter)
Excellent & easy
scalability
With serum free media only
Performances can be affected
by some surfactants or lipids
Long filtration times required
Technologies for Virus Removal
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No regulatory requirement ➔ Production risk mitigation
“0” virus required ! ≠ DSP philosophy with LRV
In real life: “0” virus = below the limit of detection …
LRV still calculated according to the detection limit & virus titer
PlanovaTM: usually LRV > 4 log (TCID50/mL)
How Much Virus Reduction Required ?
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How To Decrease Cost Of Nanofiltration?
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Specific nanofilter for USP ? NO. Same virus as for DSP to remove !
“Low cost” nanofilter ? NO. High quality nanofilter required
Much higher flux ? NO. 1) Nano-pore limitation
2) Filterability of media
More filtration volume ? YES! Unlike in DSP, much higher L/m2
Longer filtration times required
How To Decrease Cost Of Nanofiltration?
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The only way to decrease the cost of the nanofiltration
is to filter longer !
How To Decrease Cost Of Nanofiltration?
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2) PlanovaTM filters: Specifications
Filtration mechanisms
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Content
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PlanovaTM Nanofilters
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Filter PlanovaTM N PlanovaTM BioEX
Hollow fibers cellulose PVDF
Pore size (nm) 15, 20, 35, (75) Parvovirus removal
Filtration surface (m²) 0.001 ➔ 4.0 0.0003 ➔ 4.0
Max TMP (kPa) 98 343
Water flux (LMH) 20N: 66 @ 98 kPa 170 @ 343 kPa
SIP/Autoclaving NO YES
315 mm
PlanovaTM Nanofilters
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How does it work?
Filtration Mechanism
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Medium
+ Virus
Medium
Virus FreeMedium
Virus Free
Virus
Void
Single Layer
Capillary
Unique Membrane Structure
& Filtration Mechanisms
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Hollow fiber
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Medium
+ Virus
Medium
Virus FreeMedium
Virus Free
Virus
Void
Single Layer
Capillary
3D network
Unique Membrane Structure
& Filtration Mechanisms
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Hollow fiber
Size Exclusion & Depth Filtration
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Media Supply
P
P
P P
Sterile-filter
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Easy Setup
Bioreactor
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Media Supply Nanofiltration Bioreactor
P
P
P P
Sterile-filter
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Easy Setup
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3) Case studies: Filterability & Cell growth
Virus spiking filtration studies
Cost calculation
Content
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Filterability
Filterability & Flux depend on medium
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SERUM FREE MEDIA tested for CHO culturesA
V.
FL
UX
(L
MH
)
0
20
40
60
80
100
120
EXCELL302 CHO-S-SFMⅡ VP-SFM ×1 CD Opti ×1 CD Opti ×5
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Filterability
Long filtration time required to achieve high filtration volumes (L/m2)
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Sigma EX-CELL 302 + Feed supplement
0
1000
2000
3000
4000
0 1000 2000 3000 4000 5000
Time (min)
Fit
rati
on
Vo
lum
e
(L/m
2)
3 days
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Cell Growth
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10
5cell
s/m
L
No impact of BioEX on media quality after 7 days.
According to customers, no impact on media quality/composition even
after 20 days of filtration with BioEX or 20N.
0
10
20
30
40
50
60
BioEx + BioEX - BioEx + BioEX - BioEx + BioEX - BioEx + BioEX - BioEx +
Excell302 SFMII VP-SFM CD Opti CDOpti5
Day 0 to Day 7
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Filterability & Cell Growth
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To remember !
Filterability depends on media & ingredients
Very high volume/m2 with serum free media, if
filtration time is long enough
No impact on the quality of the media and therefore
on the cell growth
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Are PlanovaTM nanofilters able to remove viruses
from contaminated media, while filtering such high
volumes during several days ?
Most Important Question
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Cell Culture medium
Nanofilter
PPV (Porcine Parvo Virus), 18-22 nm
Titer 20N 4.26 log (TCID50/mL)
(in medium) BioEX 5.57 log (TCID50/mL)
20N 10 cm2; N = 1
BioEX 3 cm2; N = 2
20N: 5000 L/m2
BioEX # 1: 10 000 L/m2 (non stop)
BioEX # 2: 5 000 L/m2 (3 h stop & restart)
CD-CHO (from GIBCO Invitrogen)
Filtration Volume
Virus
TMP 20N 98 kPa
BioEX 300 kPa
Virus Spiking Filtration with CD-CHO
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No impact of the virus
spiking on Filtration Volume
Consistency of the
performances
20N:
2 000 L/m² in 1 day
5 000 L/m² in 3 days
BioEX:
Same as 20N
10 000 L/m² in 7 days
Volume (L/m²) vs. Time
Virus Spiking Filtration with CD-CHO
0
2000
4000
6000
8000
10000
12000
0 50 100 150 200
Filte
rati
on
Vo
lum
e (
L/m
²)
Time (h)
BioEX-1
BioEX-2
20N
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No virus detected ( )
Difference in PPV LRV is
due to difference in initial
virus titer
0
1
2
3
4
5
6
0 2000 4000 6000 8000 10000
PP
V L
RV
(lo
g)
Filtration Volume (L/m²)
BioEX-1
BioEX-2
Planova 20N
Virus Spiking Filtration with CD-CHO
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Filtration
Volume (L/m2)10 442 752 1678 2399 3607 4997 5005 5005 5026 5046 5066 5086 5105
Time (h) 0 4 7 19 29 48 71 71 74 74 75 75 75 76
Flux (LMH) 122 108 94 77 72 65 60 62 - 63 63 63 63 63
PPV LRV ≥ 5 ≥ 5 ≥ 5 ≥ 5 ≥ 5 ≥ 5 ≥ 5 ≥ 5 - ≥ 5 ≥ 5 ≥ 5 ≥ 5 ≥ 5
Stop of 3 hours & restart with BioEX filter # 2 :
PPV LRV still > 5 log with no virus detected in the permeate
Same flux
3h stop
Virus Spiking Filtration with CD-CHO
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To remember !
Very high filtration volumes/m2 with virus spiked media
4 log PPV removal with no virus detected in filtrate…
….despite several days of filtration and very high filtered
volumes
Virus Spiking Filtration with CD-CHO
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Price of CD-CHO:
< 30 €/L
BioEX:
After 1.5 days, NF cost
< 10 % medium cost
20N:
After 1 day, NF cost
< 10 % medium cost
The longer the filtration
time, the more cost
effective !
Medium: CD-CHO
Volume: 10 000 L
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
0 1 2 3 4 5 6 7 8
Filte
r co
st
(€/L
)
Filtration Time (days)
BioEX
20N
Medium: CD-CHO
Volume: 10 000 L
Cost Calculation:
Filter cost (€/L medium) vs. Filtration time (days)
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Conclusion
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Content
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1) Virus removal nanofiltration with serum free media
2) High quality DSP nanofilter required because viruses are the same
3) Filtration of media is not always easy, flux decay is expected
4) High virus LRV for “ALL” viruses without impacting cell growth
5) Only way to decrease nanofiltration cost long filtration times, to
be able to achieve extremely high filtration volumes/m2
6) Removal of other contaminants: mycoplasma, phage, nanoparticles…
Conclusion
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Thank you to my colleagues:
Hongo-san
Mihara-san
Kederer-san
Dayani-san
Tanimoto-san
Kobayashi-san
Schrankler-san
Teitz-san
Martirene-san
Mathithas-san
Acknowledgements
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OR
Goal
95
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どうもありがとうDomo Arigato!
(thank you very much)