BioPAT ViaMass Real-time, Inline Biomass Measurement for Cell Culture Processes in single-use. 03 May 2013 Page 1
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1 BioPAT ViaMass Realtime, Inline Biomass Measurement for Cell Culture Processes in singleuse 03 May 2013 Page 1
2 Agenda Demand Technical background Examples Outlook & Future Steps 03 May 2013 Page 2
3 Agenda Demand Technical background Examples Outlook & Future Steps 03 May 2013 Page 3
4 Biomass Measurement (Capacitance) in reusable systems enables better process control Cultivation: Insect cells (SF9), 27 C, SF900 media, 180rpm Correlation online / offline Online measurement 03 May 2013 Page 4
5 Single Use: Strong Market Demand for Biomass Measurement Cell Density 64.0% Cell Viability 50.0% Glucose 50.0% pco % Flow 32.8% MostWanted SingleUse sensors (Aspen Brooks Report 2011): 03 May 2013 Page 5
6 BioPAT ViaMass extends single use process monitoring towards biomass monitoring 03 May 2013 Page 6
7 Scalable biomass measurement from R&D to production R&D PD Clinical/Production Data Information Process Understanding Demo of Understanding Process Control
8 SU Biomass Measurement Added Value Realtime monitoring of viable cell volume for entire batch Automated process control and process modeling Automated substrate feed strategies Harvest point determination Optimal time of infection for viral production Reduced risk of contamination due to limited sampling need Reduced risk of unrepresentative samples (manual handling) Decreased labor cost for offline analysis 03 May 2013 Page 8
9 Agenda Demand Technical background Examples Outlook & Future Steps 03 May 2013 Page 9
10 Software Automation Analytical Systems Sensors PAT Toolbox for Enhanced Process Understanding and Process Automation Technology Status Selected Sartorius products Application Electrochemical sensors SU PH sensor, MU PH sensor, MU redox sensor Mixing Fermentation CC Optical sensors SU Sensors for ph and DO Fermentation Cell Culture Pressure sensors SU MU sensor All Unit Operations Flowmeters SU MU sensor All Unit Operations Temperature Pt 100 or Pt 1000, MU sensor All Unit Operations Conductivity MU sensor, SU under development Mixing Homogeneity Glucose / Lactate BioPAT Trace Fermentation Cell Culture Spectroscopy Ammonia Refractive Microwave Index Resonance BioPAT Spectro (NIR UVVIS CCD) BioPAT Reflex Fermentation Cell Culture Formulation Fingerprinting CIP Inline Dilution Formulation Turbidity Refractive Index BioPAT Fundalux Fermentation Capillar Exhaust electrophorese Gas Analysis BioPAT Xgas Fermentation Biomass BioPAT Viamass Cell Culture Design of Experiments BioPAT MFCS DoE Module BioPAT MODDE Bioprocess Chain Multivariate Data Anal. BioPAT MFCS MVA Module BioPAT SIMCA online Bioprocess Chain SCADA Automation Platform BioPAT MFCS BioPAT DCU Bioprocess Chain Bioprocess Chain Sartorius offering Products available Products in development 03 May 2013 Page 10
11 Every cell can be polarized Cytoplasmic Lipid membrane impermeable to the free flow of ions 03 May 2013 Page 11
12 Influence of electric field is polarising viable cells Electronics controlling the electric field + Polarising ions available in the cytoplasm and suspending media Cell Direction of the field 03 May 2013 Page 12
13 Dead and ruptured / fragmented cells cannot be polarized Electronics controlling the electric field Cell with badly Plasma membrane ruptured plasma fragments + membrane Direction of the field 03 May 2013 Page 13
14 In situ four pin electrode probe used for biomass measurement Dead cells invisible to measurement field Only live cells polarized Living biomass is measured Sensitivity of measurement field approx. 30mm 03 May 2013 Page 14
15 Alternative Biomass Measurements do not give similar response Offline Methods Trypan blue exclusion Cells need intact membrane, subjective method FACS analysis Cells need intact membrane and active enzymes Offline counter mostly based on Trypan blue exclusion with CCD camera counting Dry weight / Wet weight not specific, mostly used in microbial fermentation Offline methods are highly time consuming and do not give direct process feedback Online Methods OD / Turbidity measurement mostly used in microbial fermentation OD Turbidity is a determination of the sum of living and dead cells 03 May 2013 Page 15
16 Agenda Demand Technical background Examples Outlook & Future Steps 03 May 2013 Page 16
17 1. Application Cultivation of E.coli in single use (STR50) Comparison of different Methods: Dry cell weight DCW Wet cell weight WCW OD 600 Capacitance 03 May 2013 Page 17
18 Capacitance (pf/cm) VCD (10E6 cells/ml) Biomass Capacitance VCD (E6 cells/ml) 2. Application Cell Cultures Comparison of offline and online capacitance measurement in 2 cell lines Cell Line B Capacitance L STR VCD Cell Line B Run Time (Days) Data provided by: Runtime (Decimal Hours) Capacitance (pf/cm) Point Capacitance 50L STR 03 May 2013 Page 18
19 Agenda Demand Technical background Examples Outlook & Future Steps 03 May 2013 Page 19
20 BioPAT ViaMass Online Measurement of Biomass Culture control Implementation of online biomass Measurement in control strategy Single use biomass sensor Integrated calibration & cell counting Global BioPAT ViaMass Trends Measurement of biomass Determination of cell numbers Compact design for flexible integration Reduce sampling and labour work DCU Local Control Unit Direct display of capacitance Cell number Quick and simple process monitoring Central data monitoring without delays BioPAT MFCS/win + Recipe Module Recipes for process automation Automatic eventbased control of cultivations to assure batchtobatch consistency Fully automated process steps based on cell numbers, for robust processes and reduced labour work 03 May 2013 Page 20
21 Timelines Product Availability Production Transfer + Sensor Qualification + DCU Integration Cultibag RM Integration Cultibag STR Integration Application Tests Customer trials Milestones: Customer trials by 09/2013 RM + STR Launch Q1 / May 2013 Page 21
22 Facts for integration For both systems (RM and STR) the BioPAT ViaMass will be integrated in bags with the new film (bags with old film will not be considered) For RM: Only new Rocker can carry bags with biomass sensor! Any upgrade for old Rocker is not possible! 03 May 2013 Page 22
23 Take Home Message o Number of live cells with intact membranes become polarized and thus measured o Dead cells with porous membranes are not taken into account o The resulting capacitance is directly proportional to the total membrane bound volume of the cells o o o The number of cells, and the size of the cells The total biological volume The system is insensitive to cells with leaky membranes, gas bubbles and other debris The electric field typically propagates about 30mm from the probe into the liquid Be careful when comparing different methods of determining live and dead cells, this is a grey area, and you can get different answers 03 May 2013 Page 23
24 Appendix
25 Online Measurement of Biomass Viable Cell Volume Realtime monitoring of viable cell volume for entire batch allows automated process control and process modeling automated substrate feed strategies with MFCS harvest point determination time of induction / infection Dead cells invisible to RF Field Only live cells polarized RF capacitance proportional to viable cell volume Reduced risk of contamination due to limited sampling need Reduced risk of unrepresentative samples (manual handling) Decreased labor cost for offline analysis Single use sensor integration for various SU bioreactors 03 May 2013 Page 25
26 Measurement details o System measures capacitance + conductivity between 50 khz and 20 MHz o 3 presets, 1 customer setting o Viable biomass (volume) proportional to capacitance: Calibration = enter proportionality factor o In future optional: scan of 25 frequencies should be measured o only one probe table is used for all sensors 03 May 2013 Page 26
27 Principle Setup and BioPAT MFCS integration USB PC 420 ma MFCS May 2013 Page 27
28 Integration and retro fit of existing systems Adaptation cable ODU M12, Modbus 420 ma? USB PC 03 May 2013 Page 28
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