ReadyToProcess columns

Transcription

1 GE Healthcare Prepacked chromatography s s chromatography s are validated high-performance bioprocessing s that are supplied prepacked and ready for use. The s are available with a range of BioProcess resins in different sizes (Fig 1). Standardized formats allow off-the-shelf availability for short delivery lead times. s are closed units and the design allows easy disposal after completed production, enabling flexibility in operations. Reliable supply, predictable performance: Standardized formats allow reduced cost and off-the-shelf availability for short delivery lead times. Robust design and validated automated packing methods enable consistent performance. Cost-savings by eliminating the need for preparation, packing, and validation procedures. Customer safety stock possibility for security of supply. Security of supply s are covered by an extensive security of supply program for chromatography resins. As a supplier of both chromatography resins and prepacked s, GE Healthcare takes responsibility for the complete supply chain, from chromatography resin production to the final prepacked s. Delivery lead times are shortened with a wide range of stock items and an efficient planning between bulk resin production and prepacked production for non-stock items. GE Healthcare also works with supply chain sustainability for s, which includes inventory management both at GE and at its suppliers of empty parts to minimize supply interruptions. GE supports the technical aspects of both resin and prepacked as well as share expertise in various applications throughout the purification process. A business continuity plan is in place for the production, which is located in Uppsala, Sweden, and the production site is ISO certified for business continuity. GE's business continuity plan follows international standards and is complemented with a strategic reserve of chromatography resins to mitigate supply chain risks. Fig 1. s are easily connected to a chromatography system and can be disposed after completed production. Standardized format Standardization of the format means that each is validated against its defined specifications. A validated design and robust packing methods enable production with high lot-to-lot consistency. Prepacked s offer speed and flexibility s make several steps such as preparation, packing, and qualification redundant, and significant time saving can be achieved in downstream processing. Disposable s offer the possibility of working in a flexible mode in early clinical phases to medium manufacturing scale (processing of up to 2 L bioreactor harvests), while keeping a conventional option for larger-scale manufacturing open. The chromatography resins used in s have a long track-record of use in full-scale manufacturing including conventional, largescale chromatography, where s can be used for tens or hundreds of cycles. The transition from the format to full-scale manufacturing is therefore straightforward. Available in sizes from 8 to 45 mm i.d., s are well-suited for use with the single-use Xcellerex XDR bioreactor systems with working volumes ranging from 1 to 2 L, for design of a disposable process from upstream to downstream (Fig 2). Data file, AK

2 Preclinical Clinical manufacturing Full-scale manufacturing s Ø 8 mm Ø 126 mm Ø 178 mm Ø 359 mm Ø 45 mm Ø 251 mm 1 L 2 L Corresponding bioreactor harvest volumes Fig 2. s can be used with ÄKTA ready and ÄKTA ready XL chromatography systems. Consistency in geometry allows for convenient scaling of s from 8 to 45 mm in i.d. BioProcess resin groups currently available in the format are MabSelect SuRe, MabSelect, Capto S ImpAct, Capto ImpRes, Capto, Sepharose 6 Fast Flow, and Sepharose High Performance resins. The full offering is listed in the Product sheet ( ). Additional chromatography resins can be available in the format upon request. s are available with bed heights of 15, 2, and 25 mm as standard. Other bed heights can be available through GE's customized offerings. Please contact your local sales representative for more information. characteristics s are packed using a pack-in-place method that combines the benefits of the packing methods for the AxiChrom and Chromaflow s. The packing process is developed and optimized for each chromatography resin and is controlled through a specific packing system that automatically controls the pressure specific for the particular resin. For packing, the resin is supplied to the through a packing valve. Packing is followed by mechanical compression of the resin. s have fixed bed heights, enabling optimization of contact time, flow rates, and capacity of modern chromatography resins. s are recommended for up-flow mode running condition but can be run in down-flow mode if desired (Fig 3). Pressure/flow curves for operation with water at room temperature (2 C) are shown in Figure 4 for Capto adhere, MabSelect SuRe, Phenyl Sepharose 6 FF, Capto S ImpAct, Capto MMC ImpRes, SP Sepharose HP, Capto Q, and Q Sepharose FF s. The polymeric materials used for manufacturing of s have been chosen for their biological and chemical compatibility with the samples, buffers, and solutions used during operation and sanitization procedures. Extractable studies and risk assessment have been performed (see details under Column validation). The materials meet the United States Pharmacopeia (USP) class VI requirements according to USP <88> Biological Reactivity Tests, In Vivo and FDA CFR 177. The materials are animal-derived component free or has been produced under manufacturing conditions complying with EMEA/41/1. The s are designed to comply with hygienic requirements. Materials used in wetted parts are listed in Table 1. Fig 3. with assembled parts and packing valve for resin. Arrows show flow direction AK

3 (A) MabSelect SuRe 2.5 L (126/2) 2 L (359/2) 32 L (45/2) (B) Capto adhere 2.5 L (126/2) 2 L (359/2) 32 L (45/2) (C) Phenyl Sepharose 6 Fast Flow (low sub) 2.5 L (126/2) 2 L (359/2) (D) 4 (E) 5 (F) 2 Capto S ImpAct Capto MMC ImpRes SP Sepharose High Performance L (8/2) 15 1 L (8/2) 6 1 L (8/2) 1 5 L (178/2) 1 5 L (178/2) 5 L (178/2) L (359/2) 2 L (359/2) 2 L (359/2) (G) 1 Capto Q (H) 4 Q Sepharose Fast Flow L (251/15) 1 L (251/2) 12.4 L (251/25) L (45/2) Fig 4. Examples of pressure/flow curves for s prepacked with (A) MabSelect SuRe, (B) Capto adhere, (C) Phenyl Sepharose 6 FF (low sub) (D) Capto S ImpAct, (E) Capto MMC ImpRes, (F) SP Sepharose High Performance, (G) Capto Q, and (H) Q Sepharose Fast Flow resins. Table 1. Materials used in wetted parts of s (see User manual for details) Trade name Material Column part PP Polypropylene Column tube*, lids, TC connections, support nets*, support screens*, stream stoppers, hose connections, welded tubing for inlet/outlet protection PMMA Polymetylmetakrylat Column tube 32 L (45/2) PEEK Polyetheretherketone Plug at inlet tubing, filter holder, resin packing valve PO 2475 Polyolefin (Tygon ) Hose (inlet tubing) UHMWPE Ultra high molecular weight polyethylene FPM Fluorocarbon rubber O-rings Sinter mesh 1 μm, 32 L (45/2) PE Polyethylene Sinter mesh 2 μm, 32 L (45/2) EPDM Ethylenepropylenediene TC gaskets The most important characteristics of the s are listed in Table 2. On delivery, s are ready for immediate use. The s are packed in cleanroom environment (class ISO 8) using validated packing protocols. As a part of the production procedure, each individual is qualified by efficiency testing towards its validated specifications, that is, by analysis of number of theoretical plates per meter packed bed (N/m) and asymmetry factor (A s ). Acceptance limits have been established for efficiency testing at a flow velocity of 1 cm/h (except for Sepharose High Performance, which is tested at 3 cm/h) and the analytic results are specified in the certificate of analysis (CoA) accompanying each. After qualification, the s are sanitized and equilibrated with storage solutions. Every delivery is accompanied with a reference side sample of the same resin lot as packed in the (125 ml as a 5% slurry). * For the 8 to 359 mm i.d. s, the inner, wetted surface of the tube, support nets, and support screens is made of polypropylene AK 3

4 Table 2. Characteristics of s.8 L 1 L 1.3 L 1.9 L 2.5 L 3.1 L 3.7 L 5 L 6.2 L 7.4 L 1 L 12.4 L 15 L 2 L 25 L 32 L Column volume (L) Inner diameter (mm) Inner cross section (cm 2 ) Packed bed height (mm) Net size (μm)* 14/25 14/25 14/25 14/25 14/25 1/2 Mechanical compression factor (%) Outer height (mm) Outer diameter incl. lid (mm) Packed weight (kg) ~ 3 ~ 5 ~ 6 ~ 7 ~ 11 ~ 13 ~ 15 ~ 2 ~ 24 ~ 27 ~ 43 ~ 49 ~ 56 ~ 18 Inlet TC25 connectors, tubing i.d. (mm [inch]) 4.8 (.19) 4.8 (.19) 9.5 (.375) 9.5 (.375) 12.7 (.5) 12.7 (.5) Outlet TC25 connectors, tubing i.d. (mm) Ambient temperature ( C) Liquid temperature ( C) Maximum pressure empty (bar) Estimated shelf life (months) * Net mesh 25/2 µm for beads with a mean particle size of the cumulative volume distribution (d 5,volume ) 75 µm and net mesh 14/1 µm for beads with a d 5,volume 5 µm. The mechanical compression factor does not include flow compression and varies depending on the resin and/or the size of the. The temperature difference between the fluid running through the and the ambient temperature in the room should never be greater than 2 C. The maximum pressure for an empty is 4. bar (58 psi,.4 MPa). For a packed, restrictions regarding maximum pressure drop depend on the chromatography resin. The pressure drop between inlet and outlet of the should never exceed the specified maximum pressure drop for the resin in the. See User manual ( ) for details. Column validation Sanitization Although most s are delivered presanitized, the design allows for easy sanitization. The sanitization procedure reduces both endotoxins and microorganisms, including spore-forming organisms. Each sanitized is sampled for endotoxin analysis (acceptance limit <.25 EU/mL) and microbial growth (colony forming units < 1 CFU/1 ml). The results, including results from efficiency testing as well as endotoxin and microbial analyses, are presented in the CoA. As a last step, the is equilibrated in 2% ethanol (2% ethanol with.2 M sodium acetate, ph 5.5 when applicable). The data is included in the validation guide (see Related literature). All resins are not sodium hydroxide-stable, such as some of the affinity chromatography resins. Hence, s containing such resins are delivered non-sanitized. For more information, please refer to the validation guide for the specific. Transport simulation Tests performed during transport simulations were vertical impact by dropping test (SS-ISO 2248), compression test (ISO 1248), vibration test (SRETS packing-complete, filled transport packages and unit loads, vertical random vibration tests, level 3), and horizontal shock test (ISO 2244) according to a defined test program. Transport simulation studies were performed at a certified testing facility. For testing performed at a flow velocity of 3 cm/h, acceptance criteria for number of theoretical plates (N) per meter (m) packed bed were set to 37 N/m for Capto Q*, Capto S, and Phenyl Sepharose 6 FF (low sub) s; 39 N/m for MabSelect SuRe s; and 44 N/m for Capto adhere s. The acceptance criterion for A s was set to be within the range.8 to 1.8, both before and after testing. The results in Figure 5 show that the determined values for these parameters lie within set limits, demonstrating that s are stable and robust and can be transported without effects on their performance. * The 5 L (178/2) size was only tested with Capto Q resin AK

5 Lane 1 Capto adhere 2 Capto Q 3 Capto S 4 MabSelect SuRe 5 Phenyl Sepharose 6 Fast Flow (low sub) Asymmetry (A S ) Plates/meter (N/m) (A) 2.5 L (126/2) Lane: Lane: Before After 1.8 A S.8 A S Asymmetry (A S ) Plates/meter (N/m) (B) 2 L (359/2) Lane: Lane: Fig 5. Test results after transport simulation on (A) 2.5 L (126/2) s and (B) 2 L (359/2) s show that both the number of theoretical plates (N/m) and the asymmetry factor (A s ) were within the predefined ranges. Study on extractables and strategy for leachables Studies on extractable compounds have been performed to identify potential compounds leachable from the assembled hardware (unpacked). The results from identified and quantified extractables were used to assess potential safety risks associated with the polymeric materials used in s. Extractions were performed under conditions that exceed worst case process conditions regarding polarity/nonpolarity of the solvents, ph, temperature, and contact time. The studied extraction solutions were water for injection (WFI), phosphoric acid (ph 3), sodium hydroxide (ph 14), and ethanol (1%). Temperature was 4 C and contact time 24 h. Four assembled 2.5 L (126/2) s were filled with respective extraction solution, closed, and agitated for 24 h at 4 C and 1 rpm before the solutions were analyzed for extractables with a set of analytical methods according to a test matrix. The concentrations of all detected compounds were below ppm level except triphenylphosphine oxide, which was at 3.3 ppm when extracted in 1% ethanol. In addition, a study on extractables was conducted on plastic materials exclusively used in the 32 L (45/2). Solutions used in generating the extractables profile for this size were deionized water, 5 M sodium chloride,.5 M sodium hydroxide,.1 M phosphoric acid, 5% ethanol, and 1% polysorbate 8. An assembled 32 L (45/2) was also tested with each solvent. A safety assessment of extractable compounds was performed in order to identify safety risk for the tested s. The chemical and toxicological information of extractable compounds used in A S.8 A S the assessment did not indicate any toxicological concern regarding the use of s in typical biopharmaceutical manufacturing. As each purification process has specific process liquids and process conditions, it should be noted that it is always the responsibility of the user to evaluate extractables and leachables with respect to the actual process conditions and target product together with the relevant toxicological information. BioProcess resin characteristics BioProcess chromatography resins from GE Healthcare are specifically designed to meet the demands of industrial biotechnology, meaning that the resins are scalable from laboratory to manufacturing scale, are produced with validated manufacturing procedures, and can withstand standard cleaning-in-place (CIP) and sanitization-in-place (SIP) procedures. All BioProcess resins are supported by GE's security of supply services as well as regulatory support files (RSF) and comprehensive documentation. Characteristics of chromatography resins available in the format are listed in corresponding resin data files. Detailed information about each resin is available from their respective data file (see Ordering information). Regulatory product documentation Each is accompanied with an extensive documentation package to help customers register a manufacturing process containing a chromatography step including a. The documentation is divided into three parts. Product documentation a user manual, including a list of wetted parts, is provided. Material conformance of wetted parts shows conformance with 21CFR177, USP Class VI, and animal-free origin (or EMEA/41/1) for each wetted part material as well as traceability of the material. The product documentation contains a certificate of analysis showing packing performance as well as endotoxin and microbiology test results for the delivered. The user manual is distributed with each and the CoA can be downloaded from gelifesciences.com/certificates. Validation guides gives access to product information of the including stability, validation, and quality as well as a brief description of the production process. RSF current files include additional information on each BioProcess chromatography resin. RSF addenda and RSF are available at gelifesciences.com/rsf AK 5

6 Process scale-up studies To show process scalability, a study was performed to verify that a protein separation experiment gives the same result regardless of size or chromatography system used. A mixture of BSA and lactoferrin was applied to s of different sizes. Columns used were XK 16/4; BPG 1; and 2.5 L (126/2), 1 L (251/2), and 2 L (359/2) s, all packed with Capto S resin and run in bind-and-elute mode on an ÄKTA system. Columns: A 28 (mau) XK 16/4 packed with Capto S to a bed height of 2 cm BPG 1 packed with 1.5 L Capto S to a bed height of 2 cm Capto S 2.5 L (126/2) Capto S 1 L (251/2) Capto S 2 L (359/2) Sample: Mixture of BSA (M r 66 ) and lactoferrin (Mr 9 ) Equilibration: 5 mm sodium acetate, ph 5. Elution: Systems: Stepwise with 3 volumes each of 5 mm sodium acetate +.3 M NaCl, ph 5. and 5 mm sodium acetate +.65 M NaCl, ph 5. ÄKTA chromatography systems 5 1 Time (min) Conductivity (ms/cm) 2 L (359/2) 2.5 L (126/2) 1 L (251/2) BPG 1, 1.5 L XK 16/4 Fig 6. Stacked chromatograms comparing step elution of BSA and lactoferrin on five different s. Results were similar over scale-up from XK 16/4 to s regardless of or chromatography system used. The elution peaks in the resulting chromatograms were compared. The results indicate that scale-up from XK 16/4 and BPG 1 to the s was possible and that the outcome was similar regardless of or chromatography system used (Fig 6). Scalability was also demonstrated for a monoclonal antibody (mab) purification process. In this study, performance of s was compared with the performance of the small-scale XK 16/4. The processes were run side-by-side using a generally applicable three-step mab purification process including MabSelect SuRe, Capto Q, and Capto adhere resins. The s exhibited similar performance to the XK 16/4 s in all aspects studied, demonstrating that the purification process is directly scalable between the XK and formats. More detailed information can be found in application note In a study of a separate mab purification processes, performance was compared with the performance of conventional AxiChrom s. A mab purification processes comprising chromatography steps including MabSelect SuRe and Capto adhere resins packed in the two different formats were compared. The results from the process run in s were similar to the results obtained from the process run in AxiChrom s (Table 3). Yield and impurity levels were almost identical over the process steps, demonstrating equivalent performance of the different types. These results indicate that purification processes are also scalable between the and AxiChrom formats. More detailed information can be found in application note Table 3. Comparative evaluations of scaled-up processes with s and conventional AxiChrom s (yield is expressed as monomer yield for the Capto adhere step) Process step Yield (%) Aggregate content (%) Host cell protein (HCP) (ppm) Protein A (ppm) Conventional Conventional Conventional Conventional Fermentation N/A* N/A* Harvest N/A* N/A* Capture, MabSelect SuRe UF/DF Polishing, Capto adhere < LOQ < LOQ < LOQ < LOQ UF/DF and sterile filtration < LOQ Overall yield * N/A = not applicable UF/DF = ultrafiltration/diafiltration Average LOQ = level of quantification (4.6 ng/ml for HCP, 3 ng/ml for ligand) Unit operations with > 1% in yield were calculated as 1% AK

7 Column performance in multiple runs To investigate the effects of multiple runs on performance, MabSelect SuRe 2.5 L (126/2) s were run five times consecutively with cell culture feed supernatant and with CIP performed between cycles (Fig 7). All chromatograms were largely identical, showing that multiple runs can be conducted with retained performance. Column: MabSelect SuRe 2.5 L (126/2) Sample: A 28 mab in Chinese hamster ovary (CHO) cell supernatant Equilibration:.2 M sodium phosphate +.15 M NaCl, ph 3.5 Elution:.1 M sodium phosphate +.1 M sodium citrate, ph 3.5 System: ÄKTAprocess chromatography system Volume Fig 7. Overlay of chromatograms from five parallel runs of a mab purification step. Operation Fast development of scalable methods For efficient process development, high-throughput screening and optimization can be conducted in prefilled PreDictor 96-well filter plates or in prepacked PreDictor Robo or HiScreen formats. As the chromatography resins used in s are also available in bulk, process development can also be achieved using the small-scale Tricorn, XK, or HiScale s. After optimization at laboratory scale, the process can be scaled up keeping the residence time constant for maintained capacity. Constant residence time between s of different sizes can be achieved by increasing the diameter and flow rate (L/min), while keeping the flow velocity (cm/h) and sample-to-bed volume ratio constant. Yield and clearance of critical impurities might change when bed height or residence time is changed and should be validated using the final bed height. Storage s are delivered prepacked with chromatography resin in a storage solution consisting of 2% ethanol. s with resin coupled with the S- or SP-ligand as well as Capto MMC ImpRes are delivered in 2% ethanol +.2 M sodium acetate, ph 5.5. The s should be cleared from storage solution in a wash step before starting the purification process. The wash will also adjust the temperature of the to working temperature. All s, except affinity chromatography s, are preferably stored at room temperature or colder (storage temperature range for these s is 4 C to 3 C). affinity chromatography s should be stored at 2 C to 8 C. Shelf life is maximum three years or based on the shelf life of the included chromatography resin. The shelf life is based on a real-time study for up to 48 months at 3 C. The three year shelf life is valid for 1 to 2 L (8 to 359 mm i.d.) s. The 32 L (45/2) has an estimated shelf life of two years. Equipment s are intended for use with the ÄKTA ready product family, but can also be used with standard chromatography systems, such as the ÄKTAprocess system. 1 L (8/2) and 2.5 L (126/2) s can also be used with the ÄKTApilot and ÄKTA pilot 6 systems within a limited flow velocity range. Pressure alarm should be set to avoid exceeding the maximal recommended pressure drop for the packed AK 7

8 Ordering information Stock items (for complete list of available standard s, see Product sheet ) Case study Improve process economy by cycling of prepacked chromatography s Product code Product Column size Product code MabSelect SuRe 1 L (8/2) MabSelect SuRe 2.5 L (126/2) MabSelect SuRe 5 L (178/2) MabSelect SuRe 1 L (251/2) MabSelect SuRe 2 L (359/2) MabSelect SuRe 32 L (45/2) SP Sepharose FF 1 L (8/2) SP Sepharose FF 2.5 L (126/2) SP Sepharose FF 5 L (178/2) SP Sepharose FF 1 L (251/2) SP Sepharose FF 2 L (359/2) Capto Q 1 L (8/2) Capto Q 2.5 L (126/2) Capto Q 5 L (178/2) Capto Q 1 L (251/2) Capto Q 2 L (359/2) Q Sepharose FF 1 L (8/2) Q Sepharose FF 2.5 L (126/2) Q Sepharose FF 5 L (178/2) Q Sepharose FF 1 L (251/2) Q Sepharose FF 2 L (359/2) Capto adhere 1 L (8/2) Capto adhere 2.5 L (126/2) Capto adhere 5 L (178/2) Capto adhere 1 L (251/2) Capto adhere 2 L (359/2) Related literature Product Product code Product sheet: s Validation guide: s User manual: s Application notes Product code Efficiency test of s Purification of a monoclonal antibody using s increases facility capacity and shortens change-over time A flexible antibody purification process based on products Scale-up and process economy calculations of a dab purification process using only ready-to-use products Evaluation of performance of a disposable mab affinity chromatography used over multiple process cycles Data files KA AN Product code ÄKTA ready ÄKTA ready XL KA DF MabSelect MabSelect PrismA KA DF MabSelect SuRe MabSelect SuRe LX Capto S ImpAct Capto adhere ImpRes Capto MMC ImpRes Capto SP ImpRes, Capto Q ImpRes Capto Phenyl ImpRes and Butyl ImpRes Capto adhere Capto MMC Capto Q and Capto S Sepharose Fast Flow ion exchangers Phenyl Sepharose 6 Fast Flow (low sub), Phenyl Sepharose 6 Fast Flow (high sub) Q Sepharose High Performance, SP Sepharose High Performance Q Sepharose XL, SP Sepharose XL gelifesciences.com/-s GE Healthcare Bio-Sciences AB Björkgatan Uppsala Sweden GE, the GE Monogram, AxiChrom, ÄKTA, ÄKTApilot, ÄKTAprocess, BioProcess, Capto, Chromaflow, HiScale, HiScreen, MabSelect, MabSelect SuRe, PreDictor,, Sepharose, Tricorn, and Xcellerex are trademarks of General Electric Company. RoboColumn is a trademark of Atoll GmbH. Tygon is a trademark of Saint-Gobain Performance Plastics. All other third-party trademarks are the property of their respective owners General Electric Company. All goods and services are sold subject to the terms and conditions of sale of the company within GE Healthcare which supplies them. A copy of these terms and conditions is available on request. Contact your local GE Healthcare representative for the most current information. GE Healthcare UK Ltd., Amersham Place, Little Chalfont, Buckinghamshire, HP7 9NA, UK GE Healthcare Europe GmbH, Munzinger Strasse 5, D Freiburg, Germany GE Healthcare Bio-Sciences Corp., 1 Results Way, Marlborough, MA 1752, USA GE Healthcare Dharmacon Inc., 265 Crescent Dr, Lafayette, CO 826, USA HyClone Laboratories Inc., 925 W 18 S, Logan, UT 84321, USA GE Healthcare Japan Corp., Sanken Bldg., , Hyakunincho Shinjuku-ku, Tokyo , Japan For local office contact information, visit gelifesciences.com/contact AK KA DF