How to reach high plasma protein concentration with Single-Pass TFF: A case study from Baxter and

Transcription

1 How to reach high plasma protein concentration with Single-Pass TFF: A case study from Baxter and Merck Millipore Eric Youssef Asia and Europe Plasma Market Lead Merck Millipore Bioplasma World Asia 2014 Singapore July

2 Agenda 1 What is SPTFF? 2 Use of SPTFF in the Plasma industry 3 Baxter collaboration Preliminary study 4 Baxter collaboration DOE study 5 Summary 6 Acknowledgment 2

3 Agenda 1 What is SPTFF? 2 Use of SPTFF in the Plasma industry 3 Baxter collaboration Preliminary study 4 Baxter collaboration DOE study 5 Summary 6 Acknowledgment 3

4 What is Single-Pass TFF (SPTFF)? The product is sufficiently concentrated after a single pass through the filter assembly *No retentate tank return needed The product is not sufficiently concentrated after a single pass *Requires retentate return and multiple passes through filter Continuous operation Run in-line with no tank or pump Batch operation Requires skid with tank and pump

5 What is Single-Pass TFF (SPTFF)? How does SPTFF work? Increase residence time in feed channel to increase conversion Time=(L/m 2 holdup)/(lmh feed flux) Longer Feed Channel (3 sections of 1 Module) = 3x Residence Time at same flux 1/3 Feed Flux (1 section of 3 Modules) = 3X Residence Time at same channel length Conversion [permeate flow w/feed flow] 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 20g/L 1 section 20g/L 2 section 20g/L 3 section 80g/L 1 section 80g/L 2 section 80g/L 3 section 0% Residence time (sec) Slight advantage over 3 sections configuration due to higher flows and higher mass transfer

6 What is Single-Pass TFF (SPTFF)? SPTFF benefits vs. batch Simple operation Continuous at same conditions Run in-line with other steps Eliminate tanks, pumps Save time, buffers, hold-up losses Simple system (holder, retentate valve, gauges) Smaller footprint & piping Lower hardware cost Lower holdup for better recovery and no volume reduction limit Reduced pumping damage Only one pass Easy implementation with existing components

7 Agenda 1 What is SPTFF? 2 Use of SPTFF in the Plasma industry 3 Baxter collaboration Preliminary study 4 Baxter collaboration DOE study 5 Summary 6 Acknowledgment 7

8 Use of SPTFF in the Plasma industry High proteins Concentration Drivers Immunoglobulin Represents nearly half of the plasma-derived market Used for many therapeutic applications High doses required lead to subcutaneous administration Patients preferred delivery mode Save time and money Reduce the volume for administration by increasing the protein concentration High doses require high protein concentration up to 250 g/l

9 Use of SPTFF in the Plasma industry Issue with conventional TFF for high concentration Constraints Requires special UF cassettes with more coarse membrane spacing Yield might be compromised because of high hold-up volume Final volume becomes small relative to tank size and mixing might be an issue Foam formation and shearing effects due to recirculation Overconcentration might lead to UF membrane clogging Implications Installation of a dedicated UF system Need a specific design with minimal dead-volume Might need a special process step to recover proteins from membrane Install dedicated tanks or modify existing tank and mixer Adjust design of piping and pumps Need to avoid going above a certain protein concentration SPTFF can be used to overcome these challenges

10 Agenda 1 What is SPTFF? 2 Use of SPTFF in the Plasma industry 3 Baxter collaboration Preliminary study 4 Baxter collaboration DOE study 5 Summary 6 Acknowledgment 10

11 Baxter Lessines at a glance Baxter in Belgium Lessines employees Lessines site expertise: Purification of plasma immunoglobulin for the treatment of primary immune disorders Baxter is exploring Single-pass TFF with the objective to : m² Increase capacity Increase yield and achieve high product recovery Simplify installation and reduce cost of operation m² 11

12 Baxter collaboration Preliminary study SPTFF: different approaches Restrictive flow using specific UF Cassettes with a defined flow path Stacked linear flow (Merck Millipore) using conventional TFF cassettes Section 1 : 3x3 Section 2 : 3x2 Section 3 : 3x1 Section 1 : 2x3 Section 2 : 2x3 Section 3 : 2x3 Advantages Disadvantages Advantages Disadvantages Can reach higher concentration factors Restrictive flowpath Can lead to higher pressure hold-up Can reach higher protein concentrations Flow rate slows down with the stages Favorable for cleaning Needs special UF cassettes Less pressure hold-up Needs separators

13 Baxter collaboration Preliminary study Preliminary SPTFF screening Baxter had performed earlier trials with restrictive flow system Objective was to concentrate the solution from 10% to 20% in 1 step A feasibility study was performed with cellulose membranes cassette Initial studies looked promising but during DOE execution it was found that the target concentration could not be reached Moreover the system was unstable in terms of pressure Evaluation of Merck Millipore solution Feasibility study was promising Target was reached and the system was more stable Decision was made to conduct a DOE study with Merck Millipore solution

14 Agenda 1 What is SPTFF? 2 Use of SPTFF in the Plasma industry 3 Baxter collaboration Preliminary study 4 Baxter collaboration DOE study 5 Summary 6 Acknowledgment 14

15 Baxter collaboration DOE study Comparison: traditional vs. DOE development Traditional development DOE development Information about the study s points only No interaction between parameters Difficult to find the optimal setting Sometimes not possible find it at all Information about all the points in the square (cfr. Contour Plots) The optimum can be determined 15

16 Baxter collaboration DOE study Single-Pass set-up for the DOE Study Study S1 S2 S3 Using 3 x Pellicon 2 cassettes The cassettes are connected using a special flow path distributor/diverter plates The pressure is measured at the inlet and at each retentate outlet

17 Baxter collaboration DOE study Full Factorial Design with 3 levels for the following 3 factors Flow rate (pump speed) Retentate pressure Temp: cold, intermediate and room temp Followed by another Full Factorial Design with 3 levels for the following 2 factors Flow rate (pump speed) Retentate pressure Temp: higher setting With the following responses Concentration Factor Inlet Pressure Retentate Flow Total of 42 runs

18 Baxter collaboration DOE study Investigation: Millipore (MLR) Outcomes of DOE: model Summary of Fit robustness R2 Q2 Model Validity Reproducibility 1.0 R2 0.8 Q2 Model Validity Reproductibility Concentration Factor~ Inlet P Retentate Flow Rate~ Concentration Factor Inlet Pressure Retentate Flowrate N=29 Cond. no.=3.008 MODDE :35:30 (UTC+1)

19 Baxter collaboration DOE study Outcomes of DOE: model robustness Investigation: Millipore (MLR) Investigation: Millipore (MLR) Concentration Factor~ with Experiment Number labels Inlet P with Experiment Number labels Retentate Flow Rate~ with Experiment Number labels Concentration Factor~ with Experiment Number labels Inlet P with Experiment Number labels Retentate Flow Rate~ with Experiment Number labels y=0.9399*x R2= y=0.9372*x R2= y=0.9226*x R2= Deleted Studentized Residuals Deleted Studentized Residuals Deleted Studentized Residuals N-Probability N-Probability N-Probability Run Order Run Order Run Order Deleted Studentized Residuals Deleted Studentized Residuals Deleted Studentized Residuals N=29 R2=0.978 RSD= DF=24 Q2=0.968 N=29 R2=0.988 RSD= DF=23 Q2=0.982 N=29 R2=0.992 RSD= DF=24 Q2=0.988 N=29 R2=0.978 RSD= DF=24 Q2=0.968 N=29 R2=0.988 RSD= DF=23 Q2=0.982 N=29 R2=0.992 RSD= DF=24 Q2=0.988 MODDE :40:21 (UTC+1) MODDE :39:28 (UTC+1) The data show good random distribution with no time effect The residuals are small and normally distributed

20 Baxter collaboration DOE study Outcomes of DOE: model robustness Investigation: FR Millipore all DOE (MLR) Outcomes of DOE: model Normalized Coefficients robustness Temp Ret FR*FR Ret*Ret FR Ret Temp FR*FR Ret*Ret Concentration Factor~ Inlet P Retenate Flow Rate Concentration Factor Inlet Pressure Retentate Flowrate N=41 MODDE :04:48 (UTC+1)

21 Baxter collaboration DOE study Outcomes of DOE: CF & Retentate flow rate Concentration Factor Retentate Flowrate Flowrate Retentate P Flowrate Retentate P The 3D plots provide information on the process behavior and the interaction between 2 input and 1 output parameters The optimal setting is a balance between Concentration Factor and Retentate Flow Rate

22 Baxter collaboration DOE study Outcomes of DOE: conclusion Concentration Factor Inlet P Retentate Flowrate Flowrate Flowrate Flowrate Behavior of the 3D space for the 2 main process input parameters (Flow Rate and Retentate P) on the 3 output parameters (Concentration Factor, Inlet Pressure and Retentate Flow Rate) are now determined for a wide range of temperature The DOE enables to find at any temperature optimal settings and to predict outputs Next steps are: decision on the process setup, assessing cleaning, optimizing yield

23 Agenda 1 What is SPTFF? 2 Use of SPTFF in the Plasma industry 3 Baxter collaboration Preliminary study 4 Baxter collaboration DOE study 5 Summary 6 Acknowledgment 23

24 Summary Merck-Millipore s SPTFF approach Single Pass TFF is a fairly simple and easy process The linear stacked setup enables to reach the target (to concentrate a protein solution from 10% to 20%) in 1 step and appears robust and stable. Conventional UF cassettes are used to mitigate regulatory constraints of changing towards Single Pass DOE approach Quicker determination of the optimal process parameters compared to with conventional development methods Allow study of the process parameters interactions With only 42 test runs, the behavior in the 3D space gives a strong prediction model for a wide range of temperature

25 Agenda 1 What is SPTFF? 2 Use of SPTFF in the Plasma industry 3 Baxter collaboration Preliminary study 4 Baxter collaboration DOE study 5 Summary 6 Acknowledgment 25

26 Acknowledgments Baxter Christophe Carnewal, Head of Technical Services Sylvie Defrère, Process Improvement Specialist Merck Millipore Torsten Bisschop, Biomanufacturing Engineer Consultant Europe Frederic Sengler, Field Marketing Specialist TFF Europe Sarah Cummings, Global TFF Technology Consultant