Integration of a perfusion reactor and continuous precipitation in an entirely membrane-based process for antibody capture.

Continuous precipitation coupled with continuous tangential flow filtration is a cost-effective alternative for the capture of recombinant antibodies from crude cell culture supernatant. The removal of surge tanks between unit operations, by the adoption of tubular reactors, maintains a continuous harvest and mass flow of product with the advantage of a narrow residence time distribution (RTD). We developed a continuous process implementing two orthogonal precipitation methods, CaCl2 precipitation for removal of host-cell DNA and polyethylene glycol (PEG) for capturing the recombinant antibody, with no influence on the glycosylation profile. Our lab-scale prototype consisting of two tubular reactors and two stages of tangential flow microfiltration was continuously operated for up to 8 days in a truly continuous fashion and without any product flow interruption, both as a stand-alone capture and as an integrated perfusion-capture. Furthermore, we explored the use of a negatively charged membrane adsorber for flow-through anion exchange as first polishing step. We obtained a product recovery of approximately 80% and constant product quality, with more than two logarithmic reduction values (LRVs) for both host-cell proteins and host-cell DNA by the combination of the precipitation-based capture and the first polishing step.

Biomimetic models of fish gill rakers as lateral displacement arrays for particle separation.

Ram suspension-feeding fish, such as herring, use gill rakers to separate small food particles from large water volumes while swimming forward with an open mouth. The fish gill raker function was tested using 3D-printed conical models and computational fluid dynamics simulations over a range of slot aspect ratios. Our hypothesis predicting the exit of particles based on mass flow rates, dividing streamlines (i.e. stagnation streamlines) at the slots between gill rakers, and particle size was supported by the results of experiments with physical models in a recirculating flume. Particle movement in suspension-feeding fish gill raker models was consistent with the physical principles of lateral displacement arrays ('bump arrays') for microfluidic and mesofluidic separation of particles by size. Although the particles were smaller than the slots between the rakers, the particles skipped over the vortical region that was generated downstream from each raker. The particles 'bumped' on anterior raker surfaces during posterior transport. Experiments in a recirculating flume demonstrate that the shortest distance between the dividing streamline and the raker surface preceding the slot predicts the maximum radius of a particle that will exit the model by passing through the slot. This theoretical maximum radius is analogous to the critical separation radius identified with reference to the stagnation streamlines in microfluidic and mesofluidic devices that use deterministic lateral displacement and sieve-based lateral displacement. These conclusions provide new perspectives and metrics for analyzing cross-flow and cross-step filtration in fish with applications to filtration engineering.

Process monitoring framework for cross-flow diafiltration-based virus-like particle disassembly: Tracing product properties and filtration performance.

Virus-like particles (VLPs) are an emerging biopharmaceutical modality with great potential as a platform technology. VLPs can be applied as gene therapy vectors and prophylactic or therapeutic vaccines. For non-enveloped VLPs, recombinant production of the protein subunits leads to intracellular self-assembly. The subsequent purification process includes VLP dis- and reassembly which aim at removing encapsulated impurities and improving particle properties. Filtration-based separation and processing has proven successful for VLPs but requires large product quantities and laborious experiments in early development stages. Both challenges can be tackled by implementation of process analytical technology (PAT) to efficiently obtain extensive process information. In this study, an existing PAT setup was extended to comprehensively monitor the diafiltration-based disassembly of hepatitis B core antigen (HBcAg) VLPs. Process-related signals were monitored in-line, while product-related signals, such as ultraviolet light (UV) spectra as well as static and dynamic light scattering (SLS and DLS), were monitored on-line. The applicability of the sensors for disassembly monitoring was evaluated under varying processing conditions. HBcAg VLP subunit concentrations were accurately predicted based on UV data using ordinary and partial least squares regression models (Q2 from 0.909 to 0.976). DLS data were used for aggregation monitoring while the SLS intensity qualitatively reflected the disassembly progress.

Geometrical Influence on Particle Transport in Cross-Flow Ultrafiltration: Cylindrical and Flat Sheet Membranes.

Cross-flow membrane ultrafiltration (UF) is used for the enrichment and purification of small colloidal particles and proteins. We explore the influence of different membrane geometries on the particle transport in, and the efficiency of, inside-out cross-flow UF. For this purpose, we generalize the accurate and numerically efficient modified boundary layer approximation (mBLA) method, developed in recent work by us for a hollow cylindrical membrane, to parallel flat sheet geometries with one or two solvent-permeable membrane sheets. Considering a reference dispersion of Brownian hard spheres where accurate expressions for its transport properties are available, the generalized mBLA method is used to analyze how particle transport and global UF process indicators are affected by varying operating parameters and the membrane geometry. We show that global process indicators including the mean permeate flux, the solvent recovery indicator, and the concentration factor are strongly dependent on the membrane geometry. A key finding is that irrespective of the many input parameters characterizing an UF experiment and its membrane geometry, the process indicators are determined by three independent dimensionless variables only. This finding can be very useful in the design, optimization, and scale-up of UF processes.

Process development for cross-flow diafiltration-based VLP disassembly: A novel high-throughput screening approach.

Virus-like particles (VLPs) are particulate structures, which are applied as vaccines or delivery vehicles. VLPs assemble from subunits, named capsomeres, composed of recombinantly expressed viral structural proteins. During downstream processing, in vivo-assembled VLPs are typically dis- and reassembled to remove encapsulated impurities and to improve particle morphology. Disassembly is achieved in a high-pH solution and by the addition of a denaturant or reducing agent. The optimal disassembly conditions depend on the VLP amino acid sequence and structure, thus requiring material-consuming disassembly experiments. To this end, we developed a low-volume and high-resolution disassembly screening that provides time-resolved insight into the VLP disassembly progress. In this study, two variants of C-terminally truncated hepatitis B core antigen were investigated showing different disassembly behaviors. For both VLPs, the best capsomere yield was achieved at moderately high urea concentration and pH. Nonetheless, their disassembly behaviors differed particularly with respect to disassembly rate and aggregation. Based on the high-throughput screening results, a diafiltration-based disassembly process step was developed. Compared with mixing-based disassembly, it resulted in higher yields of up to 0.84 and allowed for integrated purification. This process step was embedded in a filtration-based process sequence of disassembly, capsomere separation, and reassembly, considerably reducing high-molecular-weight species.

Cross-flow microfiltration for isolation, selective capture and release of liposarcoma extracellular vesicles.

We present a resource-efficient approach to fabricate and operate a micro-nanofluidic device that uses cross-flow filtration to isolate and capture liposarcoma derived extracellular vesicles (EVs). The isolated extracellular vesicles were captured using EV-specific protein markers to obtain vesicle enriched media, which was then eluted for further analysis. Therefore, the micro-nanofluidic device integrates the unit operations of size-based separation with CD63 antibody immunoaffinity-based capture of extracellular vesicles in the same device to evaluate EV-cargo content for liposarcoma. The eluted media collected showed ∼76% extracellular vesicle recovery from the liposarcoma cell conditioned media and ∼32% extracellular vesicle recovery from dedifferentiated liposarcoma patient serum when compared against state-of-art extracellular vesicle isolation and subsequent quantification by ultracentrifugation. The results reported here also show a five-fold increase in amount of critical liposarcoma-relevant extracellular vesicle cargo obtained in 30 min presenting a significant advance over existing state-of-art.

Automated tangential-flow diafiltration device.

Tangential flow filtration (TFF) is a chemical unit operation used to purify and concentrate liquid suspensions of colloids, proteins, or cells. The solution flows tangentially across a membrane, such that a selective part of the fluid permeates the membrane while the filtrated matter is retained, increasing its concentration. TFF is a mild mechanical purification method that does not interact chemically with the filtrate. It is applied in sensitive separation tasks in protein chemistry, microbiology, or immunology. It is a fast alternative for dialysis applications, also applicable in the field of colloid purification. However, the costs of automated lab-scale devices (30,000 €) and the consumable membrane modules (100-600 €) make TFF currently hardly accessible for lab-scale polymer researchers. Therefore, we built a low-cost TFF system (2400 €) partly automated by an Arduino microcontroller and optimized for diafiltration buffer exchange and concentration processes in soft matter colloid research. We use medical hemodialysis membrane modules that only cost a share (20-50 €) of alternative TFF modules, and we demonstrate the functionality of the system for an exemplary colloidal microgel purification process.

Harvesting microalgal biomass using negatively charged polysulfone patterned membranes: Influence of pattern shapes and mechanism of fouling mitigation.

Membranes have a lot of potential for harvesting microalgae, but membrane fouling is hampering their breakthrough. In this study, the effects of charge and corrugated surface on membrane filtration performance were investigated. The clean water permeance (CWP), the microalgae harvesting efficiency and the membrane flux for a microalgal broth were determined using patterned polysulfone (PSf) membranes with different shapes of the surface patterns and containing different charge densities by blending sulfonated polysulfone (sPSf). The flow behavior near the patterned membrane surface, as well as the interaction energy between membrane and microalgae were investigated using computational fluid dynamics (CFD) simulation and the improved extended "Derjaguin, Landau, Verwey, Overbeek" (XDLVO) theory, respectively. Membrane charge and pattern shape significantly improve the membrane performance. The critical pressures of all sPSf blend patterned membranes were higher than 2.5 bar. A 4.5w% sPSf blend patterned membranes with wave patterns showed the highest CWP (2300 L/m2 h bar) and membrane flux in the microalgal broth (1000 L/m2 h bar) with 100% harvesting efficiency. XDLVO analysis showed that sPSf blend patterned membranes prepared obtained the lowest interaction energy and highest energy barrier for microalgal attachment. CFD simulation showed a higher velocity and wall shear on the pattern apexes.

Integrated Process for Capture and Purification of Virus-Like Particles: Enhancing Process Performance by Cross-Flow Filtration.

Virus-like particles (VLPs) are emerging nanoscale protein assemblies applied as prophylactic vaccines and in development as therapeutic vaccines or cargo delivery systems. Downstream processing (DSP) of VLPs comes both with challenges and opportunities, depending on the complexity and size of the structures. Filtration, precipitation/re-dissolution and size-exclusion chromatography (SEC) are potent technologies exploiting the size difference between product and impurities. In this study, we therefore investigated the integration of these technologies within a single unit operation, resulting in three different processes, one of which integrates all three technologies. VLPs, contained in clarified lysate from Escherichia coli, were precipitated by ammonium sulfate, washed, and re-dissolved in a commercial cross-flow filtration (CFF) unit. Processes were analyzed for yield, purity, as well as productivity and were found to be largely superior to a reference centrifugation process. Productivity was increased 2.6-fold by transfer of the wash and re-dissolution process to the CFF unit. Installation of a multimodal SEC column in the permeate line increased purity to 96% while maintaining a high productivity and high yield of 86%. In addition to these advantages, CFF-based capture and purification allows for scalable and disposable DSP. In summary, the developed set-up resulted in high yields and purities, bearing the potential to be applied as an integrated process step for capture and purification of in vivo-assembled VLPs and other protein nanoparticles.

ß-Cyclodextrin Polymerized in Cross-Flowing Channels of Biomass Sawdust for Rapid and Highly Efficient Pharmaceutical Pollutants Removal from Water.

Water pollution arising from pharmaceuticals has raised great concerns about the potential risks for biosphere and human health. However, rapid and efficient removal of pharmaceutical contaminants from water remains challenging. Wood sawdust, a byproduct of the wood-processing industry, is an abundant, cost-effective, and sustainable material with a unique hierarchically porous microstructure. These features make wood sawdust quite interesting as a filtration material. Here, we report a novel cross-flow filtration composite based on ß-cyclodextrin-polymer-functionalized wood sawdust (ß-CD/WS) in which the pharmaceutical contaminant water flows through the sawn-off vessel channels and the micropores on the surface of the cell walls, generating the turbulence. Such water flow characteristics ensure full contact between pharmaceutical pollutants and ß-CD grafted on the cellulose backbone of wood sawdust, thereby enhancing the water treatment efficiency. Consequently, the ß-CD/WS filter device shows a high removal efficiency of over 97.5% within 90 s for various pharmaceutical contaminants including propranolol, amitriptyline, chlortetracycline, diclofenac, and levofloxacin, and a high saturation uptake capacity of 170, 156, 257, 159, and 185 mg g-1, respectively. The high-performance wood-sawdust-based cross-flow filtration opens new avenues for solving the global water pollution issues, especially those caused by pharmaceutical contaminants.

Continuous Cell Separation Using Microfluidic-Based Cell Retention Device with Alternative Boosted Flow.

The development of a continuous process for cell separation is growing rapidly due to the current trend of cost-effective manufacturing in biological industries. The continuous cell separation process has a significant reduction in capital equipment costs and facility size compared to the conventional batch process. In the study, a multi-layered microfluidic-based device integrated with the porous membranes was fabricated for continuous size-based isolation of the cells based on the mechanism of restrictive cross-flow filtration, allowing the biological sample entered in a single inlet of the device and separated into two outlet streams. One stream which contained the cells returned back to the original sample fluid, while another stream with conditioned medium only was collected for later applications. The membrane fouling issue was overcome by introducing the alternative flow rate consisted of a set of higher and lower flows. The device integrated with the controllable flow restriction allows to increase the permeate flow rate, and alternative boosted flow demonstrates the high permeate flow rate (0.3 mL/min), high cell viability (> 98%), and increase of cell concentration (48%). As a result, we believe that the microfluidic-based continuous cell separation system is a promising tool for downstream bioprocess.

Tangential Flow Microfiltration for Viral Separation and Concentration.

Microfluidic devices that allow biological particle separation and concentration have found wide applications in medical diagnosis. Here we present a viral separation polydimethylsiloxane (PDMS) device that combines tangential flow microfiltration and affinity capture to enrich HIV virus in a single flow-through fashion. The set-up contains a filtration device and a tandem resistance channel. The filtration device consists of two parallel flow channels separated by a polycarbonate nanoporous membrane. The resistance channel, with dimensions design-guided by COMSOL simulation, controls flow permeation through the membrane in the filtration device. A flow-dependent viral capture efficiency is observed, which likely reflects the interplay of several processes, including specific binding of target virus, physical deposition of non-specific particles, and membrane cleaning by shear flow. At the optimal flow rate, nearly 100% of viral particles in the permeate are captured on the membrane with various input viral concentrations. With its easy operation and consistent performance, this microfluidic device provides a potential solution for HIV sample preparation in resource-limited settings.

Simple Theoretical Results on Reversible Fouling in Cross-Flow Membrane Filtration.

In cross-flow membrane filtration, fouling results from material deposit which clogs the membrane inner surface. This hinders filtration, which experiences the so-called limiting flux. Among the models proposed by the literature, we retain a simple one: a steady-state reversible fouling is modelled with the use of a single additional parameter, i.e., N d , the ratio of the critical concentration for deposition to the feed concentration at inlet. To focus on fouling, viscous pressure drop and osmotic (counter-)pressure have been chosen low. It results in a minimal model of fouling. Solved thoroughly with the numerical means appropriate to enforce the nonlinear coupling between permeation and concentration polarization, the model delivers novel information. It first shows that permeation is utterly governed by solute transfer, the relevant non-dimensional quantities being hence limited to N d and P e i n , the transverse Péclet number. Furthermore, when the role played by N d and moderate P e i n (say P e i n < 40 ) is investigated, all results can be interpreted with the use of a single non-dimensional parameter, F l , the so-called fouling number, which simply reads F l ≡ P e i n N d - 1 . Now rendered possible, the overall fit of the numerical data allows us to put forward analytical final expressions, which involve all the physical parameters and allow us to retrieve the experimental trends.

Process monitoring of virus-like particle reassembly by diafiltration with UV/Vis spectroscopy and light scattering.

Virus-like particles (VLPs) have shown great potential as biopharmaceuticals in the market and in clinics. Nonenveloped, in vivo assembled VLPs are typically disassembled and reassembled in vitro to improve particle stability, homogeneity, and immunogenicity. At the industrial scale, cross-flow filtration (CFF) is the method of choice for performing reassembly by diafiltration. Here, we developed an experimental CFF setup with an on-line measurement loop for the implementation of process analytical technology (PAT). The measurement loop included an ultraviolet and visible (UV/Vis) spectrometer as well as a light scattering photometer. These sensors allowed for monitoring protein concentration, protein tertiary structure, and protein quaternary structure. The experimental setup was tested with three Hepatitis B core Antigen (HBcAg) variants. With each variant, three reassembly processes were performed at different transmembrane pressures (TMPs). While light scattering provided information on the assembly progress, UV/Vis allowed for monitoring the protein concentration and the rate of VLP assembly based on the microenvironment of Tyrosine-132. VLP formation was verified by off-line dynamic light scattering (DLS) and transmission electron microscopy (TEM). Furthermore, the experimental results provided evidence of aggregate-related assembly inhibition and showed that off-line size-exclusion chromatography does not provide a complete picture of the particle content. Finally, a Partial-Least Squares (PLS) model was calibrated to predict VLP concentrations in the process solution. Q2 values of 0.947-0.984 were reached for the three HBcAg variants. In summary, the proposed experimental setup provides a powerful platform for developing and monitoring VLP reassembly steps by CFF.

Digestion performance and contributions of organic and inorganic fouling in an anaerobic membrane bioreactor treating waste activated sludge.

This study evaluates the performance of an anaerobic membrane bioreactor (AnMBR) digesting waste activated sludge. A digestion reactor equipped with an external hollow fiber microfiltration membrane module was operated in continuous-mode for 248 days. The system demonstrated 56% volatile solids degradation at an organic loading rate of 0.40 g-VS/(L·d) in 15 days of hydraulic retention time. The average methane content in the biogas produced was 76% which is considerably high compared to that from a typical continuously stirred tank reactor. The transmembrane pressure remained under 12 kPa without membrane cleaning during the experimental period due to low filtration flux (0.01-0.07 m/d) and cross-flow-mode filtration. Ex situ membrane cleaning revealed that physically irreversible fouling was the dominant form of membrane fouling. Inorganic and organic fouling accounted for 16% and 45% of total membrane fouling, respectively.

A Passive Microfluidic Device Based on Crossflow Filtration for Cell Separation Measurements: A Spectrophotometric Characterization.

Microfluidic devices have been widely used as a valuable research tool for diagnostic applications. Particularly, they have been related to the successful detection of different diseases and conditions by assessing the mechanical properties of red blood cells (RBCs). Detecting deformability changes in the cells and being able to separate those cells may be a key factor in assuring the success of detection of some blood diseases with diagnostic devices. To detect and separate the chemically modified RBCs (mimicking disease-infected RBCs) from healthy RBCs, the present work proposes a microfluidic device comprising a sequence of pillars with different gaps and nine different outlets used to evaluate the efficiency of the device by measuring the optical absorption of the collected samples. This latter measurement technique was tested to distinguish between healthy RBCs and RBCs chemically modified with glutaraldehyde. The present study indicates that it was possible to detect a slight differences between the samples using an optical absorption spectrophotometric setup. Hence, the proposed microfluidic device has the potential to perform in one single step a partial passive separation of RBCs based on their deformability.

Optimized upstream and downstream process conditions for the improved production of recombinant human asparaginase (rhASP) from Escherichia coli and its characterization.

The present work elucidates the production of recombinant human asparaginase (rhASP) under optimized fermentation and downstream processes in Escherichia coli. The maximum biomass yield of 6.7 g/L was achieved with fed-batch fermentation. The highest rhASP inclusion bodies recovery yield (91%) was achieved with the optimized lysis conditions. The 8.0 M urea at pH 8.5 has shown efficient solubilization (94%) of rhASP inclusion bodies. The refolding efficiency of rhASP increased at pH 8.5 (84%) and temperature 25°C (86%). The diluted rhASP solution was concentrated and partially purified (92%) using cross flow filtration. A single step ion exchange chromatography is successfully achieved the maximum purity of ≥ 97%. The molecular mass of purified rhASP is confirmed as 34.1 kDa by mass spectrometry. The secondary structure of rhASP is characterized by FT-IR spectroscopy based on the structural elements. Finally, cell proliferative assay of purified rhASP is signifies the similar biological activity over the standard.

Graphene Oxide (GO)-Blended Polysulfone (PSf) Ultrafiltration Membranes for Lead Ion Rejection.

Graphene oxide (GO) has been widely reported and used for treatment of heavy metals from different waste streams. Although their use as additives for membranes has greatly enhanced membrane properties, there is still a bottleneck in obtaining membranes with high heavy-metal rejection efficiencies while maintaining high flux, mechanical strength, and porosity. In the present study, different compositions of GO (0⁻1 wt %)-blended membranes were prepared using 1-methyl-2-pyrrolidone (NMP) as solvent and water with 5% ethanol as non-solvent, and studied for the rejection of the chosen model heavy-metal lead. The prepared membranes were characterized for hydrophilicity, membrane porosity, flux, permeability, pore-size, mechanical strength, and membrane morphology. From the results, it was inferred that membranes having maximum GO in their blend (1 wt %) showed better hydrophilicity (water contact angle 34.2°), porosity (82.2%), permeability (52.1 L/m² h bar), and pure water flux (163.71 L/m² h) at 3-bar pressure as opposed to other compositions. The pore sizes of the membranes ranged between 18 to 24 nm. Tensile strength tests showed the role of GO as a positive reinforcement on the mechanical properties of membranes through Young's modulus (188.13 ± 15.36 MPa) for the membrane having 0.25 wt % GO composition. Environmental Scanning Electron Microscopy (ESEM) images displayed the dense top layer supported by a porous, finger-like structure, obtained from instantaneous de-mixing favored by NMP and GO. The observed reduction in flux of lead solution for GO-blended membranes was due to osmotic pressure build-up caused by the retained nitrate salt by GO on the retentate side of the membrane. A maximum rejection of 98% was achieved with 1 wt % GO membrane at 1-bar pressure with flux of 43.62 L/m² h, which decreased to 94% at 3-bar pressure with flux of 142.95 L/m² h. These results showed how the application of NMP as solvent and GO as an additive could facilitate in obtaining high-flux and high-rejection membranes.

Assessment of cross-flow filtration as microalgae harvesting technique prior to anaerobic digestion: Evaluation of biomass integrity and energy demand.

In the present study, the effect of cross-flow filtration (CFF) on the overall valorization of Chlorella spp. microalgae as biogas was assessed. The effect of CFF on microalgae cell integrity was quantified in terms of viability which was correlated with the anaerobic biodegradability. The viability dropped as the biomass concentration increased, whereas anaerobic biodegradability increased linearly with the viability reduction. It was hypothesized that a stress-induced release and further accumulation of organic polymers during CFF increased the flux resistance which promoted harsher shear-stress conditions. Furthermore, the volume reduction as the concentration increased entailed an increase in the specific energy supply to the biomass. The energy demand was positive in the whole range of concentrations studied, yielding an overall energy efficiency as high as 22.9% for the highest concentration studied. Specifically, heat requirements were lower than electricity requirements only when the biomass concentrations exceeded 10 g COD·L-1.

Filtration and removal performances of membrane adsorbers.

Membrane adsorbers are promising candidates for the efficient and effective removal of heavy metals in waste water due to their unattainable adsorption and filtration capabilities. In the present study, zeolite nanoparticles incorporated polysulfone (PSf10) membrane was synthesized by means of non-solvent induced phase separation technique for the removal of lead and nickel ions in water. PSf10 showed a remarkable sorption capability and after repeated (adsorption/desorption)5 cycles in batch experiments, it preserved 77% and 92% of its initial sorption capacity for the lead and nickel, respectively. Addition of nanoparticles increased the pore radius of the native PSf from 10 to 19nm, while bovine serum albumin rejection remained unchanged at 98%. Increments in the pore size and enhancement in hydrophilicity caused to increase hydraulic permeability of the native PSf from 23 to 57L/m2hbar. Cross-flow filtration studies revealed that the filtrate concentrations were inversely affected by the initial metal concentration and transmembrane pressure due to reaction limited region. Nonlinear rational regression model perfectly described the filtration behavior of the PSf10 within the experimental range and suggested that lower initial metal concentration and pressure with a short filtration time should be selected for the target response to be minimum.