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  • MDPI AG  (14)
  • Vetter, Florian Lukas  (14)
  • 1
    In: Processes, MDPI AG, Vol. 10, No. 4 ( 2022-04-07), p. 715-
    Abstract: Process chromatography modelling for process development, design, and optimization as well as process control has been under development for decades. Still, the discussion of scientific potential and industrial applications needs is open to innovation. The discussion of next-generation modelling approaches starting from Langmuirian to steric mass action and multilayer or thermodynamic consistent real and ideal adsorption theory or colloidal particle adsorption approaches is continued.
    Type of Medium: Online Resource
    ISSN: 2227-9717
    Language: English
    Publisher: MDPI AG
    Publication Date: 2022
    detail.hit.zdb_id: 2720994-5
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  • 2
    Online Resource
    Online Resource
    MDPI AG ; 2022
    In:  Processes Vol. 10, No. 5 ( 2022-04-20), p. 809-
    In: Processes, MDPI AG, Vol. 10, No. 5 ( 2022-04-20), p. 809-
    Abstract: Quality-by-Design (QbD) is demanded by regulatory authorities in biopharmaceutical production. Within the QbD frame advanced process control (APC), facilitated through process analytical technology (PAT) and digital twins (DT), plays an increasingly important role as it can help to assure to stay within the predefined proven acceptable range (PAR).This ensures high product quality, minimizes failure and is an important step towards a real-time-release testing (RTRT) that could help to accelerate time-to-market of drug substances, which is becoming even more important in light of dynamical pandemic situations. The approach is exemplified on scFv manufacturing in Escherichia coli. Simulation results from digital twins are compared to experimental data and found to be accurate and precise. Harvest is achieved by tangential flow filtration followed by product release through high pressure homogenization and subsequent clarification by tangential flow filtration. Digital twins of the membrane processes show that shear rate and transmembrane pressure are significant process parameters, which is in line with experimental data. Optimized settings were applied to 0.3 bar and a shear rate of 11,000 s−1. Productivity of chromatography steps were 5.3 g/L/d (Protein L) and 2167 g/L/d (CEX) and the final product concentration was 8 g/L. Based on digital twin results, an optimized process schedule was developed that decreased purification time to one working day, which is a factor-two reduction compared to the conventional process schedule. This work presents the basis for future studies on advanced process control and automation for biologics production in microbials in regulated industries.
    Type of Medium: Online Resource
    ISSN: 2227-9717
    Language: English
    Publisher: MDPI AG
    Publication Date: 2022
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  • 3
    Online Resource
    Online Resource
    MDPI AG ; 2023
    In:  Processes Vol. 11, No. 4 ( 2023-04-05), p. 1115-
    In: Processes, MDPI AG, Vol. 11, No. 4 ( 2023-04-05), p. 1115-
    Abstract: Due to the progressive digitalization of the industry, more and more data is available not only as digitally stored data but also as online data via standardized interfaces. This not only leads to further improvements in process modeling through more data but also opens up the possibility of linking process models with online data of the process plants. As a result, digital representations of the processes emerge, which are called Digital Twins. To further improve these Digital Twins, process models in general, and the challenging process design and development task itself, the new data availability is paired with recent advancements in the field of machine learning. This paper presents a case study of an ANN for the parameter estimation of a Steric Mass Action (SMA)-based mixed-mode chromatography model. The results are used to exemplify, discuss, and point out the effort/benefit balance of ANN. To set the results in a wider context, the results and use cases of other working groups are also considered by categorizing them and providing background information to further discuss the benefits, effort, and limitations of ANNs in the field of chromatography.
    Type of Medium: Online Resource
    ISSN: 2227-9717
    Language: English
    Publisher: MDPI AG
    Publication Date: 2023
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  • 4
    In: Processes, MDPI AG, Vol. 9, No. 11 ( 2021-10-21), p. 1874-
    Abstract: SARS-COVID-19 vaccine supply for the total worldwide population has a bottleneck in manufacturing capacity. Assessment of existing messenger ribonucleic acid (mRNA) vaccine processing shows a need for digital twins enabled by process analytical technology approaches in order to improve process transfer for manufacturing capacity multiplication, a reduction in out-of-specification batch failures, qualified personal training for faster validation and efficient operation, optimal utilization of scarce buffers and chemicals and speed-up of product release by continuous manufacturing. In this work, three manufacturing concepts for mRNA-based vaccines are evaluated: Batch, full-continuous and semi-continuous. Technical transfer from batch single-use to semi-continuous stainless-steel, i.e., plasmid deoxyribonucleic acid (pDNA) in batch and mRNA in continuous operation mode, is recommended, in order to gain: faster plant commissioning and start-up times of about 8–12 months and a rise in dose number by a factor of about 30 per year, with almost identical efforts in capital expenditures (CAPEX) and personnel resources, which are the dominant bottlenecks at the moment, at about 25% lower operating expenses (OPEX). Consumables are also reduceable by a factor of 6 as outcome of this study. Further optimization potential is seen at consequent digital twin and PAT (Process Analytical Technology) concept integration as key-enabling technologies towards autonomous operation including real-time release-testing.
    Type of Medium: Online Resource
    ISSN: 2227-9717
    Language: English
    Publisher: MDPI AG
    Publication Date: 2021
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  • 5
    Online Resource
    Online Resource
    MDPI AG ; 2022
    In:  Processes Vol. 10, No. 2 ( 2022-02-15), p. 373-
    In: Processes, MDPI AG, Vol. 10, No. 2 ( 2022-02-15), p. 373-
    Abstract: Crystallization is the main thermal process resulting in the formation of solid products and, therefore, is widely spread in all kinds of industries, from fine chemicals to foods and drugs. For these high-performance products, a quality by design (QbD) approach is applied to maintain high product purity and steady product parameters. In this QbD-context, especially demanded in the foods and drugs industry, the significance of models to deepen process understanding and moving toward automated operation is steadily rising. To reach these aspired goals, besides major process influences like crystallization temperature, other impacting parameters have to be evaluated and a model describing these influences is sought-after. In this work, the suitability of a population balance-based physico-chemical process model for the production of sugar is investigated. A model overview is given and the resulting model is compared to a statistical DoE scheme. The resulting process model is able to picture the effects of secondary process parameters, alongside temperature or temperature gradients, the influences of seed crystal size and amount, stirrer speed, and additives.
    Type of Medium: Online Resource
    ISSN: 2227-9717
    Language: English
    Publisher: MDPI AG
    Publication Date: 2022
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  • 6
    In: Processes, MDPI AG, Vol. 9, No. 3 ( 2021-03-06), p. 472-
    Abstract: This study proposes a reliable inline PAT concept for the simultaneous monitoring of different product components after chromatography. The feed for purification consisted of four main components, IgG monomer, dimer, and two lower molecular weight components of 4.4 kDa and 1 kDa molecular weight. The proposed measurement setup consists of a UV–VIS diode-array detector and a fluorescence detector. Applying this system, a R2 of 0.93 for the target component, a R2 of 0.67 for the dimer, a R2 of 0.91 for the first side component and a R2 of 0.93 for the second side component is achieved. Root mean square error for IgG monomer was 0.027 g/L, for dimer 0.0047 g/L, for side component 1 0.016 g/L and for the side component 2 0.014 g/L. The proposed measurement concept tracked component concentration reliably down to 0.05 g/L. Zero-point fluctuations were kept within a standard deviation of 0.018 g/L for samples with no IgG concentration but with side components present, allowing a reliable detection of the target component. The main reason inline concentration measurements have not been established yet, is the false-positive measurement of target components when side components are present. This problem was eliminated using the combination of fluorescence and UV–VIS data for the test system. The use of this measurement system is simulated for the test system, allowing an automatic fraction cut at 0.05 g/L. In this simulation a consistent yield of 〉 99% was achieved. Process disturbances for processed feed volume, feed purity and feed IgG concentration can be compensated with this setup. Compared to a timed process control, yield can be increased by up to 12.5%, if unexpected process disturbances occur.
    Type of Medium: Online Resource
    ISSN: 2227-9717
    Language: English
    Publisher: MDPI AG
    Publication Date: 2021
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  • 7
    In: Processes, MDPI AG, Vol. 9, No. 5 ( 2021-04-23), p. 748-
    Abstract: Supplying SARS-COVID-19 vaccines in quantities to meet global demand has a bottleneck in manufacturing capacity. Assessment of existing mRNA (messenger ribonucleic acid) vaccine processing shows the need for digital twins enabled by process analytical technology approaches to improve process transfers for manufacturing capacity multiplication, reduction of out-of-specification batch failures, qualified personnel training for faster validation and efficient operation, optimal utilization of scarce buffers and chemicals, and faster product release. A digital twin of the total pDNA (plasmid deoxyribonucleic acid) to mRNA process is proposed. In addition, a first feasibility of multisensory process analytical technology (PAT) is shown. Process performance characteristics are derived as results and evaluated regarding manufacturing technology bottlenecks. Potential improvements could be pointed out such as dilution reduction in lysis, and potential reduction of necessary chromatography steps. 1 g pDNA may lead to about 30 g mRNA. This shifts the bottleneck towards the mRNA processing step, which points out co-transcriptional capping as a preferred option to reduce the number of purification steps. Purity demands are fulfilled by a combination of mixed-mode and reversed-phase chromatography as established unit operations on a higher industrial readiness level than e.g., precipitation and ethanol-chloroform extraction. As a final step, lyophilization was chosen for stability, storage and transportation logistics. Alternative process units like UF/DF (ultra-/diafiltration) integration would allow the adjustment of final concentration and buffer composition before lipid-nano particle (LNP) formulation. The complete digital twin is proposed for further validation in manufacturing scale and utilization in process optimization and manufacturing operations. The first PAT results should be followed by detailed investigation of different batches and processing steps in order to implement this strategy for process control and reliable, efficient operation.
    Type of Medium: Online Resource
    ISSN: 2227-9717
    Language: English
    Publisher: MDPI AG
    Publication Date: 2021
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  • 8
    In: Processes, MDPI AG, Vol. 9, No. 12 ( 2021-11-25), p. 2121-
    Abstract: Preparative and process chromatography is a versatile unit operation for the capture, purification, and polishing of a broad variety of molecules, especially very similar and complex compounds such as sugars, isomers, enantiomers, diastereomers, plant extracts, and metal ions such as rare earth elements. Another steadily growing field of application is biochromatography, with a diversity of complex compounds such as peptides, proteins, mAbs, fragments, VLPs, and even mRNA vaccines. Aside from molecular diversity, separation mechanisms range from selective affinity ligands, hydrophobic interaction, ion exchange, and mixed modes. Biochromatography is utilized on a scale of a few kilograms to 100,000 tons annually at about 20 to 250 cm in column diameter. Hence, a versatile and fast tool is needed for process design as well as operation optimization and process control. Existing process modeling approaches have the obstacle of sophisticated laboratory scale experimental setups for model parameter determination and model validation. For a broader application in daily project work, the approach has to be faster and require less effort for non-chromatography experts. Through the extensive advances in the field of artificial intelligence, new methods have emerged to address this need. This paper proposes an artificial neural network-based approach which enables the identification of competitive Langmuir-isotherm parameters of arbitrary three-component mixtures on a previously specified column. This is realized by training an ANN with simulated chromatograms varying in isotherm parameters. In contrast to traditional parameter estimation techniques, the estimation time is reduced to milliseconds, and the need for expert or prior knowledge to obtain feasible estimates is reduced.
    Type of Medium: Online Resource
    ISSN: 2227-9717
    Language: English
    Publisher: MDPI AG
    Publication Date: 2021
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  • 9
    In: Processes, MDPI AG, Vol. 10, No. 4 ( 2022-04-05), p. 709-
    Abstract: Preparative chromatography is a well-established operation in chemical and biotechnology manufacturing. Chromatography achieves high separation performances, but often has to deal with the yield versus purity trade-off as the optimization criterium regarding through-put. The initial trade-off is often disturbed by the well-known phenomenon of chromatogram shifts over process lifetime, and has to be corrected by operators via adjustment of peak fraction cutting. Nevertheless, with regard to autonomous operation and batch to continuous processing modes, an advanced process control strategy is needed to identify and correct shifts from the optimal operation point automatically. Previous studies have already presented solutions for batch-to-batch variance and process control options with the aid of rigorous physico-chemical process modeling. These models can be implemented as distinct digital twins as well as statistical process operation data analyzers. In order to utilize such models for advanced process control (APC), the model parameters have to be updated with the aid of inline Process Analytical Technology (PAT) data to describe the actual operational status. This updating process also includes any operational change phenomena that occur, and its relation to their physico-chemical root cause. Typical phenomena are fluid dynamic changes due to packing breakage, channelling or compression as well as mass transfer and phase equilibrium-related separation performance decrease due to adsorbent aging or feed and buffer composition changes. In order to track these changes, an Artificial Neural Network (ANN) is trained in this work. The ANN training is in this first step, based on the simulation results of a distinct and previously experimentally validated process model. The model is implemented in the open source tool CasADi for Python. This allows the implementation of interfaces to process control systems, among others, with relatively low effort. Therefore, PAT signals can easily be incorporated for sufficient adjustment of the process model for appropriate process control. Further steps would be the implementation of optimization routines based on PAT and ANN predictions to derive optimal operation points with the model.
    Type of Medium: Online Resource
    ISSN: 2227-9717
    Language: English
    Publisher: MDPI AG
    Publication Date: 2022
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  • 10
    In: Processes, MDPI AG, Vol. 9, No. 1 ( 2021-01-18), p. 172-
    Abstract: Continuous manufacturing opens up new operation windows with improved product quality in contrast to documented lot deviations in batch or fed-batch operations. A more sophisticated process control strategy is needed to adjust operation parameters and keep product quality constant during long-term operations. In the present study, the applicability of a combination of spectroscopic methods was evaluated to enable Advanced Process Control (APC) in continuous manufacturing by Process Analytical Technology (PAT). In upstream processing (USP) and aqueous two-phase extraction (ATPE), Raman-, Fourier-transformed infrared (FTIR), fluorescence- and ultraviolet/visible- (UV/Vis) spectroscopy have been successfully applied for titer and purity prediction. Raman spectroscopy was the most versatile and robust method in USP, ATPE, and precipitation and is therefore recommended as primary PAT. In later process stages, the combination of UV/Vis and fluorescence spectroscopy was able to overcome difficulties in titer and purity prediction induced by overlapping side component spectra. Based on the developed spectroscopic predictions, dynamic control of unit operations was demonstrated in sophisticated simulation studies. A PAT development workflow for holistic process development was proposed.
    Type of Medium: Online Resource
    ISSN: 2227-9717
    Language: English
    Publisher: MDPI AG
    Publication Date: 2021
    detail.hit.zdb_id: 2720994-5
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