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HexaScreen®
Biotechnological Screening in Animal Cell Culture
            Equipment to reduce required time &
              costs for bioprocess development




                                          EXPOQUIMIA 2011




                                                  www.telstar-lifesciences.com
The Team




                                 •Cell Culture
     •Manufacturing
                                 •Bioreactors
     •Marketing & Sales
                             +   • Measurement Systems
     •Internationalization
                  +                    +
                                 •Biocompatible materials




                                                            www.telstar-lifesciences.com
Increasing importance of animal cell culture.




                                           www.telstar-lifesciences.com
Animal Cell Culture Bioprocesses


The potential of animal cell culture arises from the capability of this type of
cells to carry out complex post-translational modifications providing proteins
with the required biological activity to be used for therapeutical and
diagnostic applications

CHO (Chineese Hamster Ovary)
NSO (mouse mieloma)
BHK (Baby Hamster Kidney)
HEK (Human Embryo Kidney)
PER.C6 (Human Retinal Cells)
MDCK (Madin Darby Canine Kidney)

Sf9 (insect cells, Spodoptera frugiperda)



                                                                www.telstar-lifesciences.com
Bioprocess Development: Animal Cell Culture
”The optimization of the bioprocess is specially important for animal cell culture”

    – Less Cellular Concentration than Bacterium and Yeast:
        • Bacterium and Yeast cultures: [X]f ≈ 109 cells/ml
        • Animal cell cultures: [X]f ≈ 106 cells/ml
                      If Ps=ct, we have 1000 times more product
                     with bacterium or yeast than with animal cells

    – More expensive & complex process:
       • Culture media:
            – Bacterium and Yeast cell culture: Simple undefined mediums
              containing only salts (usually NaCl) and carbon & nitrogen sources
              (usually within yeast extract and tryptone).
            – Animal cell culture: Rich & complex mediums containing salts,
              carbon & nitrogen sources, but also complements (AA, vitamins,
              trace elements…) and serums (FCB, FBS…).
       • Easier to be contaminated:
            – Bacteria, yeast, mycoplasma or cross contamination.

    – Specific challenges for animal cell culture: slow growth and specific
      production rates, cell sensitivity (shear stress, nutrient limitation,
      metabolite accumulation..).                             www.telstar-lifesciences.com
Bioprocess Development: Main Steps

       Genetic Engineering              Culture Conditions      Operational Conditions




          Best Clones:                       Best Conditions:       Optimal Process:
          Specific Productivity              [X]                    [X]
                                             Growth rate            Death times

                                                                         www.hexascreen.com
from F. Wurm. Nat. Biotechnol., vol. 22:1393-1398 (2004)
Multiple aspects need to be optimized to establish optimal
           and profitable production processes
                              Purification
                                process
         Culture                                      Fisico-chemical
         medium                                         parameters
                               PROCESS
          Clonal             OPTIMIZATION               Operation
         selection                                       strategy
           Cell                                           Process
           line                 Scale-up                  control
                                 GMP
                               production


High cell concentration, high specific productivity, maintain product quality
                                                                www.telstar-lifesciences.com
Bioprocess Development: Phases
         •   PHASE I: Initial screening                                     IMPORTANT!!!
             1. Cell line selection (bacterium, yeast, animal cell…)
             2. Cell modification (genetic engineering)                       Check the
 7/8         3. Clonal activity selection                                   activity of the
clones
                  Select which cells are producing the protein target        protein in all
             4. Protein target characterization:
                                                                                 phases
                  Measurement of the protein activity
         •   PHASE II: Advanced screening
             1.   Clonal growth selection (select which cells grow faster…)
 1/2         2.   Culture medium composition: serum, glutamine, glucose…
clones
             3.   Initial cell concentration.
             4.   Effects of stirring, [O2] and other culture conditions
             5.   Needs of the cell culture adaptation (ex: from adherent to suspension)
         •   PHASE III: Lab scale production
             1. Scale-up the advanced screening optimum conditions
             2. Purification process
             3. Type of Bioreactor (Batch, Fed-Batch, Perfusion)
         •   PHASE IV: Pilot Plant and Industrial scale production
             1. Scale-up the lab scale optimum production conditions

                                                                            www.telstar-lifesciences.com
Screening                      Bioreactors: Differences
             – Reproducibility problems when scaling up from usual
               screening phases into lab or pilot & production plant
               scales due to:
                  • Homogeneity: Non agitated systems can produce cells or nutrient
Reproducibility
                    accumulations giving not representative and impossible to repeat
  problems          experiments.
                  • [O2] limitations: Can produce a decrease of the cell culture growth
                    velocity, metabolic differences or stopping the cellular cycle leading to an
                    unreal productivity determination (higher or lower).
             – Lack of probes: few knowledge of the main cellular
               growth parameters : cell concentration, pH & pO2.

             – Lack of automatization: human manipulation is highly
               needed.

             – Current screening agitated systems (spinner flasks)
Cost and time characteristics  include  high  volumes  and   post-
   issues      experiment treatments.
                                                                           www.telstar-lifesciences.com
Screening : The HexaScreen Alternative
            Initial Screening         Advanced Screening              Lab Scale



 New automated & controlled
 screening platform




                                                                      Bioreactors




      Usual scale-up procedure                    Spinner flask

         Multiwell plates             T-flask

0,1                         1    10                  100                1000+
                                            Vessel volume (ml)    www.hexascreen.com
Bioprocess Development: Phases
       Bioprocess development for a biotechnology product
                     requires a number of steps
           Scale-up Methodology: Laboratory to Pilot to
                             Industrial
        Initial                            HEXABATCH
      Screening




             Advanced
             Screening            Lab scale
Since Biotechnological Processes are not
completely known, the transition from bench to   Pilot Plant Production Plant
final volume is done step by step.                            www.telstar-lifesciences.com
Screening: HexaBatch®Design Criteria
 – Simultaneous multiple experiment capability.
 – Low minibioreactor volumes (10-15 mL), but not too low
   to allow cell culture similarities with lab scale
   bioreactors.
 – Agitation requirement to allow system homogeneity, but
   without upsetting cell viability.
 – Parts in contact with cells must be manufactured with
   single use biocompatible plastic (no contamination,…).
 – Cell growth (optical density), pH and dissolved oxygen
   monitoring via non invasive probes.




                                                  www.hexascreen.com
HexaScreen®: HexaBatch Features
                   Initial/Advanced                                         Pilot Plant
                                                      HexaBatch
                       Screening                                            / Industry
                                        Stirred & O2 fed Culture            Stirred Culture
Equipment used & Stationary Culture
                                        System to allow                     Systems:
environment      Systems: Heterogeneous
                                        homogeneity                         Homogeneous
                                                 Multiple experiments run
                                                 simultaneously to
                                                                            Unique cell
Methodology       Multiple experiments           decrease the time
                                                                            culture process
                                                 required for the
                                                 screening phase
                                                                            From 2 to
                                                 10-15 ml (bench top
Vessel size       Micro liters and milliliters                              thousands of
                                                 scale)
                                                                            liters
                                                 pH, pO2 and OD (cell
                  Discontinuous and                                         Continuous
Process control                                  concentration) on-line
                  manual                                                    and monitored
                                                 monitoring
                                                 Disposable bioreactor
                                                 made of sterile
Asepsis           Difficult / uncontrolled                                  Necessary
                                                 biocompatible plastic
                                                 material
                                                                             www.telstar-lifesciences.com
HexaScreen®: HexaBatch Elements
HexaBatch version consists in two differentiated parts,
the 6-minibioreactors’ plate and the workstation with a
computer/software .
– Single use Minibioreactors’ Plate. Previously sterilized
  inside a plastic bag, includes 6 individual vessels equipped
  with gas filters, one septum for inoculation, miniaturized
  ports for probe’s allocation and a magnetic actuator for
  stirring.




– Workstation.        Contains    the    chamber   where     the
  minibioreactors’s plate remains during its culture, while
  maintaining optimal agitation & temperature (common),
  sterility, providing individual aeration and acquiring pH, DO
  and OD data. WorkStation is controlled via software.



                                                                   www.telstar-lifesciences.com
HexaBatch: Minibioreactor plate characteristics
1-. Optical port for OD and pH measurements.         2
                                                                  3       4
                                          1
2-. Gas filters (inlet and outlet).

3-. Optical port for DO measurements via
   fluorescence.

4-. Septum for cell inoculation.

5-. Low shear magnetic pendular
   agitation (optimal for animal cell).

6-. Thermostated general bath.
                                          8
7-. Vessel liquid volume: 10-15 ml.

8-. Biocompatible and disposable plastic,        7       6    5
   sterile provided. Possible plasma treatment
   to   promote    cell   adherence    / non-
   adherence.
                                                             www.telstar-lifesciences.com
HexaBatch: Minibioreactors Inoculation




                                   www.hexascreen.com
HexaBatch: Minibioreactors to Workstation




                                     www.hexascreen.com
HexaBatch: Variables, Controls & Monitoring

  Variable             Control            Monitoring          Information

Aeration          Time Controlled        No              No

Agitation         Set-point controlled   No              No

Vessel
                  Set-point controlled   Monitored       System functionality
Temperature
Gas & Filters                                            Filters functionality –
                  Set-point controlled   Monitored
Temperature                                              Avoids evaporation
                                         Monitored and   Cell density information,
Optical Density   Free evolution
                                         correlated      related to total cells
Dissolved         Free evolution                         Oxygen concentration,
                                         Monitored
Oxygen            (constant aeration)                    related to alive cells
                                                         Cell activity information,
pH                Free evolution         Monitored
                                                         related to alive cells



                                                                     www.telstar-lifesciences.com
HexaBatch: Software Specifications
    HexaScreen®’s control & acquisition program runs on a Windows
    platform and will guide the user, as a wizard, through the processes of
    workstation’s configuration, calibration and data acquisition.


General specifications

•   Automatic processes:
     –   Workstation’s configuration
     –   Thermal stabilization
     –   Oxygen calibration
     –   Optical calibration
     –   Data acquisition (minibioreactors’ behaviour monitoring graphs)

•   Additional tasks:
     – Create new or edit already existing experiment set-ups
     –   Create user defined graphs
     –   Create reports
     –   Export reports to EXCEL, PDF and HTML files


                                                                           www.hexascreen.com
HexaBatch: Advantages & Benefits
         Features                                Advantages                                      Benefits
                                   - Stirring, gas exchange and oxygen supply are    - Focused.
Specially designed for animal cell
                                   specially designed for handling animal cell       - Suitable for both suspension and
culture.
                                   culture.                                          adherent cultures.
                                   - Reducing working volume means less
Benchtop Scale:
                                   development costs in medium, cell culture,        - Lower operation cost.
Small Volumes from 10 to 15 ml”.
                                   enzymes…
Parallel bioreactor system:        - Less time required to achieve final results     - Faster time to market.
“6 multiple parallel experiments   - Reproducible results: statistic data can be     - Save time.
for device”.                       obtained from replicated experiments.             - Faster product development cycles.
                                                                                     - Precision & control over all
                                   - Real-time kinetic information:
                                                                                     experimentation.
Automated on-line                    cell concentration (OD), DO & pH.
                                                                                     - Lower labour and time-consuming in
measurements.                      - No off-line control processes required.
                                                                                     order to invest in other valuable
                                   - No maintenance required during experiment.
                                                                                     tasks.
                                   - No post-experiments treatments.                 - Save money & time.
Single use.
                                   - Avoid possible cross-contaminations.            - Easier experiment validations.

Easy to use.                       - No expert personal required.                    - Less effort required.

Convenient.                        - Easier scale up to lab-size reactors.           - Optimized culture parameters.
                                   - Save automatically the data acquired from all - Control on all acquisition
PC controlled.                     the experiments done giving a comprehensive       experiment data.
                                   documentation.                                  - Possibility to do final reports easier.



                                                                                                         www.hexascreen.com
HexaBatch: Applications & Cell Lines Cultured


   Applications                            Examples                           Cell Lines Cultured

                             - Adherence and suspension lines.           Suspension:
Cellular screening.
                             - Clone selection.
                                                                         - Hybridoma.
                             - Growth parameters measurements (cell
Cellular characterization.                                               - Genetically modified hybridoma.
                             density and cell activity).
                                                                         - CHO cells (adapted).
Cellular adaptation.         - Adherent to suspension.                   - HEK (adapted)
                                                                         Adherent:
Medium definition and        - Commercial medium comparison.
optimization.                - Medium’s components definition.           - Vero cells.

                             - New drugs tests.                          - Ovine Mesenchymal Stem Cells.
Cellular tests.              - Toxicity tests.
                             - Apoptosis tests.                          - CHO.
                                                                         - HEK.
                             - Initial cellular concentration, culture
Process optimization.
                             conditions…




                                                                                                  www.hexascreen.com
Advantages of single-use technology

   Fast setup.
   No need for Cleaning.
   No risk of cross-contamination.
   Minimizes utility requirements.
   Minimizes validation.
   Minimizes space floor.
   Minimizes labor.
   Minimizes engineering design.
   Reduces COGS.
   Minimizes maintenance.
   Environmentally friendly:
             Use for generate electrical power by incineration.
             Estimated savings in WFI at over 80%.
             Estimated 72% saving in electricity compared to conventional
              manufacturing facility.




                                                                    www.hexascreen.com
Advantages of single-use technology




                                      www.hexascreen.com
Systems comparison for screening

•   Systems to evaluate:
    •   HexaBatch                               On-line measurements
    •   1L glass Bioreactor

    •   T-flasks for suspension cell cultures
                                                Off-line measurements
    •   T-flasks for adherent cell cultures




                                                      www.telstar-lifesciences.com
HexaBatch Case Study: Conditions
•   Case Study parameters:

     •   Number of conditions: 2

     •   Number of repetitions: 3

     •   Total number of cultures: 6

     •   Batch culture time: 3 days

     •   Cell line: CHO

     •   Culture media price (CDCHO): 103,52 €/L

     •   Qualified personnel costs: 30 €/hour

•   It is assumed that there is only a one-liter bioreactor, so steps of the
    experiment are performed sequentially.

•   For off-line measurements (T-Flasks), only one sample is taken each
    day, with a total of 3 cell concentration measurements during culture.
    (no metabolites concentration measured)



                                                                  www.hexascreen.com
HexaBatch Case Study: Time Analysis
                                Fins a                                                                                                   Fin
                                5040
                                699                               Total personnel cost (€)
                                                                  Inoculum Scale-up time                                                 19
                                totals                            Bioreactor set-up time operation cost (€)
                                                                                                                                         tot
                           45                      43 days        Total sterilization, CIP, calibration, post-exp. cleaning)
                                                                  (Set-up,
                                                                           bioreactor
                           40                                     Total time
                                                                  Culture culture medium cost (€)
Experimental time (days)




                           35
                                                       18


                           30


                           25                                     36 days

                           20

                                                       18
                           15


                           10

                                                                                                5 days
                           5         4 days                             4 days
                                                       7                                            3
                                         3                                  3
                                         1                                  1                       2
                           0
                                    1 HexaBatch   1L Bioreactor          T-flasks        T-flasks (adherent cell)
                                                                                                                    www.hexascreen.com
HexaBatch Case Study: Costs Analysis
                                                                                                                    Fins a
                                                                                                              Fins a a
                                                                                                               Fins5040
                                                                                                              5040  699                       Total personnel cost (€)
                                                                                                                                                                                        Fins a
                                                                                                                                                                                  Fins a a
                                                                                                                                                                                   Fins1960
                                                                                                                                                                                  1960
                                                                                                              699 totals
                                                                                                                5040
                                                                                                               699                        Total personnel cost (€)
                                                                                                                                           Total personnel cost (€)                 1960totals
                                                                                                              totals                          Total bioreactor operation cost (€) totals
                                                      Fins a                                                    totals                    Total bioreactor operation cost (€)
                                                                                                                                           Total bioreactor operation cost (€)
                                                                                                                                              Total culture medium cost (€)
                                                                                                                                                                                    totals
                                                                                                                                                                                                                           Fi
                                                                                                            2.520 €                       Total culture medium cost (€)
                                                                                                                                           Total culture medium cost (€)
                                                      5040
                                                  2500699
                                                                                                                                  Total personnel cost (€)
                                                                                                                                  Personnel costs                                                                          1
                                                                                                                                  (staff hours x costs/hour)
                                                      totals                                                                      Lab material costs
                                                                                                                                                                                                                           to
                                                                                                                                  Total bioreactor operation cost (€)
                                                                                                                                  (Single-use plate costs + T-flask costs for scale-up)
Coste de un experimento (€)
                                                           Total experimental cost (€)
    ExperimentTotal experimental cost (€)
              Total experimental cost (€)
                             Total experimental cost (€)




                                                                                                                                  Culture medium costs
                                                                                                                                  Total culture medium cost (€)
                                                  2000
                                                                                                183 €
               costs (€)




                                                                                                 22,5          1800                            161 €
                                                                                              22,5
                                                                                               22,5
                                                  1500




                                                                                                                                                                                     507 €
                                                  1000                                            151                                               150
                                                                                              151
                                                                                               151                                               150
                                                                                                                                                  150


                                                                                                                             21

                                                                                                                                                                                                 12
                                                                 500                                                                                                                  978
                                                                                                                                                                                        12
                                                                                                                                                                                         12
                                                                                                    9                                                4        7                                  21
                                                                                               99               699                             44       77                              21
                                                                                                                                                                                          21



                                                                                                                                                                              21                      12
                                                                                         0
                                                                                             1 HexaBatch   1L Bioreactor                      T-flasks                 T-flasks (adherent cell)

                                                                                                                                                                                                      www.hexascreen.com
HexaBatch Case Study: Manipulation Times
Qualified Personnel Manipulation Time (hours)




                                                                     60 hours
                                                60



                                                50



                                                40



                                                30



                                                20                                                   33 hours



                                                10
                                                                                   5 hours
                                                       45 min
                                                 0
                                                     1 HexaBatch   1L Bioreactor   T-flasks   T-flasks (adherent cell)
                                                                                                          www.hexascreen.com
HexaBatch Results: On-line Optical Density
        - Hexabatch gives one on-line OD measurement every five minutes vs
          just one/two per day in the case of T-flasks.
Total cells
                                    Final cell concentration



                                                                      Off-line
                                                                   Measurements
                                                                     (T-FLASK)



                                    , tdup




                                                                    www.hexascreen.com
HexaBatch Results: On-line pH Measurements



Gives
information
                                        , tdup (indirect)
about cell
activity




               Faster response than OD
              (no death cells interaction)




                                                            www.hexascreen.com
HexaBatch Results: On-line Dissolved Oxygen




        Optimal Range




                                        www.hexascreen.com
Conclusion: HexaBatch system

               HexaBatch System
                       =
          1L bioreactor specifications
                       +
    T-Flasks cheap and fast experimentation


     • Technological advantages from a bioreactor
        • System’s homogeneity: stirring and aeration
        • On-line process monitoring (pH, DO, OD)
        • Easy maintenance of asepsis
     • T-flask experiment price, speed and flexibility
        • Working volume at ml scale
        • Multiple experiment capability
     • Minimal needs on qualified personnel
                                                        www.telstar-lifesciences.com
HexaScreen Applications: Index



    1. Pharmacokinetic Tests.

    2. Clone Comparison.

    3. Media Comparison.

    4. Inoculum Concentration.

    5. Adaption to Suspension Cultures.




                                          www.hexascreen.com
Drug Functional Tests: Pharmacokinetics
                     Antibiotic effect in cell cultures

                             Functional Tests




                                                          Activity profiles




More advantages to perform functional tests
in cell cultures than in animals:
 - Faster results
 - Ethical issues                                            www.hexascreen.com
Advanced Screening: Clone Comparison

Chose the best clone in terms of:

- Cell growth rates.
- Cell activity.
- Productivity at different sample times   activity




        Growth
        rates
                                           activity




                                                      www.hexascreen.com
Advanced Screening: Media Comparison




                              Medium
                             component
• Best growth medium          depletion
• Time of action:
  - Fed-Batch start point.
  - Infection.
  - Product recovery.
                                           www.hexascreen.com
Advanced Screening: Inoculum Concentration

                            Cell concentration profiles
                            obtained from pH profiles
                             (related to cell activity)




                                             www.hexascreen.com
Advanced Screening: Suspension Adaption
Cell concentration control along passages




                                            Control over adaption process




                                                              www.hexascreen.com
GRACIAS POR SU ATENCIÓN:
JAVIER AMAYRA: jamayra@hexascreen.com            General Manager

HexaScreen Culture Technologies S.L.
Edifici Eureka, P1M1.2
Parc de Recerca de la Universidad Autónoma de Barcelona (UAB)
08193 Cerdanyola del Vallès (Barcelona)




                                                                www.hexascreen.com

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Javier Amayra - Biotechnological Screening in Animal Cell Culture

  • 1. HexaScreen® Biotechnological Screening in Animal Cell Culture Equipment to reduce required time & costs for bioprocess development EXPOQUIMIA 2011 www.telstar-lifesciences.com
  • 2. The Team •Cell Culture •Manufacturing •Bioreactors •Marketing & Sales + • Measurement Systems •Internationalization + + •Biocompatible materials www.telstar-lifesciences.com
  • 3. Increasing importance of animal cell culture. www.telstar-lifesciences.com
  • 4. Animal Cell Culture Bioprocesses The potential of animal cell culture arises from the capability of this type of cells to carry out complex post-translational modifications providing proteins with the required biological activity to be used for therapeutical and diagnostic applications CHO (Chineese Hamster Ovary) NSO (mouse mieloma) BHK (Baby Hamster Kidney) HEK (Human Embryo Kidney) PER.C6 (Human Retinal Cells) MDCK (Madin Darby Canine Kidney) Sf9 (insect cells, Spodoptera frugiperda) www.telstar-lifesciences.com
  • 5. Bioprocess Development: Animal Cell Culture ”The optimization of the bioprocess is specially important for animal cell culture” – Less Cellular Concentration than Bacterium and Yeast: • Bacterium and Yeast cultures: [X]f ≈ 109 cells/ml • Animal cell cultures: [X]f ≈ 106 cells/ml If Ps=ct, we have 1000 times more product with bacterium or yeast than with animal cells – More expensive & complex process: • Culture media: – Bacterium and Yeast cell culture: Simple undefined mediums containing only salts (usually NaCl) and carbon & nitrogen sources (usually within yeast extract and tryptone). – Animal cell culture: Rich & complex mediums containing salts, carbon & nitrogen sources, but also complements (AA, vitamins, trace elements…) and serums (FCB, FBS…). • Easier to be contaminated: – Bacteria, yeast, mycoplasma or cross contamination. – Specific challenges for animal cell culture: slow growth and specific production rates, cell sensitivity (shear stress, nutrient limitation, metabolite accumulation..). www.telstar-lifesciences.com
  • 6. Bioprocess Development: Main Steps Genetic Engineering Culture Conditions Operational Conditions Best Clones: Best Conditions: Optimal Process: Specific Productivity [X] [X] Growth rate Death times www.hexascreen.com from F. Wurm. Nat. Biotechnol., vol. 22:1393-1398 (2004)
  • 7. Multiple aspects need to be optimized to establish optimal and profitable production processes Purification process Culture Fisico-chemical medium parameters PROCESS Clonal OPTIMIZATION Operation selection strategy Cell Process line Scale-up control GMP production High cell concentration, high specific productivity, maintain product quality www.telstar-lifesciences.com
  • 8. Bioprocess Development: Phases • PHASE I: Initial screening IMPORTANT!!! 1. Cell line selection (bacterium, yeast, animal cell…) 2. Cell modification (genetic engineering) Check the 7/8 3. Clonal activity selection activity of the clones Select which cells are producing the protein target protein in all 4. Protein target characterization: phases Measurement of the protein activity • PHASE II: Advanced screening 1. Clonal growth selection (select which cells grow faster…) 1/2 2. Culture medium composition: serum, glutamine, glucose… clones 3. Initial cell concentration. 4. Effects of stirring, [O2] and other culture conditions 5. Needs of the cell culture adaptation (ex: from adherent to suspension) • PHASE III: Lab scale production 1. Scale-up the advanced screening optimum conditions 2. Purification process 3. Type of Bioreactor (Batch, Fed-Batch, Perfusion) • PHASE IV: Pilot Plant and Industrial scale production 1. Scale-up the lab scale optimum production conditions www.telstar-lifesciences.com
  • 9. Screening Bioreactors: Differences – Reproducibility problems when scaling up from usual screening phases into lab or pilot & production plant scales due to: • Homogeneity: Non agitated systems can produce cells or nutrient Reproducibility accumulations giving not representative and impossible to repeat problems experiments. • [O2] limitations: Can produce a decrease of the cell culture growth velocity, metabolic differences or stopping the cellular cycle leading to an unreal productivity determination (higher or lower). – Lack of probes: few knowledge of the main cellular growth parameters : cell concentration, pH & pO2. – Lack of automatization: human manipulation is highly needed. – Current screening agitated systems (spinner flasks) Cost and time characteristics include high volumes and post- issues experiment treatments. www.telstar-lifesciences.com
  • 10. Screening : The HexaScreen Alternative Initial Screening Advanced Screening Lab Scale New automated & controlled screening platform Bioreactors Usual scale-up procedure Spinner flask Multiwell plates T-flask 0,1 1 10 100 1000+ Vessel volume (ml) www.hexascreen.com
  • 11. Bioprocess Development: Phases Bioprocess development for a biotechnology product requires a number of steps Scale-up Methodology: Laboratory to Pilot to Industrial Initial HEXABATCH Screening Advanced Screening Lab scale Since Biotechnological Processes are not completely known, the transition from bench to Pilot Plant Production Plant final volume is done step by step. www.telstar-lifesciences.com
  • 12. Screening: HexaBatch®Design Criteria – Simultaneous multiple experiment capability. – Low minibioreactor volumes (10-15 mL), but not too low to allow cell culture similarities with lab scale bioreactors. – Agitation requirement to allow system homogeneity, but without upsetting cell viability. – Parts in contact with cells must be manufactured with single use biocompatible plastic (no contamination,…). – Cell growth (optical density), pH and dissolved oxygen monitoring via non invasive probes. www.hexascreen.com
  • 13. HexaScreen®: HexaBatch Features Initial/Advanced Pilot Plant HexaBatch Screening / Industry Stirred & O2 fed Culture Stirred Culture Equipment used & Stationary Culture System to allow Systems: environment Systems: Heterogeneous homogeneity Homogeneous Multiple experiments run simultaneously to Unique cell Methodology Multiple experiments decrease the time culture process required for the screening phase From 2 to 10-15 ml (bench top Vessel size Micro liters and milliliters thousands of scale) liters pH, pO2 and OD (cell Discontinuous and Continuous Process control concentration) on-line manual and monitored monitoring Disposable bioreactor made of sterile Asepsis Difficult / uncontrolled Necessary biocompatible plastic material www.telstar-lifesciences.com
  • 14. HexaScreen®: HexaBatch Elements HexaBatch version consists in two differentiated parts, the 6-minibioreactors’ plate and the workstation with a computer/software . – Single use Minibioreactors’ Plate. Previously sterilized inside a plastic bag, includes 6 individual vessels equipped with gas filters, one septum for inoculation, miniaturized ports for probe’s allocation and a magnetic actuator for stirring. – Workstation. Contains the chamber where the minibioreactors’s plate remains during its culture, while maintaining optimal agitation & temperature (common), sterility, providing individual aeration and acquiring pH, DO and OD data. WorkStation is controlled via software. www.telstar-lifesciences.com
  • 15. HexaBatch: Minibioreactor plate characteristics 1-. Optical port for OD and pH measurements. 2 3 4 1 2-. Gas filters (inlet and outlet). 3-. Optical port for DO measurements via fluorescence. 4-. Septum for cell inoculation. 5-. Low shear magnetic pendular agitation (optimal for animal cell). 6-. Thermostated general bath. 8 7-. Vessel liquid volume: 10-15 ml. 8-. Biocompatible and disposable plastic, 7 6 5 sterile provided. Possible plasma treatment to promote cell adherence / non- adherence. www.telstar-lifesciences.com
  • 17. HexaBatch: Minibioreactors to Workstation www.hexascreen.com
  • 18. HexaBatch: Variables, Controls & Monitoring Variable Control Monitoring Information Aeration Time Controlled No No Agitation Set-point controlled No No Vessel Set-point controlled Monitored System functionality Temperature Gas & Filters Filters functionality – Set-point controlled Monitored Temperature Avoids evaporation Monitored and Cell density information, Optical Density Free evolution correlated related to total cells Dissolved Free evolution Oxygen concentration, Monitored Oxygen (constant aeration) related to alive cells Cell activity information, pH Free evolution Monitored related to alive cells www.telstar-lifesciences.com
  • 19. HexaBatch: Software Specifications HexaScreen®’s control & acquisition program runs on a Windows platform and will guide the user, as a wizard, through the processes of workstation’s configuration, calibration and data acquisition. General specifications • Automatic processes: – Workstation’s configuration – Thermal stabilization – Oxygen calibration – Optical calibration – Data acquisition (minibioreactors’ behaviour monitoring graphs) • Additional tasks: – Create new or edit already existing experiment set-ups – Create user defined graphs – Create reports – Export reports to EXCEL, PDF and HTML files www.hexascreen.com
  • 20. HexaBatch: Advantages & Benefits Features Advantages Benefits - Stirring, gas exchange and oxygen supply are - Focused. Specially designed for animal cell specially designed for handling animal cell - Suitable for both suspension and culture. culture. adherent cultures. - Reducing working volume means less Benchtop Scale: development costs in medium, cell culture, - Lower operation cost. Small Volumes from 10 to 15 ml”. enzymes… Parallel bioreactor system: - Less time required to achieve final results - Faster time to market. “6 multiple parallel experiments - Reproducible results: statistic data can be - Save time. for device”. obtained from replicated experiments. - Faster product development cycles. - Precision & control over all - Real-time kinetic information: experimentation. Automated on-line cell concentration (OD), DO & pH. - Lower labour and time-consuming in measurements. - No off-line control processes required. order to invest in other valuable - No maintenance required during experiment. tasks. - No post-experiments treatments. - Save money & time. Single use. - Avoid possible cross-contaminations. - Easier experiment validations. Easy to use. - No expert personal required. - Less effort required. Convenient. - Easier scale up to lab-size reactors. - Optimized culture parameters. - Save automatically the data acquired from all - Control on all acquisition PC controlled. the experiments done giving a comprehensive experiment data. documentation. - Possibility to do final reports easier. www.hexascreen.com
  • 21. HexaBatch: Applications & Cell Lines Cultured Applications Examples Cell Lines Cultured - Adherence and suspension lines. Suspension: Cellular screening. - Clone selection. - Hybridoma. - Growth parameters measurements (cell Cellular characterization. - Genetically modified hybridoma. density and cell activity). - CHO cells (adapted). Cellular adaptation. - Adherent to suspension. - HEK (adapted) Adherent: Medium definition and - Commercial medium comparison. optimization. - Medium’s components definition. - Vero cells. - New drugs tests. - Ovine Mesenchymal Stem Cells. Cellular tests. - Toxicity tests. - Apoptosis tests. - CHO. - HEK. - Initial cellular concentration, culture Process optimization. conditions… www.hexascreen.com
  • 22. Advantages of single-use technology  Fast setup.  No need for Cleaning.  No risk of cross-contamination.  Minimizes utility requirements.  Minimizes validation.  Minimizes space floor.  Minimizes labor.  Minimizes engineering design.  Reduces COGS.  Minimizes maintenance.  Environmentally friendly:  Use for generate electrical power by incineration.  Estimated savings in WFI at over 80%.  Estimated 72% saving in electricity compared to conventional manufacturing facility. www.hexascreen.com
  • 23. Advantages of single-use technology www.hexascreen.com
  • 24. Systems comparison for screening • Systems to evaluate: • HexaBatch On-line measurements • 1L glass Bioreactor • T-flasks for suspension cell cultures Off-line measurements • T-flasks for adherent cell cultures www.telstar-lifesciences.com
  • 25. HexaBatch Case Study: Conditions • Case Study parameters: • Number of conditions: 2 • Number of repetitions: 3 • Total number of cultures: 6 • Batch culture time: 3 days • Cell line: CHO • Culture media price (CDCHO): 103,52 €/L • Qualified personnel costs: 30 €/hour • It is assumed that there is only a one-liter bioreactor, so steps of the experiment are performed sequentially. • For off-line measurements (T-Flasks), only one sample is taken each day, with a total of 3 cell concentration measurements during culture. (no metabolites concentration measured) www.hexascreen.com
  • 26. HexaBatch Case Study: Time Analysis Fins a Fin 5040 699 Total personnel cost (€) Inoculum Scale-up time 19 totals Bioreactor set-up time operation cost (€) tot 45 43 days Total sterilization, CIP, calibration, post-exp. cleaning) (Set-up, bioreactor 40 Total time Culture culture medium cost (€) Experimental time (days) 35 18 30 25 36 days 20 18 15 10 5 days 5 4 days 4 days 7 3 3 3 1 1 2 0 1 HexaBatch 1L Bioreactor T-flasks T-flasks (adherent cell) www.hexascreen.com
  • 27. HexaBatch Case Study: Costs Analysis Fins a Fins a a Fins5040 5040 699 Total personnel cost (€) Fins a Fins a a Fins1960 1960 699 totals 5040 699 Total personnel cost (€) Total personnel cost (€) 1960totals totals Total bioreactor operation cost (€) totals Fins a totals Total bioreactor operation cost (€) Total bioreactor operation cost (€) Total culture medium cost (€) totals Fi 2.520 € Total culture medium cost (€) Total culture medium cost (€) 5040 2500699 Total personnel cost (€) Personnel costs 1 (staff hours x costs/hour) totals Lab material costs to Total bioreactor operation cost (€) (Single-use plate costs + T-flask costs for scale-up) Coste de un experimento (€) Total experimental cost (€) ExperimentTotal experimental cost (€) Total experimental cost (€) Total experimental cost (€) Culture medium costs Total culture medium cost (€) 2000 183 € costs (€) 22,5 1800 161 € 22,5 22,5 1500 507 € 1000 151 150 151 151 150 150 21 12 500 978 12 12 9 4 7 21 99 699 44 77 21 21 21 12 0 1 HexaBatch 1L Bioreactor T-flasks T-flasks (adherent cell) www.hexascreen.com
  • 28. HexaBatch Case Study: Manipulation Times Qualified Personnel Manipulation Time (hours) 60 hours 60 50 40 30 20 33 hours 10 5 hours 45 min 0 1 HexaBatch 1L Bioreactor T-flasks T-flasks (adherent cell) www.hexascreen.com
  • 29. HexaBatch Results: On-line Optical Density - Hexabatch gives one on-line OD measurement every five minutes vs just one/two per day in the case of T-flasks. Total cells Final cell concentration Off-line Measurements (T-FLASK) , tdup www.hexascreen.com
  • 30. HexaBatch Results: On-line pH Measurements Gives information , tdup (indirect) about cell activity Faster response than OD (no death cells interaction) www.hexascreen.com
  • 31. HexaBatch Results: On-line Dissolved Oxygen Optimal Range www.hexascreen.com
  • 32. Conclusion: HexaBatch system HexaBatch System = 1L bioreactor specifications + T-Flasks cheap and fast experimentation • Technological advantages from a bioreactor • System’s homogeneity: stirring and aeration • On-line process monitoring (pH, DO, OD) • Easy maintenance of asepsis • T-flask experiment price, speed and flexibility • Working volume at ml scale • Multiple experiment capability • Minimal needs on qualified personnel www.telstar-lifesciences.com
  • 33. HexaScreen Applications: Index 1. Pharmacokinetic Tests. 2. Clone Comparison. 3. Media Comparison. 4. Inoculum Concentration. 5. Adaption to Suspension Cultures. www.hexascreen.com
  • 34. Drug Functional Tests: Pharmacokinetics Antibiotic effect in cell cultures Functional Tests Activity profiles More advantages to perform functional tests in cell cultures than in animals: - Faster results - Ethical issues www.hexascreen.com
  • 35. Advanced Screening: Clone Comparison Chose the best clone in terms of: - Cell growth rates. - Cell activity. - Productivity at different sample times activity Growth rates activity www.hexascreen.com
  • 36. Advanced Screening: Media Comparison Medium component • Best growth medium depletion • Time of action: - Fed-Batch start point. - Infection. - Product recovery. www.hexascreen.com
  • 37. Advanced Screening: Inoculum Concentration Cell concentration profiles obtained from pH profiles (related to cell activity) www.hexascreen.com
  • 38. Advanced Screening: Suspension Adaption Cell concentration control along passages Control over adaption process www.hexascreen.com
  • 39. GRACIAS POR SU ATENCIÓN: JAVIER AMAYRA: jamayra@hexascreen.com General Manager HexaScreen Culture Technologies S.L. Edifici Eureka, P1M1.2 Parc de Recerca de la Universidad Autónoma de Barcelona (UAB) 08193 Cerdanyola del Vallès (Barcelona) www.hexascreen.com