Qualification of A Chromatographic Column
Qualification of A Chromatographic Column
Qualification of A Chromatographic Column
Biopharmaceutical
Production
Qualification of a
Chromatographic Column
Why and How to Do It
Anurag S. Rathore, Robert M. Kennedy, J. Kevin ODonnell,
Ivars Bemberis, and Oliver Kaltenbrunner
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ROBERT M. KENNEDY
Qualifying Protocols and Hardware
Qualification is the
part of process validation that ensures
that the equipment
and protocols are capable of fulfilling the
specified requirements. Column qualification is documentation of work done
to ensure that the column and the protocols written to direct operation of the column are appropriate for the purification step intended. Column
qualification can be divided into two broad sub-
(a)
tr
h
W1/2
tr
Wb
1/2 h
Injection
(b)
Alternatively, use
N = 5.54
tr
W 1/2
1/10 h
Injection
in which W1/2 is the width of the peak at one half the maximum
height (figure a). Both of these equations are used widely for
estimating N and yield very similar results.
For comparing two different columns, number of plates per
meter can be calculated using:
T=
plates
= N
meters
L
Asymmetry (As)
As = b
a
HETP = L
N
h = HETP
dp
W 0.05
2 f
where a is the distance from the leading edge of the peak to the
midpoint of the peak, and b is the distance from the midpoint of
the peak to the trailing edge (figure b). As is routinely
determined at 5% or 10% of maximum peak height. As values
between 0.8 and 1.4 are typically suitable. As shown in the T
and As equations, As is not the same as peak tailing.
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The schematic diagram shows all the associated lines into and out of the column. The process
workflow diagram indicates the tanks that are
connected to the inlet side and which tanks are
connected to the outlet. Product is collected into
one of the tanks on the outlet. People responsible
for the process need to know the location and the
condition of the product at all times. Qualification of these tanks and fluid path transfers is
another part of hardware qualification. Included
in the validation package for the column is the
engineering drawing of the column. Spare parts
are associated with an individual column, and
engineers performing the scheduled maintenance
on the column can be expected to require access
to this part of the validation record to ensure that
the appropriate spare parts are used in maintenance and reordered once they are consumed.
Documentation of the gauges used to operate a
column should include the calibration record of
the gauge as well as the serial numbers or asset
number to ensure that the correct gauge is in
place during operation.
In column protocol qualification, process development work can contribute to the validation of the
chromatography step by providing data on the
stability of the chromatography resin under equilibration, operating, regenerating, cleaning and
sanitizing, and storage conditions. To operate the
column, an associated set of standard operation
protocols (SOPs) needs to be written and tested:
SOPs must be unambiguous. Regulatory requirements exist to ensure that operators are trained
and regularly retrained to maintain their competence in performing the operation.
Each column in the purification process needs
to have SOPs for column packing and testing.
Once accepted for use, each column needs SOPs
for equilibration, running (that is, applying feed
to a collection of product), regenerating, and
cleaning. SOPs are needed to direct the collection
of data for use in ascertaining performance quality, to document how preventive maintenance
should be done, and to instruct on how material
should be stored.
Assistance with writing many of these SOPs is
often available from the appropriate equipment
and chemical suppliers. The suppliers technical
department can be a valuable contributor to inhouse writers of these protocols. Chromatography
suppliers can contribute to SOPs on column
packing, performance quality, maintenance, and
storage, for example. Engineering companies can
Elements of
Biopharmaceutical
Production
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BioPharm International
MARCH 2003
provide assistance with the process workflow diagrams and advice on data storage related to the
physical column and the drawings and parts.
Purification by chromatography is at the heart
of biopharmaceutical production. Column qualification is a critical activity in the assurance of
quality in the production area.
Robert M. Kennedy is department director, separation
sciences, Amersham Biosciences Corporation, 800 Centennial Avenue, Piscataway, NJ 08855, 732.457.8438,
[email protected].
J. KEVIN ODONNELL
The Science of Column Packing
Recent FDA inspections have shown an increased
interest in the packing
characteristics of
process-scale, liquid
chromatography
columns. That is manifested by the
agencys emphasis on
reproducible packing
of chromatography
columns by pharmaceutical and biotechnology companies. Although
process-scale column packing is still, in many
cases, more of an art than a science, FDA by its
inquiries at inspections is encouraging companies to move toward a column-packing science. A
large part of that science is how a column is characterized or qualified after it is packed.
Resins. Many variables influence the science of
column packing. The first variable is the chromatographic resin. A chromatographic resin is
selected primarily for its ability to separate the
molecule of interest from its impurities, not on
how well it packs into a manufacturers column.
Many different resins are used in process chromatography, and all have individual columnpacking characteristics.
Some resins are soft and cannot withstand
even moderate pressures. As a result, when
columns are packed with this group of resins,
2030% more resin often has to be added to get
the desired column volume at standard operating
pressures. Semirigid resins, including those based
on silica, are better able to withstand normal
operating pressures and require only 515% extra
resin to get to the specified volume. Silica resins
are pressure resistant, so they can be used in
columns with extremely high backpressures.
Silica resins require little additional resin for efficient column packing.
Resin slurry concentration is often overlooked when packing process-scale columns. For
unknown reasons, resin can pack differently
when charged to the column at different concentrations. A slurry concentration that works in one
column may not work as well in another manufacturers column. Resin manufacturers generally
have a good idea of what slurry concentration
works best with different column technologies.
Column packing. Traditional columns with
adjustable upper adaptors can be packed reproducibly with repeated practice. The caveat here is
that it may take several attempts to get the first
optimal pack. Once the technique is determined,
subsequent packing can proceed more efficiently.
Newer process-scale column designs, which
include dynamic axial compression and selfpacking technologies, are generally more user
friendly and can be packed successfully on the
first try. However these columns require more
up-front training, and the hardware is usually
more expensive because it includes additional
equipment specially designed to assist in column
packing. Expanded-bed columns may be the easiest to pack; however they also require more supervision while running.
Ideally, all resins should be defined before
packing, eliminating any small fragments that can
be generated by shipping and handling resin.
Trace amounts of fines may not have any effect
on the actual chromatography, but can eventually
lead to occlusion of the bottom screens or frits.
Such occlusion would ultimately create increased
backpressure, which would require a reduced
flow rate. As a result, the column would have a
reduced throughput.
The mobile phase plays an important role in
packing process columns. Generally the solvent
that packs the resin most tightly is preferred.
Placing and securing the upper adaptor directly
on the top of the settled bed minimizes swelling
when the mobile phase is changed. Exceptions to
this method include some polymeric reversedphase resins that can swell 1525% in organic
solvents. Under those conditions, a fixed adaptor
or column housing could fail, with resulting obvious safety concerns. Allowing a void above the
resin bed or using a dynamic axial compression
column that moves with the shrinking and
swelling of the resin prevents that.
Test result variations. Once a column is packed,
a series of standard tests should be conducted to
evaluate performance and qualify the column.
The results of these tests do not predict success in
the actual chromatography step; however, the
results are useful for column packing repro-
Troubleshooting
Performance Evaluation
As0.8
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Elements of
Biopharmaceutical
Production
IVARS BEMBERIS
Choosing the Right Metric
To ensure robust
chromatographic performance, it is essential to have a proper
packing and qualification protocol. Because chromatographic purification
typically involves
several columns,
packing and qualifying columns is an important
process validation concern. An effective packing
and qualification protocol typically consists of a
prepacking checklist, a description of the medias
properties, choosing the right metric for column
qualification, and qualifying the packing protocol.
Prepacking checklist. A columns mechanical
robustness must be ensured before packing. That
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Product Concentration
100
50
Percent
dC/dV
0
Feed Volume
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BioPharm International
MARCH 2003
Bemberis
is
technology
manager,
Bedford,
MA
01730,
781.533.8452,
OLIVER KALTENBRUNNER
Preventing Erroneous Results
Chromatography
column packing integrity is usually
tested before process
use of a column.
Typically, a pulse of
a noninteracting sample tracer is applied
while flowing a column signal (which
alters the initially rectangular tracer) under defined conditions. An analysis of the response signal of the pulse sample can be used to assess
1.4
0.020
HETP (cm)
1.2
0.015
1
0.8
0.010
HETP (cm)
As
0.6
0.4
0.005
0.2
0.000
3
4
Pa
ck
5
Av
er
ag
e
R
un
1
R
un
2
Pa
ck
Pa
ck
Pa
ck
Pa
ck
Packing Number
Average Results:
HETP 0.014 cr
As
1.082
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BioPharm International
MARCH 2003
Column 2 =
VR
=
N
2
d
4
L 0.95
L
5 dp
Elements of
Biopharmaceutical
Production
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BioPharm International
MARCH 2003
setup is also higher. Obviously the tracer application technique can have an even bigger effect on
the test result, and a defined and reproducible
sample application method or device needs to be
established.
Preventing erroneous conclusions. Once
reproducible test methods are in place, HETP
results can be used to accept or reject columns for
processing. Acceptance criteria should be set primarily by considering the best practice for column packing and the available equipment, then
establishing criteria that are specific to that system. Consequently, there is not necessarily a
close correlation between a columns qualification test result and its process performance.
However, as in any acceptance test, there are two
possible erroneous conclusions.
The most likely error is that a column fails the
test criteria but would not fail to meet process
requirements. This is the typical error to expect if
the testing operation failed to follow the required
best practices. It causes an operational problem of
producing extra work and unnecessary repacking,
but it does not set the process at risk. Setting
appropriate acceptance criteria, reproducible test
methods, and operator training can minimize the
risk.
The second type of erroneous result is to
accept a column that is not fit for the process.
This obviously sets the process at risk and needs
to be avoided. Reasons for this error can be column failure occurring at a particular flow rate, or
viscosity of a process feed while the test conditions allow good packing integrity.
Bed stability is not only a function of the bed
height and compression, but also of the height-todiameter ratio of the packing. Identical linear velocities cause increasing bed compression with
increasing column diameter. This leads to decreasing maximum operating linear velocities,
with increasing column diameter (5). If the
process flow rates are developed using small column diameters without consideration of potential
flow rate limitations at large column diameters,
bed instabilities can occur that are not evident
during typical column qualification conditions.
Consequently, test conditions have to be evaluated column by column, considering the process
conditions at the respective scale.
Oliver Kaltenbrunner is in process engineering,
MS: 30W-2-A, Amgen Inc., One Amgen Center Drive,
Thousands
Oaks,
CA
91320,
805.447.2641,
ANURAG RATHORE
From the Series Coordinator
BioPharm International and I hope that
the insightful comments from these authors are useful for biochemists and engineers
practicing preparative
chromatography in the
biopharmaceutical industry. We conclude
this article with a caution about some common
pitfalls found in preparative chromatography:
Packing procedures need to be optimized for
each different type of resin to get reproducible
packing;
Measures of bed integrity need to be carefully
chosen along with their specifications to
guarantee robust column performance;
The tracer used for estimating HETP or As can
interact with column packing, yielding
erroneous results;
Flow rate or particle size effects must be
eliminated when qualifying column packing to
achieve consistent results;
Function tests might be necessary, and lot-to-lot
variations in chromatography media may be
unacceptable for some applications if the
process is very sensitive; and
Resin qualification procedures need to be
carefully chosen because excessive testing can
be expensive and should be reduced gradually
through reexamination.
Anurag Rathore , series coordinator, is at
Pharmacia Corporation, 700 Chesterfield Parkway North,
Chesterfield, MO 63017, 636.737.6790, fax 636.737.7281,
[email protected]. BPI
REFERENCES
(1) Rathore, A.S. et al., Process Validation: How Much
to Do and When to Do It, BioPharm 15(10), 1828
(October 2002).
(2) Rathore, A.S. and Velayudhan, A., Guidelines for
Optimization and Scale-Up in Preparative
Chromatography, BioPharm International 16(1),
3442 (January 2003).
(3) Van Deemter, J.J., Zuiderweg, F.J., and Klinkenberg,
A., Longitudinal Diffusion and Resistances to Mass
Transfer as Causes of Nonideality in
Chromatography, Chem. Eng. Sci. 5, 271289
(1956).
(4) Kaltenbrunner, O., Watler, P., and Yamamoto, S.,
Column Qualification in Process Ion-Exchange
Chromatography, Progress in Biotechnology:
Bioseparation Engineering, Vol. 16, I. Endo et al.
Eds. (Elsevier Science, Amsterdam, The Netherlands,
2000), pp. 201206.
(5) Stickel, J.J. and Fotopoulos, A., PressureFlow
Relationships for Packed Beds of Compressible
Chromatography Media at Laboratory and
Production Scale, Biotechnol. Prog. 17(4), 744751
(2001).