An2700en Ms
An2700en Ms
Typically, the first three experiments are performed Figure 1. Basic Optimization Experiments
sequentially to bracket process performance and
obtain data for analysis. This information is then
combined with actual manufacturing considerations
Use this step-by-step guide to
(batch volume, process time, etc.) to design a
develop a robust UF/DF process
process simulation.
with Pellicon® cassettes (cutoffs
of 100 kD and lower) that will
deliver superior product quality,
reproducible results, and high yields.
Tight membranes (1 kD, 5 kD, etc.) Can use large TMP increases since optimum is typically >30 psi
Open membranes (50 kD, 100 kD, etc.) Can use small TMP increases since optimum is typically <10 psi
2
200 Feed Flux = 5 L/min/m2
Optimum Point Feed ∆P = 20 psid
TMP = 30 psid
160 Jf = 150 LMH
Flux (LMH)
2
Feed Flux = 3 L/min/m
120 Feed ∆P = 10 psid
80
Optimum Point
TMP = 25 psid
40 Jf = 86 LMH
0
0 10 20 30 40 50
TMP (psid)
Figure 3. TMP Excursion at Two Feed Flows
Calculations
3
Part 2. Concentration
1. Use the product from Part 1 in the starting buffer. 8. Repeat the TMP excursion outlined in Part 1 to
Based on desired final product concentration factor, determine optimum TMP at the final concentration
add additional feed volume as needed to ensure in the starting buffer.
sufficient volume at end of concentration6.
9. Diafilter with one diavolume to get product into
2. Sample feed to confirm product concentration. final buffer and dilute with final buffer back to initial
concentration.
3. Put the system in total recycle.
10. Repeat the TMP excursion to determine the
4. Start the feed pump and achieve the optimum
optimum TMP at the initial concentration in the
TMP and feed flow as determined in Part 1 by
final buffer.
partially closing the retentate valve and adjusting
the pump speed. 11. Repeat Part 2 steps 2–7 once in final buffer using
the optimum TMP as determined above.
5. Direct the permeate to a separate container to
concentrate product and reduce volume. 12. Plot the data as shown in Figure 4, remembering
to apply a temperature correction in the flux
6. Record temperatures, pressures, and flows
calculations8.
throughout the concentration; sample feed and
permeate for product retention7. Note, concentration should be plotted in a
logarithmic manner.
7. Concentrate slightly beyond desired final product
concentration.
Starting Buffer
Diafiltration Buffer
Flux (LMH)
4
Calculations
The tradeoff between flux and diafiltration buffer Plotting the DF optimization parameter as a function of
volume create an optimum bulk concentration at which product concentration yields the optimum concentrations
to perform diafiltration; this can be calculated using the for diafiltration in both the starting and final buffers, as
DF optimization parameter at each data point: shown in Figure 5.
DF Optimization Parameter =
Concentration [g/L] x Flux [LMH]
Starting Buffer
800
Diafiltration Buffer
600
Optimum
Cb for DF
400
200
0
0 20 40 60 80 100 120
5
Part 3. TMP Excursion at Final Concentration
1. Use the product from Part 2 at the final concentration Calculations
in the final buffer.
Reference Part 1.
2. Repeat steps 2–10 of Part 1.
Note: Reference Part 1 and Part 2 notes.
Part 4. Diafiltration
1. Use the product from Part 3 at the optimum – Use 3–5 diavolumes as an initial estimate for
concentration for diafiltration; dilute as needed upstream UF/DF steps, or
using the final buffer.
– Use 7–12 diavolumes as an initial estimate for final
2. Configure the system for constant volume formulation UF/DF steps
diafiltration.
5. Record temperatures, pressures, and flows at every
3. Start the feed pump and achieve the optimum TMP diavolume; sample feed and permeate for both
and feed flow as determined in Part 1 and Part 3. product retention, and retention and concentration
of the contaminant of interest.
4. Diafilter the product with the chosen number of
diavolumes: 6. Plot the data as shown in Figure 6.
– Choose the number of diavolumes based on the
product purity specifications (if known, see calculation
below) and add a safety factor of 2 diavolumes, or
100
Contaminant Retained
10
[% of original]
R = 0.4
0.1
0.01 R = 0.2
R=0
0.001
0 5 10 15
Diavolumes
Calculations
The percentage of the original contaminant in the For upstream steps, add 1–2 diavolumes. If the goal
retentate at each diavolume can be calculated from the of diafiltration is not to wash out a contaminant but
retention values using the following: rather to reach a target pH or conductivity, then the
measurement of that quality can be plotted against the
Remaining Contaminant [%] = 100 x e (Retention – 1) x N
number of diavolumes instead.
where N is the number of diavolumes.
Note:
However, since contaminant concentration is being
• If it appears necessary to diafilter past ~14 diavolumes,
directly measured in each feed sample throughout
any dead-legs or poor mixing areas in the system will
diafiltration, plot these concentrations as a percentage of
increase the apparent retention of the contaminant and
the original and use the above equation to plot several
make further removal difficult.
lines of theoretical retention, as shown in Figure 6. This
plot will help demonstrate the contaminant removal at • Ensure that choice of TMP and feed flow have
various retentions. corresponding product retention values that are
acceptable (>0.998) throughout diafiltration.
Select the whole number of diavolumes based on the
acceptable contaminant levels for the product; always
add 2–3 diavolumes as a 10-fold safety factor for
critical diafiltration steps, such as final formulation.
6
Part 5. Product Recovery
There are various methods for product recovery at 2. Recirculate at the selected feed flow rate with the
large-scale10. However, at small-scale, sufficient product retentate valve fully open for 10 minutes.
recovery can be achieved by manually tilting the system
3. Recover the buffer in a separate container using
and breaking the piping at low-points to drain the product.
the same methods that were used to recover the
Samples of the final retentate should then be analyzed for
product. Samples of this buffer rinse should be
product concentration and quality.
analyzed for product concentration.
1. After the product has been drained from the
4. After the product is recovered, the system should
system, add one system volume of diafiltration
be cleaned with the appropriate solutions8.
buffer to the feed tank.
Calculations
Ideally, the total product mass recovered in the retentate, The theoretical yield can also be calculated based on the
permeate, and buffer flush as well as unrecoverable membrane retention and compared to the actual yield.
holdup volume should equal the total mass of product in
Theoretical Yield [%] = 100 x e(Retention – 1)(N + lnX)
the feed. If the total product mass recovered is less than
the initial product mass, it is typically due to adsorption where N = number of diavolumes and X =
and/or solubility losses during processing11. However, it is concentration factor.
important to perform a mass balance and calculate total
yield to ensure optimum process parameters.
Actual Yield [%] =
100 x (Vretentate [L] x Cretentate [g/L]) / (Vinitial [L] x Cinitial [g/L])
Mass Balance [%] =
100 x {(Vretentate [L] x Cretentate [g/L]) + (Vpermeate [L] x Cpermeate [g/L]) + (Vrinse [L] x Crinse [g/L])}/(Vinitial [L] x Cinitial [g/L])
Note:
• All calculations are estimates; during these optimization
steps, the product has undergone more processing than
normal. Product degradation and yield may be slightly
affected. For a true indication of processing on product
quality, perform the entire optimized process using
fresh feed and new membranes.
• Product can be very viscous when recovered and may
affect assays; perform serial dilutions for more accurate
assay results.
• Actual yield and mass balance percentages should be
close to 100% and/or theoretical yield. If significant
losses occur, process parameters (including membrane
type) may have to be changed and then re-optimized.
• In a robust process, adsorption and solubility losses
should be very low.
7
Paper Design and Process Simulation
The optimization parameters obtained from the previous After performing the process simulation, the system
experiments can be combined to design a full process should be cleaned with the appropriate solution8.
simulation: concentration, diafiltration, (concentration,) If possible, the process should be rerun using the
and recovery. If time permits, a process simulation cleaned membranes to determine the effectiveness of
should be run immediately following the optimization the cleaning cycle and the consistency of membrane
work, and should employ the following: performance from run-to-run. If the cleaning cycle does
not prove effective, the cleaning parameters or cleaning
• New set of cassettes; same membrane type, same
solutions will need to be changed and the cleaning cycle
cassette path length
will have to be tested again.
• Fresh feedstock
• Fresh buffer(s)
• Optimized process parameters
• See detailed process simulation calculations below.
Calculations
The membrane area can be optimized to allow the Manufacturing scale volumes as determined by the user:
entire process (both concentration and diafiltration) to
• Feed volume = 5000 L
be completed in the specified timeframe (3–4 hours is
recommended). The average flux for each concentration • Retentate volume at end of 2.9X concentration =
and diafiltration step can be estimated from the 5000 L/2.9 = 1724 L
optimization data and combined with the desired volumes
to be processed. The approximate required membrane • Permeate volume removed during 2.9X concentration
area can then be calculated for both manufacturing = 5000 L – 1724 L = 3276 L
scale and scale-down runs. • 7X Diafiltration buffer volume = 7 x 1724 L = 12,068 L
Assume an example process scenario (this would have • Retentate volume at end of 3.4X Concentration =
been determined by optimization data, DF parameter, etc.): 1724 L/3.4 = 507 L
• 2.9X Concentration: • Permeate volume removed during 3.4X concentration
10 g/L to 29 g/L; flux decreases from 150 LMH to 80 LMH = 1724 L – 507 L = 1217 L
• 7X Diafiltration:
29 g/L; flux increases from 80 LMH to 85 LMH
• 3.4X Concentration:
29 g/L to 100 g/L; flux decreases from 85 LMH to 20 LMH
• Desired process time is 4 hours
8
Average process flux for concentration step12:
Javg = Jfinal + 0.33 (Jinitial – Jfinal) = Jinitial x 0.33 + Jfinal x 0.67
For 2.9X concentration:
Javg = 150 LMH x 0.33 + 80 LMH x 0.67 = 103 LMH
For 3.4X concentration:
Javg = 85 LMH x 0.33 + 20 LMH x 0.67 = 41 LMH
Required area:
Area = [(Permeate volume/Average flux)Concentration + (Permeate volume/Average flux)Diafiltration + … ]/Time
In this example:
Area = [(3,276 L/103 LMH) + (12,068 L/83 LMH) + (1,217 L/41 LMH)] / 4 hours = 51.6 m2
Add 20% safety factor:
Area = 62 m2
To perform a scale-down process simulation, the same
volume to area ratio is used and scaled based on either
the feed volume that can be used for the simulation or
the area of the desired filtration device. For example, if
the process is to be performed on one Pellicon® 2 Mini
cassette (with an area of 0.1 m2), then the required
feed volume will be:
Scale-down feed volume = 0.1 m2 x (5000 L/62 m2) = 8 L
Instead, if there is a specific volume of feedstock to
process (example: 25 L), then the required membrane
area will be:
Scale-down membrane area = 25 L x (62 m2/5000 L) = 0.3 m2
The process parameters, including Pellicon® device type,
should be consistent between scales, allowing the process
to be completed in a similar timeframe with similar fluxes,
pressures and loadings. The concentration factors, number
of diavolumes and feed quality should be kept consistent
at all scales to ensure robust scalability. However, to
demonstrate process robustness and repeatability, the
process should be tested at pilot scale before proceeding
to manufacturing.
9
Definitions
A measure of the extent of washing that has been The average applied pressure from the feed to the
performed during a diafiltration step. It is based on permeate side of the membrane.
the volume of diafiltration buffer introduced into the TMP [bar] = [(PF + PR)/2] - PP
unit operation compared to the retentate volume. If a
constant-volume diafiltration is being performed, where Volume Concentration Factor (VCF or X)
the retentate volume is held constant and diafiltration
buffer enters at the same rate that permeate leaves, The amount that the feed stream has been reduced in
a diavolume is calculated as: volume from the initial volume. For instance, if 20 L of
feedstock are processed by ultrafiltration until 18 L have
DV or N [–] = T
otal buffer volume introduced to passed through to the permeate and 2 L are left in the
the operation during diafiltration/ retentate, a ten-fold concentration has been performed
retentate volume so the Volume Concentration Factor is 10. In a Fed-Batch
concentration process, where the bulk feedstock is held
Intrinsic Sieving (Si) in an external tank and added to the TFF operation
The fraction of a particular protein that passes through continuously as permeate is removed, VCF should be
the membrane to the permeate stream. However, it is calculated based only on the volume that has been added
based on the protein concentration at the membrane to the TFF operation.
surface. Although it cannot be directly measured, it VCF or X [–] = T
otal starting feed volume added to the
provides a better understanding of the membrane’s operation/current retentate volume
inherent separation characteristics.
Si [–] = ( Concentration in permeate, CP)/
(Concentration at membrane wall, Cw)
10
References/Footnotes
1. Total recycle means retentate and permeate lines 8. See Guide: Pellicon® 2 Cassettes Installation, User,
return to feed vessel and Maintenance Guide (UG2996EN) or Pellicon® 3
Cassettes Installation and User Guide (AN1065EN00)
2. If process flux is unstable, it may be necessary to allow
additional time or investigate other membrane options 9. Ng P, Lundblad J, and Mitra G, Optimization of Solute
Separation by Diafiltration, Separation Science, 11(5):
3. Retention samples are not required at every data
499-502, 1976.
point; sampling at lowest and highest TMP is typical
10. See Technical Brief: Protein Concentration and
4. The point at which the flux levels off is defined as
Diafiltration by Tangential Flow Filtration (TB032)
the point around which the slope of the flux vs. TMP
curve decreases to ≤50% of the previous slope. This 11. See Technical Note: Increase Product Yield in Your
point is also referred to as the “knee” of the curve. UF/DF Processes (AN1026EN00)
5. These other conditions are described in more detail 12. Average flux can also be calculated for each step
in Parts 2 and 3. by dividing the total process volume by the total
process time
6. Example: 10X concentration with a final volume of
300 mL requires (300 mL x 10) = 3 L of feed
7. Retention samples are not required at every data
point; initial and final concentration are typical.
Typical data recording interval is approximately
every 10–15 minutes.
11
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