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Research ArticleTechnology/Application

Evaluation of the Design, Development, and Performance of a Mass-Flow Based, Open-Source Buffer Manufacturing System

Natraj Ram, Jeff Johnson, Hiren Ardeshna, Joseph Camire, Ryan Campbell, Doan Chau, Sam Gardner, Kevin Gibson, Joey Norikane, Paul Randolph, Kelly Smith, Katherine Stafford, Rachel Swamy, Shana Usery and Kelvin H. Lee
PDA Journal of Pharmaceutical Science and Technology March 2023, 77 (2) 79-98; DOI: https://doi.org/10.5731/pdajpst.2021.012660
Natraj Ram
1Thermo Fisher Scientific;
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Jeff Johnson
2Biotech Design LLC;
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Hiren Ardeshna
3GlaxoSmithKline plc;
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Joseph Camire
1Thermo Fisher Scientific;
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Ryan Campbell
4Rockwell Automation;
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Doan Chau
4Rockwell Automation;
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Sam Gardner
5Merck and Company;
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Kevin Gibson
6PM Group;
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Joey Norikane
7National Institute for Innovation in Manufacturing Biopharmaceuticals; and
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Paul Randolph
8Janssen
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Kelly Smith
1Thermo Fisher Scientific;
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Katherine Stafford
1Thermo Fisher Scientific;
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Rachel Swamy
7National Institute for Innovation in Manufacturing Biopharmaceuticals; and
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Shana Usery
1Thermo Fisher Scientific;
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Kelvin H. Lee
7National Institute for Innovation in Manufacturing Biopharmaceuticals; and
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  • For correspondence: KHL@udel.edu
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  • Figure 1
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    Figure 1

    System architecture for the BSB System. IP, industrial protocol; HMI, human machine interface; OPC UA, Open Platform Communications Unified Architecture; OWS, operator workstation; SQL, structured query language.

  • Figure 2
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    Figure 2

    Buffer composition and flow rates for typical monoclonal antibody process.

  • Figure 3
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    Figure 3

    BSB System flow diagram. C, conductivity; F, flow; P, pressure; T, temperature; WFI, water for injection.

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    Figure 4

    General system architecture of the BSB System. HMI, human machine interface; OPC DA/UA, Open Platform Communications Data Access/Unified Architecture; SQL, structured query language; WFI, water for injection.

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    Figure 5

    Example buffer run: 50 mM Sodium Acetate, pH 3.5. WFI, water for injection.

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    Figure 6

    Coefficient of Variation of pH (%CV). RSD, relative standard deviation.

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    Figure 7

    Coefficient of Variation of Conductivity (%CV). RSD, relative standard deviation.

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    Figure 8

    Offline/Online pH comparison.

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    Figure 9

    Offline/Online conductivity comparison.

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    Figure 10

    Performance of stock pumps vs flow rate.

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    Figure 11

    Performance of water for injection (WFI) pump vs flow rate.

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    Figure 12

    Pre-collect startup time.

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    Figure 13

    Stock wasted to drain by pump for specific stocks in buffer batches.

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    Figure 14

    Dilution Factor (mass batch/mass stocks).

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    Figure 15

    ÄKTA connected buffer production. WFI, water for injection.

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    Figure 16

    Equipment occupancy chart for various modes of buffer preparation (generated using SchedulePro V9.100).

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    Figure 17

    Cost comparison of buffer preparation by different methods. WFI, water for injection.

Tables

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    TABLE I

    Stocks Connected to Pumps and Flow Rates Used

    PumpPU-100PU-200PU-300PU-400
    PumpQuattroflow™ 1200HT 3° cam (Low Flow)Quattroflow™ 1200HT 5° cam (High Flow)LEWA Ecodos® 5 mm (Low Flow)LEWA Ecodos® 7.5 mm (High Flow)
    Optimal Flow (Kg/min)10.4–120.4–200.4–30.4–15
    Theoretical Dilution Ratio Range23.3–1002–10013.3–1002.7–100
    Stock 10.2 M NaH2PO41M NaCl0.15 M Na Acetate0.4M Na2HPO4
    Stock 21 M Acetic Acid3M (NH4)2SO41 M Tris HCl1M NaOH
    Stock 3———0.3 M Na Acetate
    Study range (Kg/min)30.52–3.30.7–9.40.6–2.82.7–9.4
    • ↵1 Optimal flow range was determined during range finding testing.

    • ↵2 Range achievable within the optimal flow range at a total flow of 40 Kg/min.

    • ↵3 Study Range was evaluated in the demonstration study.

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PDA Journal of Pharmaceutical Science and Technology: 77 (2)
PDA Journal of Pharmaceutical Science and Technology
Vol. 77, Issue 2
March/April 2023
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Evaluation of the Design, Development, and Performance of a Mass-Flow Based, Open-Source Buffer Manufacturing System
Natraj Ram, Jeff Johnson, Hiren Ardeshna, Joseph Camire, Ryan Campbell, Doan Chau, Sam Gardner, Kevin Gibson, Joey Norikane, Paul Randolph, Kelly Smith, Katherine Stafford, Rachel Swamy, Shana Usery, Kelvin H. Lee
PDA Journal of Pharmaceutical Science and Technology Mar 2023, 77 (2) 79-98; DOI: 10.5731/pdajpst.2021.012660

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Evaluation of the Design, Development, and Performance of a Mass-Flow Based, Open-Source Buffer Manufacturing System
Natraj Ram, Jeff Johnson, Hiren Ardeshna, Joseph Camire, Ryan Campbell, Doan Chau, Sam Gardner, Kevin Gibson, Joey Norikane, Paul Randolph, Kelly Smith, Katherine Stafford, Rachel Swamy, Shana Usery, Kelvin H. Lee
PDA Journal of Pharmaceutical Science and Technology Mar 2023, 77 (2) 79-98; DOI: 10.5731/pdajpst.2021.012660
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Keywords

  • Buffer manufacture
  • buffer stock blending
  • in-line conditioning
  • cGMP
  • open-source skid

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