Platform development for high‐throughput optimization of perfusion processes—Part II: Variation of perfusion rate strategies in microwell plates

Abstract

AbstractThe biopharmaceutical industry is replacing fed‐batch with perfusion processes to take advantage of reduced capital and operational costs due to the operation at high cell densities (HCD) and improved productivities. HCDs are achieved by cell retention and continuous medium exchange, which is often based on the cell‐specific perfusion rate (CSPR). To obtain a cost‐productive process the perfusion rate must be determined for each process individually. However, determining optimal operating conditions remain labor‐intensive and time‐consuming experiments, as investigations are performed in lab‐scale perfusion bioreactors. Small‐scale models such as microwell plates (MWPs) provide an option for screening multiple perfusion rates in parallel in a semi‐perfusion mimic. This study investigated two perfusion rate strategies applied to the MWP platform operated in semi‐perfusion. The CSPR‐based perfusion rate strategy aimed to maintain multiple CSPR values throughout the cultivation and was compared to a cultivation with a perfusion rate of 1 RV d−1. The cellular performance was investigated with the dual aim (i) to achieve HCD, when inoculating at conventional and HCDs, and (ii) to maintain HCDs, when applying an additional manual cell bleed. With both perfusion rate strategies viable cell concentrations up to 50 × 106 cells mL−1 were achieved and comparable results for key metabolites and antibody product titers were obtained. Furthermore, the combined application of cell bleed and CSPR‐based medium exchange was successfully shown with similar results for growth, metabolites, and productivities, respectively, while reducing the medium consumption by up to 50% for HCD cultivations.