Engineering Commons^™

Ultra High Temperature Ceramics For Hypersonic Space Vehicles: Opportunities And Challenges, Bikramjit Basu

Ultra-High Temperature Ceramics: Materials for Extreme Environment Applications IV

Among ultrahigh temperature ceramics (UHTC), ZrB₂-based ceramics have received the most attention for applications in the leading edge of hypersonic space vehicles. Despite significant research efforts, the development of ZrB₂-SiC based ceramics in reference to performance-qualifying property assessment (shock resistance, ablation, etc.) together with the design of thermal protection system (TPS) has not been extensively reported in literature. While briefly presenting our recent research in this direction, I shall discuss myriad of opportunities and challenges ahead in TPS design for hypersonic space vehicles.

To begin with, results of the carefully designed experiments using innovative multi-stage spark …

Fouling Mitigation In Membrane Based Perfusion Systems By Oscillating Tangential Flow, Maria Weinberger, Ulrich Kulozik

Integrated Continuous Biomanufacturing III

Good scalability and robust handling have promoted the application of membrane based cell retention devices. A physical barrier, i.e. a filter, retains cells and cell debris. One major drawback of these devices is their ten-dency to foul and clog. One form of fouling is deposit layer formation on the filter surface, consisting of cells, cell debris and other fermentation broth constituents. This leads to the build-up of a secondary membrane, which can alter the permeation profile. Furthermore, deposit layers lead to an increased filtration resistance and thus negatively affect permeate flux, filtration efficiency and process robustness. In tangential flow filtration, …

Scalable Technologies For Process Intensification In The Continuous Biomanufacturing Factories Of The Future, Gerben Zijlstra

Integrated Continuous Biomanufacturing III

Continuous and intensified bioprocessing is attracting much attention from biopharmaceutical companies seeking to maximize the efficiency of their manufacturing assets. Continuous and intensified bioprocessing promises smaller facilities, reduced scale-up risk, more consistent product quality and higher throughputs. However, there are still many (technical) challenges for practical implementation of intensified and continuous bioprocesses. In the upstream processing, tools for high throughput intensified and continuous cell culture development are limited, furthermore at 2000 L scale many single use bioreactors may not be suitable to support the high cell densities required for intensified processing. Furthermore, current cell retention systems are expensive, suffer from …

Continuous Gas Processing Without Bubbles Using Thin Liquid Film Bioreactors Containing Biocomposite Biocatalysts, Michael C. Flickinger, Christopher Duran, Adam Wallace, Mark J. Schulte, Orlin D. Velev, Nilay Chakraborty, Michael Guarnieri, Kamelia Boodhoo

Integrated Continuous Biomanufacturing III

Continuous microbial gas processing without bubbles is possible with thin liquid film, plug flow bioreactors. We have demonstrated that power input can be minimized by using a falling liquid film operating under laminar wavy flow conditions (Re <200) in contact with highly concentrated living, non-growing microbes stabilized in a porous biocomposite biocatalyst. This composite materials approach to continuous gas processing can dramatically increase mass transfer rates >100 fold compared to bubble aeration, decrease process volume, significantly decrease gas-liquid mass transfer energy input, decrease water use, and increase secreted product concentration. We have shown that this approach can also increase microbial specific activity for some organisms compared to microbes suspended in liquid media. Paper-based biocomposite biocatalysts provide a rough hydrophilic surface resulting in uniform ~300 μm thick falling liquid films. …

Up And Down Scale Considerations For The Continuous Production Of Glycooptimized Biopharmaceuticals, Steffen Kreye, Rainer Stahn

Integrated Continuous Biomanufacturing III

Product quality especially with respect to glycosylation is a critical product attribute which can have an immense influence on the activity of glycoproteins and should be closely monitored during process development and manufacturing. GlycoExpressTM cells have been developed in this context to provide human host cell lines with robust glycosylation machineries. This work will address challenges in two case studies for up and down scaling of production processes with focus on product quality and continuous processing. In a first section, data of a process transfer from a 200 L stainless steel to a 1000 L single-use bioreactor for a continuous …

Bioprocess Intensification And Optimisation Using Macroscopic Predictive Models Of Cell Culture Processes, Bassem Ben Yahia, Boris Fessler, Gwendal Gränicher, An-Vy Tran, Mareike Harmsen, Elmar Heinzle

Integrated Continuous Biomanufacturing III

Chinese Ovary Hamster (CHO) are an indispensable tool for biotechnological production of biologics which is a multi-million business. Recently, the pharmaceutical industry is increasingly focusing in the use of perfusion mode. Nevertheless, the optimal perfusion rate during biopharmaceutical perfusion production is dependent on cell metabolism which can be characterized by mathematical models. This study provides insights into the predictive capacities of systematic and simple cell modeling approaches of metabolism, growth and production of monoclonal antibodies (mAb) [1] to optimized medium composition and perfusion rate during CHO perfusion culture. We applied the metabolic steady state concept and used a segmented linear …

Phase Transformations In Oxides Above 2000°C: Experimental Technique Development, Sergey V. Ushakov, Alexandra Navrotsky

Ultra-High Temperature Ceramics: Materials for Extreme Environment Applications IV

Oxidation of carbides-based ultra-high temperature ceramics is the main limiting factor for its use for aerodynamic surfaces. Experimental thermodynamic and structural data for refractory oxides above 2000 °C are mostly absent. The following techniques applied to fill this gap will be discussed: i) Commercial ultra-high temperature differential thermal analyzers (DTA) allow investigation of phase transformations and melting in inert environment to the temperatures up to 2500 °C; ii) Combination of laser heating with splittable nozzle aerodynamic levitator allow splat quenching and drop calorimetry from temperatures limited only by sample evaporation; iii) Synchrotron X-ray and neutron diffraction on laser heated aerodynamically …

Extended Potentials Of Uhtcmcs In Space Vehicle Extreme Environment Applications - Large System Intergrator View And Expectations, Wolfgang Fischer

Ultra-High Temperature Ceramics: Materials for Extreme Environment Applications IV

Research and development performed in recent years in the field of UHTC revealed promising properties of these new materials in the field of extreme environments.

Particularly in applications where high thermal loadings are expected these materials offer high potentials of extended performance for various applications.

However, the combination of high thermal loadings together with high mechanical loadings requires a new class of UHTC. By creating UHTCs with fiber reinforcement an improvement of characteristic properties is anticipated.

Research in this very specific area has been initiated and is currently ongoing based on promising ideas.

This class of UHTCMCs is expected to …

Process Intensification: Enabling Technologies And Methodologies, Jonathan Souquet, Xavier Lesaout, Herve Broly

Integrated Continuous Biomanufacturing III

The objective of this presentation is to review how emerging continuous manufacturing technology solutions can be leveraged to maximize existing facility utilization, throughput and capacity with particular focus on downstream process applications. Business and Market pressures driving the industry towards more efficient and effective manufacturing models will be reviewed. Downstream process bottlenecks and their impact on facility utilization and productivity will be addressed, and insight into enabling continuous manufacturing technologies and methodologies that can address these challenges will be provided. Case studies will be used to highlight the impact of applying continuous manufacturing principles on cost of supply, facility capacity …

Testing Ultra-High Temperature Ceramics For Thermal Protection And Rocket Applications, Raffaele Savino

Ultra-High Temperature Ceramics: Materials for Extreme Environment Applications IV

The work is focused on experimental aerothermodynamic characterization of Ultra-High-Temperature Ceramic materials for aerospace applications. These materials are assuming an increasing importance in aerospace research because their high temperature resistance makes them interesting to develop components for extreme applications, such as thermal protection systems for hypersonic or atmospheric reusable re-entry vehicles, specific components for propulsion, combustion chambers, engines intakes or rocket nozzles. In order to test the materials behavior in extreme relevant environments, different facilities are available, including supersonic arc-jet wind tunnels and lab-scaled rocket motors.

Typical activities include the design of prototypes for the experimental campaigns, tests on material …

Supervisory Control Of Integrated Continuous Downstream Processes, Bernt Nilsson, Niklas Andersson, Joaquin Gomis Fons, Anton Löfgren

Integrated Continuous Biomanufacturing III

Smart downstream processing can be performed with a sequence of integrated purification steps, which minimize the number of storage tanks and reduce hold-up time. The result is an integrated unit operation sequence that performs straight through processing of the target protein, with minimal time from expression to formulation. This downstream processing technique is well suited to be connected to a continuous upstream process based on perfusion. To develop these kinds of processes it is important to do studies in small-scale in a convenient way. This paper presents a methodology for supervisory control of integrated continuous downstream processes in lab-scale. A …

Ultra Scale-Down Mimics For Perfusion Culture: Experimental Study For Rapid Biopharmaceutical Process Development, Molly Tregidgo, David Pollard, Martina Micheletti

Integrated Continuous Biomanufacturing III

With the industry driving towards the implementation of whole continuous bioprocess sequences, there becomes a requirement for the development of scale-down tools with the same consistency, reliability and throughput as those already available for traditional batch processes. This work aims to develop a perfusion scale-down system capable of reproducing the specific characteristics of the perfusion culture process, namely cell retention capabilities, the ability to support high cell densities and to operate for extended periods compared to fed-batch cultures. Cell culture in microwell plates in fed-batch mode is well defined and is in widespread use; however to the best of our …

Conversion Of An Industrial Batch Separation Process To An Autonomous Integrated Downstream Process – A Case Study, Anton Lofgren, Niklas Andersson, Joaquin Gomis Fons, Anton Sellberg, Bernt Nilsson

Integrated Continuous Biomanufacturing III

In this contribution an industrial case study, consisting of several unit operations operated in batch mode, was converted to an integrated separation process. The complete downstream process consisted of an anion exchange step, followed by virus inactivation and finally a hydrophobic interaction step. Moving from batch to integrated separation minimizes hold-up times, storage tanks and required equipment. The conversion from batch to integrated mode was achieved by extracting operating points and separation data from batch chromatograms. The integrated separation process was realized on an ÄKTA Pure controlled by a newly developed software called Orbit. The setup consisted of two column …

Application Of Single Pass Tff To Enable Intensified And Continuous Biological Manufacturing, Herb Lutz

Integrated Continuous Biomanufacturing III

No abstract provided.

Fouling Mitigation In Membrane Based Perfusion Systems By Oscillating Tangential Flow, Maria Weinberger, Ulrich Kulozik

Integrated Continuous Biomanufacturing III

Good scalability and robust handling have promoted the application of membrane based cell retention devices. A physical barrier, i.e. a filter, retains cells and cell debris. One major drawback of these devices is their ten-dency to foul and clog. One form of fouling is deposit layer formation on the filter surface, consisting of cells, cell debris and other fermentation broth constituents. This leads to the build-up of a secondary membrane, which can alter the permeation profile. Furthermore, deposit layers lead to an increased filtration resistance and thus negatively affect permeate flux, filtration efficiency and process robustness. In tangential flow filtration, …

Ultra Scale-Down Mimics For Perfusion Culture: Experimental Study For Rapid Biopharmaceutical Process Development, Molly Tregidgo, Martina Micheletti, David Pollard

Integrated Continuous Biomanufacturing III

With the industry driving towards the implementation of whole continuous bioprocess sequences, there becomes a requirement for the development of scale-down tools with the same consistency, reliability and throughput as those already available for traditional batch processes. This work aims to develop a perfusion scale-down system capable of reproducing the specific characteristics of the perfusion culture process, namely cell retention capabilities, the ability to support high cell densities and to operate for extended periods compared to fed-batch cultures. Cell culture in microwell plates in fed-batch mode is well defined and is in widespread use; however to the best of our …

Use Of A Biphasic Perfusion Process Based On Mild Hypothermia For Recombinant Glucocerebrosidase (Gba) Production, Filipa Gonçalves, Juliana Coronel, Leda R. Castilho

Integrated Continuous Biomanufacturing III

The main goal of this study was to develop an innovative CHO-based process for the production of glucocerebrosidase (GBA), an enzyme used for the replacement therapy of Type 1 Gaucher disease. The focus of the present study was on the development of a perfusion process, combining strategies that are commonly used for process optimization: temperature reduction, and supplementation of the culture medium with productivity enhancers, such as short chain fatty acids. The effects of mild hypothermic conditions combined with valeric acid supplementation were first studied in batch shake flasks for two clones (CHO-GBA-36K and CHO-GBA-65P), developed previously using as host …

Qualification Of Single Use In-Line Sensors For Use In Continuous Bioprocessing, James Furey, Dennis Annarelli, Josh Huang

Integrated Continuous Biomanufacturing III

The requirements for batch versus continuous processing will be compared along the lines of the design attributes of single use sensors for pressure, temperature, conductivity, and UV absorbance and also performance over months of continuous operation. These sensors are applicable in both upstream and downsteam processing starting with pressure monitoring on single use bioreactors, sensors required for perfusion process monitoring followed by monitoring of continuous purification processes. Dissection of the materials of the sensors and their physical nature to withstand liquid exposure of up to 90 days versus (versus shorter more discrete batch processes of less than one day) will …

Up And Down Scale Considerations For The Continuous Production Of Glycooptimized Biopharmaceuticals, Steffen Kreye, Rainer Stahn

Integrated Continuous Biomanufacturing III

Product quality especially with respect to glycosylation is a critical product attribute which can have an immense influence on the activity of glycoproteins and should be closely monitored during process development and manufacturing. GlycoExpressTM cells have been developed in this context to provide human host cell lines with robust glycosylation machineries. This work will address challenges in two case studies for up and down scaling of production processes with focus on product quality and continuous processing. In a first section, data of a process transfer from a 200 L stainless steel to a 1000 L single-use bioreactor for a continuous …

Bioprocess Intensification And Optimisation Using Macroscopic Predictive Models Of Cell Culture Processes, Bassem Ben Yahia, Mareike Harmsen, An-Vy Tran, Gwendal Gränicher, Boris Fessler, Elmar Heinzle

Integrated Continuous Biomanufacturing III

CHO cells, modeling, perfusion, ATF, segmented linear model

Optimizing Media For Perfusion Combining Predictive Scale-Down Models And Multivariate Approaches, Jochen Sieck, Christian Schultheiss, Pedro Felizardo

Integrated Continuous Biomanufacturing III

Perfusion medium development is complex and time-consuming. Thus, a methodology for efficient and cost effective development leading to a significant reduction of time to market is key in today's competitive market. Success in perfusion medium development depends strongly on the choice of optimization tools. Here a streamlined strategic approach to accentuate perfusion media development is presented by means of predictive scale down models and the application of Design of Experiments (DOE). The purpose of the study was to investigate the impact of 19 amino acids on productivity and growth of a CHO-K1 cell line in perfusion cell culture. A stepwise …

Conference Program, Suzanne Farid, Chetan Goudar, Paula Alves, Veena Warikoo

Integrated Continuous Biomanufacturing III

No abstract provided.

Clarification And Capture Of A Cho-Derived Monoclonal Antibody Through Flocculation And Aex Processes, Rimenys J. Carvalho, Leda Castilho

Integrated Continuous Biomanufacturing III

Flocculants have been widely used in the food and chemical industry, as well as in wastewater clarification. More recently, studies have shown the applicability of these agents in the clarification of mammalian cell suspensions as an alternative e.g. to centrifugation and microfiltration1,2. Flocculants present several advantages such as low cost, process simplicity and facility to run under continuous mode. On the other hand, some flocculants have shown toxicity and thus their total clearance has to be demonstrated. In this work, the cationic flocculants chitosan and poly diallyldimethylammonium chloride (PDADMAC) have been investigated and compared for the clarification of suspensions of …

Development And Application Of Screening Scale Bioreactor Systems For Very High Cell Density Perfusion Of Mammalian Cells, Caijuan Zhan, Hubert Schwarz, Magnus Lundqvist, Atefeh Shokri, Ray Field, Richard Turner, Mathias Uhlén, Johan Rockberg, Veronique Chotteau

Integrated Continuous Biomanufacturing III

The development of cultivation processes can be significantly more efficient and cost effective when performed in parallel screening systems operated at small scale. Although perfusion systems at screening scale have been proposed, none of them enables a real mimic of very high cell density perfusion bioreactors. The latter is however important to maximize the performance of processes at 80, 100 x 106 cells/mL, or higher cell densities, in particular to optimize the nutrient supply and feeding regime. The purpose of the present work was to develop such a system and to apply it to perfusion optimization. Chinese Hamster Ovary cells …

Continuous Gas Processing Without Bubbles Using Thin Liquid Film Bioreactors Containing Biocomposite Biocatalysts, Michael C. Flickinger, Orlin D. Velev, Mark J. Schulte, Adam Wallace, Christopher Duran, Nilay Chakraborty, Michael Guarnieri, Kamelia Boodhoo

Integrated Continuous Biomanufacturing III

Continuous microbial gas processing without bubbles is possible with thin liquid film, plug flow bioreactors. We have demonstrated that power input can be minimized by using a falling liquid film operating under laminar wavy flow conditions (Re <200) in contact with highly concentrated living, non-growing microbes stabilized in a porous biocomposite biocatalyst. This composite materials approach to continuous gas processing can dramatically increase mass transfer rates >100 fold compared to bubble aeration, decrease process volume, significantly decrease gas-liquid mass transfer energy input, decrease water use, and increase secreted product concentration. We have shown that this approach can also increase microbial specific activity for some organisms compared to microbes suspended in liquid media. Paper-based biocomposite biocatalysts provide a rough hydrophilic surface resulting in uniform ~300 μm thick falling liquid films. …

Novel Ir-X Thermal Protection Coatings Designed For Extreme Aerodynamic Heating Environment, Kaili Zhang, Yicong Ye, Li`An Zhu, Shuxin Bai

Ultra-High Temperature Ceramics: Materials for Extreme Environment Applications IV

Due to the rapid evaporation of SiO₂ protective layer, most Si-containing oxidation resistant coatings could not withstand a temperature above 1800℃, which is not enough for hypersonic voyage in upper atmosphere. With a higher melting point (2440℃) and lower oxygen permeability（10^-20g·m^-1·s^-1）, iridium is supposed to be a promising coating material for ultra-high temperature applications. However, Iridium has a low emissivity ε(0.017 for 2.5-25μm) and high recombination coefficient γ(0.64 at 1200℃) of atomic oxygen, resulting in a much higher thermal response compared with the ceramic materials under the same aerodynamic environment. To solve this …

Cost Modeling Of An Integrated, Continuous Downstream Mab Platform, Mark Schofield

Integrated Continuous Biomanufacturing III

Continuous manufacturing offers great potential for reducing costs in biopharmaceutical production through process intensification. However, adoption of new manufacturing methods and technologies is dependent on proof that the risk is worth the reward. Here Pall Life Science’s integrated, continuous downstream mAb platform is modeled in BioSolve Process. Supporting information is generated from a real, PD scale continuous platform. Perfusion and traditional fed batch cell culture processes are also modeled in both stainless steel and single-use forms. The cost associated with these three downstream strategies are compared across a range of bioreactor volumes, titers, and number of batches per year. This …

Conference Program, Jon Binner, Bill Lee

Ultra-High Temperature Ceramics: Materials for Extreme Environment Applications IV

No abstract provided.

Development Of A Scale Down Toolbox For Perfusion Process Development, Jean-Marc Bielser

Integrated Continuous Biomanufacturing III

Background and novelty Merck KGaA has a legacy of perfusion manufacturing processes with several commercial products that were developed in the 90s. These processes were developed for adherent cell systems. Since then, with the advances in media design and the monoclonal antibody driven portfolio, development efforts have been focusing on fed-batch with suspended cells. Recently and as many players in the biomanufacturing industry, Merck is working on the development of an integrated continuous process. To support this effort a process development platform for perfusion cell culture needs to be developed. Process development for fed-batch is clearly defined and scale down …

Novel Concepts For Efficient And Predictable Membrane Separation In Continuous Cell Retention And Downstream Processing, Ulrich Kulozik, Martin Hartinger, Maria Weinberger

Integrated Continuous Biomanufacturing III

Membranes are applied in biotechnological operations for sterile filtration, cell retention during continuous oper-ation, and cell separation as the first step after fermentation. Membranes are also in use in various steps during purification and isolation of certain target components. In all applications the retained substances, mainly bio-genic material such as cells, protein or polysaccharides, form a deposited layer at the membrane surface. This layer acts as an often dominating secondary membrane, which affects the permeability of the whole system more than the membrane as such. Thus, predictability, efficiency and consistency of all affected processing steps are impaired, which might create …