Integrated process model for the prediction of biopharmaceutical manufacturing chromatography and adjustment steps

A fundamental process understanding of an entire downstream process is essential for achieving and maintaining the high-quality standards demanded for biopharmaceutical drugs. A holistic process model based on mechanistic insights could support process development by identifying dependencies between process parameters and critical quality attributes across unit operations to design a holistic control strategy. In this study, state-of-the-art mechanistic models were calibrated and validated as digital representations of a biopharmaceutical manufacturing process. The polishing ion exchange chromatography steps (Q Sepharose FF, Poros 50 HS) were described by a transport-dispersive model combined with a colloidal particle adsorption model. The elution behavior of four size variants was analyzed and included in the model. Titration curves of pH adjustments were simulated using a mean-field approach considering interactions between the protein of interest and other ions in solution. By including adjustment steps the important process control inputs ionic strength, dilution, and pH were integrated. The final process model was capable to predict online and offline data at manufacturing scale. Process variations at manufacturing scale of 94 runs were adequately reproduced by the model. Furthermore, the process robustness against a 20% input variation of concentration, size variant and ion composition, volume, and pH could be confirmed with the model. The presented model demonstrates the potential of the integrated approach for predicting manufacturing process performance across scales and operating units.