Combinatorial analysis of host-leader-Fab can greatly improve integrated
process design
Abstract
Bioprocess development and optimization is a challenging, costly, and
time-consuming effort. In this multidisciplinary task, upstream
processing (USP) and downstream processing (DSP) are conventionally
considered distinct disciplines. This consideration fosters “one-way”
optimization without considering interdependencies between unit
operations; thus, the full potential of the process chain cannot be
achieved. Therefore, it is necessary to fully integrate USP and DSP
process development to provide balanced biotechnological production
processes. The aim of the present study was to investigate how different
host/leader/antigen binding fragment (Fab) combinations in E. coli
expression systems influence USP and primary recovery performance and
the final product quality. We ran identical fed-batch cultivations with
16 different expression clones to study growth and product formation
kinetics, as well as centrifugation efficiency, viscosity, extracellular
DNA, and endotoxin content, which are important parameters in DSP. We
observed a severe influence on cell growth, product titer, extracellular
product, and cell lysis, accompanied by a significant impact on the
analyzed parameters of DSP performance. Our results provide the basis
for establishing integrated process development considering
interdependencies between USP and DSP. These interdependencies need to
be understood for rational decision-making and efficient process
development.