Fiber chromatographic enabled process intensification increases monoclonal antibody product yield

Abstract The most straightforward method to increase monoclonal antibody (mAb) product yield is to complete the purification process in less steps. Here, three different fiber chromatographic devices were implemented using a holistic approach to intensify the mAb purification process and increase yield. Fiber protein A (proA) chromatography was first investigated, but traditional depth filtration was not sufficient in reducing the contaminant load as the fiber proA device prematurely fouled. Further experimentation revealed that chromatin aggregates were the most likely reason for the fiber fouling. To reduce levels of chromatin aggregates, a chromatographic clarification device (CCD) was incorporated into the process, resulting in single‐stage clarification of harvested cell culture fluid and reduction of DNA levels. The CCD clarified pool was then successfully processed through the fiber proA device, fully realizing the productivity gains that the fiber technology offers. After the proA and viral inactivation neutralization (VIN) hold step, the purification process was further intensified using a novel single‐use fiber‐based polishing anion exchange (AEX) material that is capable of binding both soluble and insoluble contaminants. The three‐stage fiber chromatographic purification process was compared to a legacy five‐step process of dual‐stage depth filtration, bead‐based proA chromatography, post‐VIN depth filtration, and bead‐based AEX chromatography. The overall yield from the five‐step process was 60%, while the fiber chromatographic‐enabled intensified process had an overall yield of 70%. The impurity clearance of DNA and host cell protein (HCP) for both processes were within the regulatory specification (<100 ppm HCP, <1 ppb DNA). For the harvest of a 2000 L cell culture, the intensified process is expected to increase productivity by 2.5‐fold at clarification, 50‐fold at the proA step, and 1.6‐fold in polishing. Relative to the legacy process, the intensified process would reduce buffer use by 1088 L and decrease overall process product mass intensity by 12.6%.