Quality by Design BERNT NILSSON 1, AND ARNE STABY 1,2 CHEMICAL ENGINEERING, LUND UNIVERSITY, SWEDEN 2 NOVO NORDISK, GENTOFTE, DENMARK
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1 Quality by Design BERNT NILSSON 1, AND ARNE STABY 1,2 1 CHEMICAL ENGINEERING, LUND UNIVERSITY, SWEDEN 2 NOVO NORDISK, GENTOFTE, DENMARK
2 Innehåll PICLU projekt 3: Quality by design and control Biofarmaceuptisk industri och Quality by Design Matematisk modellering vid Novo Nordisk Case story Samarbetet mellan LU och NN Results
3 Organisation PICLU etapp2 Board PIC:lub Management Group Centre Leader Project 1 Optimal transitions Project 2 Disturbance management Project 3 Quality by Design and Control PIC-LU school Project 4 Flexible design Project 5 Fed-batch control Project opic
4 Organisation PICLU etapp2 Projekt 3 Quality by Board Design and Control PIC:lub A) Modellbaserad produktionsdesign Management Group Centre Leader Project 1 Optimal transitions B) Modellering av proteinseparation Project 2 Disturbance management Project 3 Quality by Design and Control C) Tekniköverföring Verktyg, metodik & kurser PIC-LU school Project 4 Flexible design Project 5 Fed-batch control Project opic
5 PICLu - Novo Nordisk Collaboration May 20-21, 2014 Slide no 5 Novo Nordisk at a glance More than 40,000 employees in 75 countries A world leader in diabetes care since 1923 Leading position in: Haemostasis management Growth hormone therapy Hormone replacement therapy Total net turnover (2013): ~84 billion DKK R&D spent (2013): ~12 billion DKK Committed to financial, environmental and social results
6 Biopharmaceutical production UPSTREAM cultivation DOWNSTREAM purification FORMULATION packaging Regulatory Limitations Batch Manual work
7 PICLu - Novo Nordisk Collaboration May 20-21, 2014 Slide no 7 QbD Governance / Risk Assessment Patient Voice of the customer Product Profile Quality Target Product Profile Risk assessment Product List of CQA s Process Process parameters Process model Design space Facility Control Strategy Start with the end in mind
8 PICLu - Novo Nordisk Collaboration May 20-21, 2014 Slide no 8 Process Understanding Extent of Knowledge Mechanistic models Advanced statistical models / PCA etc. Simple statistical models / DoE OPAT (One parameter at a time) Preliminary experimentation Experience from other projects Theoretical knowledge
9 Mathematical Modelling Unit Operations Chromatography Ion-Exchange (IEC) mabs, Haemostasis, insulin, GLP-1 Size Exclusion (SEC) Haemostasis Hydrophobic (RP/HIC) - Insulin Multi-Modal (MM) Hæmostasis, Fab fragments Affinity (AC) Haemostasis Scaling All Chemical Reactions/Modifications PEG-modifications Haemostasis Acylations Insulin, GLP-1 Enzymatic reactions etc. Hæmostasis, hgh, Diabetes Formulation Stability All (e.g. mabs, Insulin ) Membrane Processes Filtration and virus filtration hgh, Vira Other Opportunities PICLu - Novo Nordisk Collaboration May 20-21, 2014 Slide no 9 Centrifugation, Crystallisation, Precipitation, Freeze/Spray-Drying
10 PICLu - Novo Nordisk Collaboration May 20-21, 2014 Slide no 10 Mathematical Modeling - Use Process and analytical development Process optimisation Process validation/challenge and critical parameters Plant design Process control (PAT) Trouble shooting and deviation handling Process understanding and Design Space Scaling of chromatography
11 PICLu - Novo Nordisk Collaboration May 20-21, 2014 Slide no 11 Case Story: IEC Process, Trouble shooting Starting material: 81% C, 8% A, 2% B and 9% D Experiment Simulation C Non protein peak Absorbance A B D Salt concentration Dimensionless volume Simulation and standard process compared
12 PICLu - Novo Nordisk Collaboration May 20-21, 2014 Slide no 12 Case Story: Reaction on previous step went wrong: Starting material: 39% C, 1% A, 1% B and 59% D Simulated chromatogram C D OD A B Salt concentration [M] CV Standard method process A
13 PICLu - Novo Nordisk Collaboration May 20-21, 2014 Slide no 13 Case Story: New in-silico process D OD Launch Pilot plant Plant Simulering Simulation C A B CV Simulation and process compared
14 PICLu - Novo Nordisk Collaboration May 20-21, 2014 Slide no 14 Case Story: Results After last step Purity [%] D [%] B [%] Yield [%] Other Standard method* Modified method ** 1.67 Comparison between new and standard method * Mean of all batches ** Loss due to low load (loading on total polypeptide concentration) More pure than normal Lower yield The batch was released
15 PICLu - Novo Nordisk Collaboration May 20-21, 2014 Slide no 15 Other Applications: Simulated elution profile Absorbance Salt conc. Set point
16 PICLu - Novo Nordisk Collaboration May 20-21, 2014 Slide no 16 Other Applications: Resin Properties Vendor states the ionic capacity varies -10%/+20% Simulation with different ionic capacities Low High
17 Personer och delprojekt novo LU annan finansiär novo SSF SSF novo 2015 SSF novo PiiA
18 Samarbetsprojekt Modellbaserad design Gemensam problemformulering Problemlösning, LU Tekniköverföring, NN Modellering Gemensam problemformulering Experimentella studier, NN Modellering, LU
19 Aktiva Doktorer och doktorander Marcus Degerman (PhD , postdoc ) Design of robust preparative chromatography Karin Westerberg ( ) Modeling of quality and safety in biopharmaceutical production process Niklas Borg ( ) Modeling and calibration of preparative chromatography Frida Ojala ( ) Modeling of protein aggregation Karolina Johansson ( ) Modeling of hydrophobic interactions Anton Sellberg ( ) HiQ Novo Nordisk Softhouse Amgen
20 Examensarbeten inom projekt 3 Ca 50% industrirelaterade 1) Niklas Borg (2008), Fast model calibration 2) Fredrik Nielsen (2009), Optimization of ion-exchange (Novo) 3) Niklas Andersson (2009), Simulation of continuous chromatography 4) Marcus Almqvist (2009), Modeling and calibration using gproms 5) Mikael Edmundsson (2011), Metodik för modellkalibrering 6) Karolina Johansson (2011), Flexible pooling (Pfizer) 7) Alex Olsson (2012), Calibration and optimization (Novo) 8) Peter Fransson (2012), Robust optimization 9) Owais Sulehria (2012), Data to Knowledge 10)Bruno Otero Garcia (2013), Optimization of two connected steps (Novo) 11)Anton Sellberg (2013), Design space 12)Emil Håkansson (2013), Simulated moving bed (ETH,Novartis) 13)André Bugge (pågår), Optimization of integrated separation (Novo)
21 Publikationer i tidskrifter 1. F. Ojala, M. Degerman, T. Budde Hansen, E. Broberg Hansen, B. Nilsson: Prediction of IgG1 aggregation in solution. Biotechnology journal, (Online April 24, 2014), B. Otero, M. Degerman, T. Hansen, E. Hansen, B. Nilsson: Model-based design and integration of a two-step biopharmaceutical production process. Bioprocess and biosystems engineering, (Online March 2014), N. Borg, K. Westerberg, N. Andersson, E. von Lieres, B. Nilsson: 4 (av 10) artiklar tillsammans med Novo Nordisk Effects of uncertainties in experimental conditions on the estimation of adsorption model parameters in preparative chromatography Computers & Chemical Engineering, , K. Westerberg, E. Broberg-Hansen, L. Sejergaard, B. Nilsson: Model-based risk analysis of coupled process steps. Biotechnology and bioengineering, 110(9) , K. Westerberg, E. Broberg Hansen, M. Degerman, T. Budde Hansen, B. Nilsson: Model-Based Process Challenge of an Industrial Ion-Exchange Chromatography Step Chemical Engineering & Technology, 35(1) , K. Westerberg, N. Borg, N. Andersson, B. Nilsson: Supporting Design and Control of a Reversed-Phase Chromatography Step by Mechanistic Modeling Chemical Engineering & Technology, 35(1) , K. Westerberg, M. Degerman, B. Nilsson: Pooling control in variable preparative chromatography processes. Bioprocess and biosystems engineering, , M. Degerman, K. Westerberg, B. Nilsson: Determining Critical Process Parameters and Process Robustness in Preparative Chromatography - A Model-Based Approach Chemical Engineering & Technology, 32(6) , M. Degerman, K. Westerberg, B. Nilsson: A Model-Based Approach to Determine the Design Space of Preparative Chromatography Chemical Engineering & Technology, 32(8) , M. Degerman, N. Jakobsson, B. Nilsson: Designing robust preparative purification processes with high performance Chemical Engineering & Technology, 31(6) , två under review ytterligare två manuskript
22 Sammanfattning Samarbetet mellan LU och Novo Nordisk Gemensamma problemformuleringar Mycket arbete av doktorander vid Novo Nordisk Resultat överförs till Novo Nordisk. Novo fortsätter utvecklingen för industrianpassning Gemensamma publikationer Novo har haft möjligheten att sätt in resurser, egna och vid LU. Projektet har karaktäriserats av Långsiktig och ömsesidig kompetensutveckling
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