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Although ultrafiltration is currently used for the concentration and formulation of nearly all biotherapeutics, obtaining the very high target concentrations for monoclonal antibody products is challenging. The objective of this work was to examine the effects of the membrane module design and buffer conditions on both the filtrate flux and maximum achievable protein concentration during the ultrafiltration of highly concentrated monoclonal antibody solutions. Experimental data were obtained using both hollow fiber and screened cassettes and in the presence of specific excipients that are known to alter the solution viscosity. Data were compared with predictions of a recently developed model that accounts for the complex thermodynamic and hydrodynamic behavior in these systems, including the effects of back-filtration arising from the large pressure drop through the module due to the high viscosity of the concentrated antibody solutions. Model calculations were in good agreement with experimental data in hollow fiber modules with very different fiber length and in screened cassettes having different screen geometries. These results provide important insights into the key factors controlling the filtrate flux and maximum achievable protein concentration during ultrafiltration of highly concentrated antibody solutions as well as a framework for the development of enhanced ultrafiltration processes for this application. © 2016 American Institute of Chemical Engineers Biotechnol. Prog., 32:692-701, 2016.

The behavior of monoclonal antibodies at high concentrations is important in downstream processing, drug formulation, and drug delivery. The objective of this study was to evaluate the osmotic pressure of a highly purified monoclonal antibody at concentrations up to 250 g/L over a range of pH and ionic strength, and in the presence of specific excipients, using membrane osmometry. Independent measurements of the second virial coefficient were obtained using self-interaction chromatography, and the net protein charge was evaluated using electrophoretic light scattering. The osmotic pressure at pH 5 and low ionic strength was >50 kPa for antibody concentrations above 200 g/L. The second virial coefficients determined from the oncotic pressure (after subtracting the Donnan contribution) were in good qualitative agreement with those determined by self-interaction chromatography. The second virial coefficient decreased with increasing ionic strength and increasing pH due to the reduction in intermolecular electrostatic repulsion. The third virial coefficient was negative under all conditions, suggesting that multi-body interactions in this system are attractive. The virial coefficients were essentially unaffected by addition of sucrose or proline. These results have important implications for the analysis of protein-protein interactions in downstream processing at high protein concentrations.

Self-interaction chromatography (SIC) is a well-established method for studying protein-protein interactions. The second virial coefficient in SIC is evaluated directly from the measured retention coefficient for the protein using a column packed with resin on which the same protein has been immobilized on the pore surface. One of the challenges in determining the retention coefficient is the evaluation of the dead volume, which is the retention volume that would be measured for a noninteracting solute with the same effective size as the protein of interest. Previous studies of SIC have used a "dead column" packed with the same resin but without the immobilized protein to evaluate the dead volume, but this creates several experimental and theoretical challenges. We have developed a new approach using a dextran standard with effective size equal to that of the protein (as determined by size exclusion chromatography). The second virial coefficient was evaluated for a monoclonal antibody over a range of buffer conditions using this new approach. The data were in good agreement with independent measurements obtained by membrane osmometry under conditions dominated by repulsive interactions. The simplicity and accuracy of this method should facilitate the use of self-interaction chromatography for quantifying protein-protein interactions.

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