Training Goals Describe the main functions of the manufacturing process Explain how these processes come together to make a product
Master cell Bank Large volume of the original Strain or construct is held under cryogenic preservation. –Usually in 1ml ampoules –Usually in liquid Nitrogen Access is limited to ensure integrity of product.
Working Cell bank Created from the master cell bank for producing batches of product Do not need to continually go to Master cell bank A culture of the strain that makes your product –Continuously checked for efficiency and purity –When parameters are not met then another WCB is made from MCB
Raw Materials Media for the cells Quarantined and tested for quality before being used in manufacturing Many positions exist to ensure the consistency and quality of the Raw Materials chain A list of accepted suppliers is kept A list of accepted substitutes is kept
Process Paperwork Forms, Formulas and SOP are kept current and up to date Small changes may be made but must be proved to not change the process All completed paperwork is kept Typically people with experience in writing or the process are involved
Small Scale Cell culture A sample from the WCB is transferred to successively larger culture tubes Selective Media used to keep strain Check for –Cell density –pH –Temperature –Nutrient concentration Aa, sugar, oxygen, carbon dioxide
Continuously check for Quality Quantity consistency
Large cell Culture Typically a culture is not diluted more than 10x between each fermentation exchange Fermentation process is Batch –Cells are grown until they reach a certain density then transferred en mass to a new vessel with new media
Product Recovery Harvest. This depends on where the product is –In cells Separate the cells out, break open cells and start product purification –In media Separate the cells out, start product purification from the spent media
Purification, Isolation and Viral inactivation TFF or column chromatography is used to separate proteins by size, charge, affinity or hydrophobic. The product will be separated by a complex mixture The product may not be absolutely pure –However if the process is the same the contaminants are validated with the final product
Formulation and pool bulks Formulation –Concentrated protein is formulated to become tolerable to the patients –Ensures that the product is compatible in blood pH 7.1 –Bulk is frozen and stored in freeze/thaw tanks to await filling
Filling Final vials are filled under as sterile conditions as possible
Freeze drying Process increases shelf life and product stability
Product inspection Empty vials and stoppers are checked Filled are checked Also perform a container integrity test
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