Procedure to Evaluate the Efficiency of Flocculants for the Removal of Dispersed Particles from Plant Extracts

Summary

The design-of-experiments procedure presented here allows the evaluation of different flocculants in terms of their ability to aggregate dispersed particles in plant extracts, thus reducing turbidity and the costs of downstream processing.

Abstract

Plants are important to humans not only because they provide commodities such as food, feed and raw materials, but increasingly because they can be used as manufacturing platforms for added-value products such as biopharmaceuticals. In both cases, liquid plant extracts may need to be clarified to remove particulates. Optimal clarification reduces the costs of filtration and centrifugation by increasing capacity and longevity. This can be achieved by introducing charged polymers known as flocculants, which cross-link dispersed particles to facilitate solid-liquid separation. There are no mechanistic flocculation models for complex mixtures such as plant extracts so empirical models are used instead. Here a design-of-experiments procedure is described that allows the rapid screening of different flocculants, optimizing the clarification of plant extracts and significantly reducing turbidity. The resulting predictive models allow the identification of robust process conditions and sets of polymers with complementary properties, e.g. effective flocculation in extracts with specific conductivities. The results presented for tobacco leaf extracts can easily be adapted to other plant species or tissues and will thus facilitate the development of more cost-effective downstream processes for commodities and plant-derived pharmaceuticals.

Introduction

Plants are widely used to produce food commodities such as fruit juices, but they can also be developed as platforms for the manufacture of higher-value biopharmaceutical products ^1-3. In both cases, downstream processing (DSP) often begins with the extraction of liquids from tissues such as leaves or fruits, followed by the clarification of particle-laden extracts ^4,5. For the manufacture of biopharmaceuticals, the costs of DSP can account for up to 80% of the overall production costs ^6,7 and this in part reflects the high particle burden present in extracts prepared by disruptive methods such as blade-based homogenization ^8,9

Protocol

1. Develop an Adequate Experimental Strategy

1. Identify the environmental and process parameters that are relevant for the flocculation procedure to be established or optimized, i.e. which factors have the strongest effect on flocculation. Typically, there are several such parameters so a DoE approach as recently described ²⁰ is necessary due to the lack of mechanistic models.
   1. Select parameters (factors) based on literature data ¹², prior knowledge and experience with the system. Typical factors include buffer pH, buffer conductivity, incubation time and temperature as well as polymer type and concentration ^15,....

Results

Flocculation of tobacco extract with different polymers

The method described above was successfully used to develop a process for the flocculation of tobacco extracts during the manufacture of a monoclonal antibody (the HIV-neutralizing antibody 2G12) and a fluorescent protein (DsRed) (Figure 1) ¹⁶, and has since been transferred to other proteins including lectins, malaria vaccine candidates and fusi.......

Discussion

The most important aspect to consider when setting up a DoE to characterize particle flocculation is that the design must in principle be able to detect and describe the anticipated or possible effects ^36,38, e.g. the influence of pH, polymer type and polymer concentration ¹⁶. Therefore, it is important to evaluate the fraction of design space (FDS) before starting the actual experiments. The FDS is the fraction of the multidimensional experimental space (covered by the design factors, .......

Materials

List of materials used in this article

Name	Company	Catalog Number	Comments
2100P Portable Turbidimeter	Hach	4650000	Turbidimeter
2G12 antibody	Polymun	AB002	Reference antibody
Biacore T200	GE Healthcare	28-9750-01	SPR device
BP-410	Furh	2632410001	Bag filter
Catiofast VSH	BASF	79002360	Flocculating agent
Centrifuge 5415D	Eppendorf	5424 000.410	Centrifuge
Centrifuge tube 15 ml	Labomedic	2017106	Reaction tube
Centrifuge tube 50 ml self-standing	Labomedic	1110504	Reaction tube
Chitosan	Carl Roth GmbH	5375.1	Flocculating agent
Design-Expert(R) 8	Stat-Ease, Inc.	n.a.	DoE software
Disodium phosphate	Carl Roth GmbH	4984.3	Media component
Ferty 2 Mega	Kammlott	5.220072	Fertilizer
Forma -86C ULT freezer	ThermoFisher	88400	Freezer
Greenhouse	n.a.	n.a.	For plant cultivation
Grodan Rockwool Cubes 10 x 10 cm	Grodan	102446	Rockwool block
HEPES	Carl Roth GmbH	9105.3	Media component
K700P 60D	Pall	5302305	Depth filter layer
KS50P 60D	Pall	B12486	Depth filter layer
Miracloth	Labomedic	475855-1R	Filter cloth
MultiLine Multi 3410 IDS	WTW	WTW_2020	pH meter / conductivity meter
Osram cool white 36 W	Osram	4930440	Light source
Phytotron	Ilka Zell	n.a.	For plant cultivation
Polymin P	BASF	79002360	Flocculating agent
POLYTRON PT 6100 D	Kinematica	11010110	Homogenization device with custom blade tool
Protein A	Life technologies	10-1006	Antibody binding protein
Sodium chloride	Carl Roth GmbH	P029.2	Media component
Synergy HT	BioTek	SIAFRT	Fluorescence plate reader
TRIS	Carl Roth GmbH	4855.3	Media component
Tween-20	Carl Roth GmbH	9127.3	Media component
VelaPad 60	Pall	VP60G03KNH4	Filter housing
Zetasizer Nano ZS	Malvern	ZEN3600	DLS particle size distribution measurement