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In-house capillary column packing is highly popular in large laboratories working on multiple independent projects. However, a common packing method from a low concentration sorbent suspension has major limitations in the speed and is unable to produce long UHPLC columns.
FlashPack is a modification of the standard packing procedure which makes packing from a very high sorbent concentration possible. The theoretical basis of the method lies in the continuous sorbent cupola destabilization at the column entrance for the whole packing duration. The latter is technically achieved by column entrance being continuously hit with a magnet bar. The method of cupola destabilization is intentionally developed to have the packing setup completely similar to the common packing process, but the trick of FlashPack lies in the details of the sorbent slurry preparation, capillary positioning, and magnet bar usage during the packing process.
The sorbent slurry is prepared as a sediment sorbent layer in a large solvent volume. It is interesting that the pressure bomb-based packing does not require the same packing conditions for column to column. In FlashPack, we never know the exact sorbent slurry concentration around the column entrance. It is impossible to measure and control exactly, as it also changes during the packing process. However, the final columns are still very reproducible4 irrespective of how the packing was achieved.
The basis for the fast packing lies in the efficient sorbent cupola destabilization. For this reason, it is important to control sorbent entering the capillary and to maintain the optimal cupola destabilization conditions throughout the whole packing duration. There are several possible issues that might prevent efficient sorbent delivery. Some examples of these are sorbent layer resuspension by fast magnetic bar rotation, inefficient cupola destabilization due to either wrong relative capillary to the magnet bar positioning or too slow magnet bar rotation. The issues themselves and how they are to be addressed are discussed in detail in the protocol section.
After the column is packed, the major column parameter to check is the column backpressure. The pressure values listed in Table 5 provides a reference point to what is expected for one of the popular sub 2 µm bead size sorbent-ReproSil PUR C18 AQ (1.9 µm). At the same time, additional backpressure might be added by the frit or a too narrowly pulled emitter and one should constantly monitor for that. If packing is done into a pulled emitter, we still suggest measuring the expected column backpressure for the particular sorbent in use by packing fritted capillaries first, and then to see whether the self-assembling frit adds too much. For any high-pressure issues, use the guidelines provided in Table 1 to pinpoint the problem.
In our experience, a packed column without discolorations, gaps, and with the proper backpressure works in 100% of the cases and gives the separation quality close to what can be expected from the column length and sorbent characteristics. A column with discolorations is not guaranteed to work properly but can still give satisfactory results.
Most of the time, if there are any problems with the separation quality, they do not come from the column itself, but rather from other parts of the separation system, namely, pumps, solvents, or connections. Especially potentially harmful is any post-column connections. Bad connection with a dead volume between the emitter and the fritted column leads to major peak broadening and tailing due to very low flow rates in capillary chromatography.
One more important issue specific to the FlashPack approach is that it uses a lot of expensive sorbents in a working sorbent slurry vial. Please remember, that the sorbent slurry in FlashPack is intended for multiple use. Take care of the sorbent. Avoid unnecessary magnet bar stirring to reduce sorbent grinding-remember to stop the rotation as soon as the packing is finished. And do not leave the open sorbent vial in the pressure bomb to avoid sorbent drying. Though the sorbent can still be used after that, it takes time to remake the sorbent slurry.
The method works equally well for both fritted capillaries and pulled-emitter capillaries. The FlashPack principle increases the packing rate for capillary IDs from 20 to 250 µm (smaller and larger were not tested). It is also applicable to all the sorbents, both fully and superficially porous, we could test (reflecting that the sorbent cupola formation in high sorbent slurry concentration is not limited specifically to RP sorbents). Besides, solvent parameters clearly affect the packing according to their physical and chemical characteristics. For example, less viscous acetone gives even higher packing rate than methanol at the same packing pressure. However, it is also less polar than methanol and reduces sorbent particles sticking to each other. The effect by itself prevents sorbent cupola formation in the beginning of the packing when the flowrate is still high. However, reduction in sorbent particle interaction also leads to less reliable self-assembling frit formation and more frequent pulled-end blocking during the packing. So, while acetone is better for packing of fritted capillaries, it is less suitable for pulled-emitter capillaries, with the methanol as a slurry solvent being slower but suitable for both types of ending. Packing from hexane or dichloromethane (DCM) are extreme cases of switching to acetone from methanol: they are even less polar, so they prevent sorbent cupola formation completely, however they are not fit for pulled-emitter packing at all. Besides, it was noted that extremely low DCM polarity leads to sorbent particles sticking to the internal capillary wall and making a thick layer on it. The layer thickness gradually grows and random local blocks form resulting in the column packed in several parts separated by regions without sorbent. Such effect was observed for C18 Peptide Aeris sorbent.
Another observed issue was YMC Triart C18 sorbent not being suspended in methanol properly, but to form some sort of flakes. However, that does not prevent it from getting packed with the FlashPack and giving very decent separation efficiency (unpublished data). Thus, while not being optimal for some cases, methanol was the most universal solvent to work for all the tested sorbents and columns. It is necessary to mention that we did not yet analyze how different slurry solvents affect column separation efficiency. At the same time, the efficiency of columns packed from methanol is already completely equal to commercial columns for the same sorbents4.
FlashPack is not the only existing approach to improve the packing rate of UHPLC columns. Fast packing from high sorbent slurry concentration is also possible with the use of ultra-high pressure packing7. The advantage of FlashPack is that it is much simpler as it does not require special ultra-high pressure pumps and pressure bombs for sorbent delivery and capillary connections. At the same time, it was demonstrated that the columns packed at extreme pressures can have separation efficiency higher than lower pressure packed columns17. And while FlashPack produces columns identical to commercial ones used in the comparison4, for which we do not know the packing method, it was not yet tested how FlashPack columns stand against ultra-high pressure packed columns.
In summary, the described FlashPack method can be easily adapted to the existing packing protocol in the laboratory with some adjustments made to the protocol, while the setup stays completely the same. It speeds up the HPLC capillary column packing to minutes' time and allows production of long UHP capillary columns, which is plainly impossible with the standard packing procedure. The overall economy in the time and money for the laboratory by application of the FlashPack approach can be counted in tens of thousands of Euros per year. Additionally, ability to produce UHP capillary columns locally opens the possibilities for experiment customization impossible with the available commercial products.