Model-based control of titer and glycosylation in fed-batch mAb production: Modeling and control system development

Therapeutic monoclonal antibodies (mAbs) are typically manufactured using mammalian cell cultures in fed-batch bioreactors, with increasing emphasis on meeting productivity and product quality attribute targets that depend strongly on such process variables as nutrient feed rates and bioreactor operating conditions. In this article, we identify, categorize, and address the challenges of achieving both productivity and product quality goals simultaneously, by developing a multivariable, model-based control system that can satisfy multiple production objectives in a fed-batch cell culture process. Here, we discuss model development and present theoretical concepts of observability and controllability that are essential to understanding and handling effectively these intrinsic challenges. Subsequently, we evaluate via simulation the performance of the outer-loop model predictive control and demonstrate the overall capability to satisfy complex production objectives in a laboratory scale bioreactor, as a first step toward the ultimate goal of creating an advanced control system for fed-batch mAb manufacturing processes.