Clinical Pharmacology & Biopharmaceutics
Open Access

Refolding; Scale up; Industrial perspective; In vitro; Process development; Additives; PAT; Online monitoring; Simulation

Introduction

One of the most important and widely utilized expressing hosts for innovative medicinal proteins is Escherichia coli. E. coli is currently used to create more than 25% of all heterologous biopharmaceuticals (Walsh, 2018). Its widely recognized genetics, in-depth comprehension of its physiology, and accessibility to an extensive selection of wellcharacterized strains and expression vectors, along with its inexpensive cultivation costs, quick generation time, and ability to produce a substantial amount of recombinant protein(s), make it a desirable host organism for use in both fundamental research and commercial manufacturing [1]. Nevertheless the formation of refractory product complexes known as Inclusion Bodies (IBs) is frequently the consequence of E. coli overproducing recombinant protein. IBs are very stable and provide a relatively pure starting material for protein purification, which are two benefits for the biopharmaceutical industry. Yet, IB-based manufacturing is quite demanding when it comes to setting up the ideal parameters for dissolution and retracting conditions. With this review, we aim to shed light on industrial development of the refolding processes. This work is divided into four sections each focusing on different aspects of protein refolding applied to the production of biopharmaceuticals. In the first section, we highlight fundamental knowledge including historical and theoretical background to refolding and give insights into kinetic modelling. Then, we explain refolding methods relevant for industrial manufacturing and discuss their economic and ecological impact with focus on chemicals (see section 3). Based on experience, we also emphasize and discuss the process parameters that influence process development and scaleup (see section 4). Furthermore, advances using process modelling and computer fluid dynamic simulation to cope with scale-up issues are highlighted. Finally, we bring perspectives to light for industrial refolding (see section 5).The objective in doing this review is to deliver some insight into the industrial advancements made in refolding techniques. The four sections that make up this book each emphasis on one specific aspect of protein refolding as it relates to the synthesis of biopharmaceuticals. In the first section, we describe key information on refolding, including its theoretical and historical context, and we provide an understanding of kinetic models. Next, with an emphasis on chemicals, we describe refolding methodologies pertinent to industrial manufacturing and talk about their effects on the environment and economy (see section 3). We also highlight and go over the process qualities that affect process development and scale-up, based on experience (see section 4). Additionally, developments in computer fluid dynamic simulation and process modeling to address scale-up challenges are pointed out. Lastly, we provide light on prospects for industrial [2,3].

Discussion

Protein refolding is a fundamental process within the modern biopharmaceutical industry. It is a critical bioprocessing technique that involves the transformation of biologically active, but often misfolded or denatured proteins, into their native, functional conformation. The significance of protein refolding in the biopharmaceutical industry cannot be overstated, as it plays a pivotal role in the production of biologic drugs, including monoclonal antibodies, enzymes, and other therapeutic proteins. In this discussion, we will explore the importance, challenges, and advancements related to protein refolding in the contemporary biopharmaceutical landscape [4].

Importance of protein refolding

Enhancing biotherapeutic production: Many biologic drugs are produced in microbial or cell culture systems. However, the conditions of these systems may lead to the expression of proteins in an insoluble and non-functional form. Protein refolding allows these denatured or misfolded proteins to regain their biological activity, making them suitable for pharmaceutical use [5].

Minimizing production costs: In the competitive biopharmaceutical market, cost-effectiveness is paramount. Protein refolding can salvage misfolded proteins that would otherwise be discarded, reducing waste and improving overall production efficiency.

Improving drug efficacy: Properly folded proteins are crucial for the efficacy and safety of biologic drugs. Protein refolding ensures that the final product is biologically active and compatible with the human body [6].

Challenges in protein refolding

Aggregation and misfolding: During the refolding process, proteins can aggregate, form non-native disulphide bonds, or misfold, which can lead to product loss and reduced efficacy. Managing these challenges is a critical aspect of protein refolding.

Optimization: Refolding conditions must be carefully optimized for each protein, which can be a time-consuming and resourceintensive process [7]. The choice of refolding buffers, redox conditions, temperature, and the presence of specific additives all influence the success of the refolding process.

Scale-up: Scaling up protein refolding from laboratory to industrial scales presents technical challenges. Ensuring uniformity and consistency across large volumes is crucial to maintaining product quality.

Advancements in protein refolding

High-throughput screening: The development of high-throughput screening techniques has significantly expedited the optimization of refolding conditions. This allows researchers to screen various parameters simultaneously, accelerating the process [8].

Chaperones and co-factors: The use of molecular chaperones and co-factors, which assist in correct protein folding, has shown promise in improving refolding yields and minimizing aggregation.

Integrated process design: Many biopharmaceutical companies are integrating protein refolding into their overall bioprocess design. This approach considers refolding from the outset, optimizing upstream and downstream processes for efficient protein recovery and refolding.

Future outlook

Protein refolding is poised to remain a critical bioprocessing technique in the biopharmaceutical industry. As new biologic drugs and biosimilars continue to emerge, the demand for efficient and effective refolding methods will only grow. The integration of advanced technologies, such as artificial intelligence and machine learning, in process optimization and the development of novel refolding agents, is likely to further improve the success and scalability of this essential step in biopharmaceutical production.protein refolding stands as a linchpin in the biopharmaceutical industry, ensuring the production of safe and effective biologic drugs [9 ,10 ]. As technology and knowledge in this field advance, the industry will continue to benefit from more efficient and cost-effective protein refolding processes, ultimately improving patient outcomes and the accessibility of biologic therapies.

Conclusion

In the contemporary biopharmaceutical sector, protein refolding has emerged as a pivotal and ever-evolving process. This essential bioprocessing technique addresses the challenges and opportunities presented by the production of biologic drugs. As we delve into the occlusion on this subject, we find several key aspects that reflect its significance, trends, and ongoing innovations.

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