A continuous supermacroporous monolithic chromatographic matrix has been characterized using a capillary model, experimental breakthrough curves, and pressure drop experiments. The model describes the convective flow and its dispersive mixing effects, mass transfer resistance, pore size distribution, and the adsorption behavior of the monolithic matrix. It is possible to determine an effective pore size distribution by fitting the capillary model to experimental breakthrough curves and pressure drop experiments. The model is able to describe the flow rate dependence of the experimental breakthrough curves. Mass transport resistance was due to: (i) dispersive mixing effects in the convective flow in the pores; and (ii) slow diffusion in the stagnant film covering the surface within each pore, under adsorption conditions. The monolithic matrix can be described by a very narrow pore size distribution, illustrating one of the advantages of the gel. A broader pore size distribution results in increased band broadening. This can be studied easily using the model developed in this investigation.

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A continuous integrated bioprocess available from the earliest stages of process development allows for an easier, more efficient and faster development and characterization of an integrated process as well as production of small-scale drug candidates. The process presented in this article is a proof-of-concept of a continuous end-to-end monoclonal antibody production platform at a very small scale based on a 200 ml alternating tangential flow filtration perfusion bioreactor, integrated with the purification process with a model-based design and control. The downstream process, consisting of a periodic twin-column protein A capture, a virus inactivation, a CEX column and an AEX column, was compactly implemented in a single chromatography system, with a purification time of less than 4 hr. Monoclonal antibodies were produced for 17 days in a high cell density perfusion culture of CHO cells with titers up to 1.0 mg/ml. A digital twin of the downstream process was created by modelling all the chromatography steps. These models were used for real-time decision making by the implementation of control strategies to automatize and optimize the operation of the process. A consistent glycosylation pattern of the purified product was ensured by the steady state operation of the process. Regarding the removal of impurities, at least a 4-log reduction in the HCP levels was achieved. The recovery yield was up to 60%, and a maximum productivity of 0.8 mg/ml/day of purified product was obtained.

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