Spherical nanoparticles can be used as non-penetrating tracers to determine the extra-particle void volume in packed-bed chromatography columns

•Conductivities >100 mS cm−1 can suppress tracer-resin interactions.•Inter-particle porosities seem to be as low as 0.2 for Q Sepharose HP.•Linear flow rate during column packing appears to alter apparent pore size distribution. The optimization of downstream processing in silico can accelerate bioprocess development by limiting experiments to the most promising separation conditions that have been identified using chromatography models. Such models describe protein binding and mass transport in packed-bed columns and thus require precise knowledge about the columns and the resins they contain. One important set of properties is the resin porosities, often determined using combinations of penetrating and non-penetrating tracers. However, the former can be disproportionately small, providing data of limited practical relevance, and the latter can undergo unwanted interactions with the resin, interfering with porosity calculations. Here we characterize and minimize the interactions of three novel hard-sphere non-penetrating tracers with the model resin Q Sepharose HP under various conditions and determine the corresponding inter-particle porosities. We found that conductivities > 100 mS cm−1 were necessary to suppress tracer–resin interactions despite them sharing the same surface charge. We combined these data with those from proteins studied under non-binding conditions, which can be used as authentic penetrating tracers, to determine both the intra-particle and total porosities. Furthermore, we found that the inter-particle porosity was below the theoretical limit of dense sphere packing (25.95%) and provide experimental data showing that the discrepancy is caused by resin particle deformation during the packing of columns under pressure.