Definitive benchmarking of DDA and DIA for host cell protein analysis on the Orbitrap Astral in a regulatory-aligned framework

Host cell proteins (HCPs) are critical quality attributes in biotherapeutics and require accurate, protein-resolved quantification beyond the coverage limits of immunoassays. The Orbitrap Astral mass spectrometer was evaluated for label-free HCP analysis through a direct comparison of data-dependent acquisition (DDA, Top80) and data-independent acquisition (DIA, 4 m/z windows). Deterministic protein inference was implemented to ensure invariant protein grouping across datasets and software versions. Quantification was anchored using a whole-proteome stable isotope–labeled HCP standard, with identification error controlled through empirical false discovery proportion estimation. Both acquisition modes quantified total HCP content with high linearity (R ² > 0.99) and total error within ±30% acceptance limits across a seven-point spike-in series. DIA achieved greater analytical depth, identifying 45% more proteins and 68% more peptides than DDA, with substantially reduced missingness. Protein-level fold-change behavior was evaluated using hierarchical Bayesian regression, with slopes centered near unity for DIA and systematic compression observed for DDA. Abundance-stratified resampling analysis demonstrated trueness and precision across the dynamic range and defined lower limits of quantification of approximately 0.6 ppm for DIA and 1.6 ppm for DDA. Both acquisition strategies accurately report global HCP content, while DIA provides improved coverage, fold-change fidelity, and sensitivity for low-abundance impurities. This study demonstrates that untargeted MS-based HCP measurements can be analytically qualified for use in regulated biopharmaceutical settings.