achieving intensification and flexibility in virus purification with … · 2017. 10. 9. ·...
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DRAFT
Achieving intensification and flexibility in virus purification with state-of-the-art chromatography tools
Authors:MochaoZhao,MelissaVandersluis
Abstract Vaccinesgreatlyreducedisease,disability,death,andinequityworldwide.TheyevenpermittedtotaleradicationofSmallPox.However,mostvaccinesavailabletodayarestillmanufacturedwiththeoriginalprocesstechnologiesincomplexandcapital-intensivefacilities.Thelabor-intensive,low-yieldandlowthroughputprocesses,andthelackofmanufacturingflexibility,diminishaffordabilityfordevelopingcountries,forcingmanufacturerstoaddresstheproblembysupplyingthesemarketswithsubsidizedproductsand/ornon-sustainableprices.Advancementsinvaccinesmanufacturingwouldbenefitbothglobalhealthandtheindustry.
Needs for better processes Viruses,widelyknownfortheirprophylacticuseasvaccinesinthebiotechnologyworld,arealsogainingpopularityintherapeuticfields.Viralvectorsarebeingusedasdeliveryvehiclesinmorethantwo-thirdsofgenetherapyclinicaltrials.Oncolyticvirotherapies,with2commerciallyavailableand48currentlyinclinicalpipelines,representthenextpotentialbreakthroughtherapeuticmodalitiesforcancertreatment.However,despiteoftheprovensuccessofviralvaccinesortherapeuticpromisesofemerginggeneandviraltherapies,therearestillmultiplebarrierstoextendingtheaccesstotheseproductsaroundtheworld.Thelackofbreakthroughsinmanufacturingtechnologyisoneofthem.Whilecurrentviralvaccinemanufacturingmethodsareinsomecaseseffectiveforsmall-scaleproduction,thesemethodsshareseveralcriticalshortcomings:theyaretooslow,toocomplicated,lackrobustness,andrequireexpensivespecializedfacilitiesandequipmentforlarge-scaleproduction.Thelackofmodern,efficientproductiontechnologyisrestrictingprogressonseveralfronts(bb).Duetohighcapitalanddevelopmentcostsandthelowproductprofitabilitycreatedbyhighmanufacturingcostsandlimitsonproductpricing,nichevaccineopportunitiesareseenasfinanciallyrisky,withlowprobabilityofbreakevenorprofitability.Promisingnewvaccinesdevelopedfromlargevirusesremainundevelopedduetothelackofviableprocessingcapabilitiestohandlethelargeviruses.Likewise,progressindevelopmentofoncolyticvirotherapiesislimitedbecauselargedosesofhighlypurifiedmaterialarerequired,butefficientmanufacturingprocessesarelacking(cc).Meanwhile,viralvectorshavebeenwidelyexploitedforgenedeliveryapproaches,furtherincreasingthedemandforlarge-scaleproductionofhighlypurifiedviralmaterial.Inallcases,progressisdirectlylimitedbygapsinmanufacturingtechnologies.
The Solution Resides in Innovation State-of-the-artvirusproductionprocessesandtechnologiesholdthepromiseofenablingproductionofnewvaccinesaswellasviralvectorplatformsforotherapplications,whilealsostreamliningandstrengtheningcurrentprocesses.Thesetechnologies,manyofwhicharebeingusedsuccessfullyinmodernbiotherapeuticsmanufacturing,canalsocreatedramaticcostandproductivityimprovementsforvirusmanufacturing(dd).
Anewgenerationofhigh-productivity,disposableprocessingtechnologiesgreatlysimplifyproductionarchitectureandreducefacilityfootprint.Inupstreamprocesses,stainlesssteelbioreactorsandmicro-carriersarebeingreplacedbymicrofibers(ex.iCELLis)thatcanachievecelldensityupto150millioncells/mL(ee,ff).Thenextgenerationfixed-bedcontinuousperfusionbioreactorsdevelopedbyUnivercellscanreachhighcelldensitywith50-70%volumereduction(gg).Withreducedbioreactorsize,mediausageaswellasfacilitydesignandcostcanbesignificantlyimproved.Indownstreamprocesses,advancementsinchromatographytechnologysuchasaffinitymediaspecificallyforviruscaptureandsingle-usehigh-productivitymembranechromatographyofferseveralperformanceandcostadvantagesoverthetraditionalpurificationtechniques.Withapowerfulcapturetool,theprocessarchitecturecanbesimplifiedwithfewerunitoperationsyetstillmaintaincriticalqualityattributes,leadingtosignificantcostsavingsaslessspace,utilities,andlabourarerequired.Single-use,high-throughputmembranecolumnsfurtherreducevalidation,cleaning,andstorage-relatedexpenseswhileimprovingproductivityviahighbindingcapacitiesandfastflowrates.Theeaseofscalabilityofchromatographycolumnsalsoenablessmoothproductiontransitionfromthelabbenchtothemanufacturingsite.Whencombined,newsingle-use,highproductivityprocesstechnologiescanovercomethemanufacturingconstraintsthathavelimitedmorewidespreadproliferationofvaccineuse,whilealsoopeningdoorstopromisingnewvaccinesandviral-basedtreatments.Replacingtraditionallarge,inflexibleandcomplexstainlesssteeloperationswithsmallfootprintfacilitiesenablesquickbatch-to-batchturnoverandrapidchangeoverbetweendifferentproducts.Thesmaller,morecompactprocessarchitectureallowsvirusestobeprocessedinsmallfacilitiesacrossmultiplegeographies,withthepromiseofeventuallyplacingproductionproximatetothepointofcare.Inaddition,simplified,smallfootprintprocessesenableflexibleprocessingwhichallowanewlevelofagilityforrespondingtochangesindemandandhandlingmulti-productmanufacturing.
Acornerstoneofthenewpurificationtechnologiesishighproductivitymembranechromatography,astate-of-the-arttechnologythatcombineshighbindingcapacityandrapidmasstransfertoimprovepurificationthroughput.High-productivitymembranechromatographywithcommonmodalities(ex.cationexchange,anionexchange,ormixed-mode)havebeenavailableandimplementedinmanybiotherapeuticsmanufacturingprocess.Insomecases,suchmembraneswithhighselectivitycandeliversufficientpuritylevelinasinglestep,makingsingle-steppurificationaviablesolution.Inaddition,affinitychromatographycanbecombinedwithmembranechromatographytoreplacemanypurificationunitsforhighlyintensifiedandproductiveprocesses.Threecasesstudiesofprocessintensificationusingstate-of-the-artchromatographytoolsarediscussedbelow.
Case Study 1: Newcastle Disease Virus single step purification using HD-Q Inthisexample,engineeredNewcastleDiseaseVirus(NDV)producedforoncolyticvirotherapyisamplifiedinembryonatedeggsandpurifiedfromtheallantoicfluid.Theconventionalcentrifugation-
basedpurificationmethodresultsinlowvirusrecovery(12%-35%)andonlypartialremovalofimpurities(upto6.3mghostcellproteinleftafterTFFandUC)(hh).
Thisconventionalpurificationschemeisslow,non-scalable,labor-intensiveandalsoleadstolowproductivity,non-optimalprocesseconomics,andhighfailureratesinamanufacturingenvironment.Consequently,themanufacturersofNDVforoncolytictherapywilllikelysufferfromthehighcostofgoodsandinabilitytoreliablymeetmarketdemand.Thisapproachforcesatradeoffbetweenproductpurityandproductrecovery.
Thenewsingle-stepmembranechromatographymethodforpurifyingengineeredNDVisfast,scalable,andachieveshighvirusrecovery(78.1%)with>99%purity(hh).
FigureYY:
Case Study 2: Influenza Single-Step purification using affinity membrane
Inthisexample,affinitymembraneswereemployedtopurifyinfluenzavaccinefromallantoicfluidharvest.
Theaffinitymembrane’shighproductivityenabledprocessintensification,resultinginsuccessfulpurificationinasinglestep:targetpurity,highcapacity,andhighrecoveryareallachieved(99.9%HCPclearance(3LRV),87%yield,and30-foldconcentration)(aa).Theprototypeaffinitymembranesachievedperformanceequaltoorexceedingcommercialaffinityresins.
Theaffinitymembrane’shighproductivityenables100Xsmallercolumns(comparedtocommercialresins)forsamebatchsize.Inthisexample,a500mLmembranecolumncanpurifyallantoicfluidharvestfrom1Millionembryonatedchickeneggsin1shift(8h,average104HAU/mL@5mL/egg).
FigureXX:Comparisonofinfluenzapurificationusingaffinityresinsandaffinitymembranes.Productivitycalculationsarebasedonahypotheticalloadof200columnvolumes(CV)plus20CVforadditionalequilibrationandcleaningstepsforeachproduct.
ImpurityClearance Productivity
Media BC(HAU/mL) Recovery Virusin
FTFlowrate(CV/min)
CycleTime(min)
Productivity(HAU/L.h)
AffinityResin#1 1x106 96% 2% 0.7 315 1.9E+08
AffinityResin#2 7x105 87% 4% 1 220 1.9E+08
AffinityResin#3 2x105 74% NA 2.9 76 1.6E+08
PrototypeH15 2x106 81% 10% 33 7 1.8E+10
PrototypeX40 2x106 95% 3.6% 33 7 1.8E+10
Case Study 3: Modelling a VLP-based vaccine process Avaccinemanufacturerre-engineereditstraditionalvaccinepurificationprocessforVLP-basedvaccines,enabledlargelybythepowerofaffinitymembraneperformance.Thenewmembrane-basedprocessaccomplishedthepurificationinthreeunitoperations,ascomparedtothirteenoperationsinthebaselineprocess.Thesimplifiedprocessresultedinmuchgreaterproductrevoery(lessproductloss),whichfurtherenableddownsizingoftherequiredupstreamoperations.Thisupstreamdownsizingenabledtheadoptionofsimpler,single-usebioreactors.Thenewprocessmodelsignificantlyreducedthecapitalinvestmentrequired,whilealsoimprovingcostperdose,processreliabilityandplantfootprint(CANWEQUANTIFYANYOFTHESECAPITALANDCOSTIMPROVEMENTS??).
(modellingslidesbelowmaybeeliminatedforfinalsubmission)
Conclusion Thehighproductivityandcost-efficiencyofthesingle-usechromatographymembraneprocessenablefavorableprocesseconomicscomparedtothelabor-andcapital-intensivereferenceprocesses.The
simplifiedarchitectureofthemembraneprocess,combinedwithpotentiallyfullycontinuousandclosed(aseptic)operation,shouldenablemanufacturinginatrulyflexible,lowcostandsmallfootprintfacility.Thehighthroughputmembranepurificationprocesscanimprovecurrentegg-basedvirusprocesses,andwillalsomarryperfectlywithimproved,high-throughputupstreamprocess(ex.adaptNDVstraintocellcultureandimplementintoascalablemanufacturingstrategyusingPalliCELLisreactor).
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