1
|
Ito T, Lutz H, Tan L, Wang B, Tan J, Patel M, Chen L, Tsunakawa Y, Park B, Banerjee S. Host cell proteins in monoclonal antibody processing: Control, detection, and removal. Biotechnol Prog 2024; 40:e3448. [PMID: 38477405 DOI: 10.1002/btpr.3448] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/30/2023] [Revised: 02/13/2024] [Accepted: 02/14/2024] [Indexed: 03/14/2024]
Abstract
Host cell proteins (HCPs) are process-related impurities in a therapeutic protein expressed using cell culture technology. This review presents biopharmaceutical industry trends in terms of both HCPs in the bioprocessing of monoclonal antibodies (mAbs) and the capabilities for HCP clearance by downstream unit operations. A comprehensive assessment of currently implemented and emerging technologies in the manufacturing processes with extensive references was performed. Meta-analyses of published downstream data were conducted to identify trends. Improved analytical methods and understanding of "high-risk" HCPs lead to more robust manufacturing processes and higher-quality therapeutics. The trend of higher cell density cultures leads to both higher mAb expression and higher HCP levels. However, HCP levels can be significantly reduced with improvements in operations, resulting in similar concentrations of approx. 10 ppm HCPs. There are no differences in the performance of HCP clearance between recent enhanced downstream operations and traditional batch processing. This review includes best practices for developing improved processes.
Collapse
Affiliation(s)
- Takao Ito
- Life Science, Process Solutions, Merck Ltd. (An Affiliate of Merck KGaA, Darmstadt, Germany), Tokyo, Japan
| | - Herb Lutz
- Independent Consultant, Sudbury, Massachusetts, USA
| | - Lihan Tan
- Life Science Services, Sigma-Aldrich Pte Ltd, Singapore, Singapore
| | - Bin Wang
- Life Science, Process Solutions, Merck Chemicals (Shanghai) Co. Ltd. (An Affiliate of Merck KGaA Darmstadt, Germany), Shanghai, China
| | - Janice Tan
- Life Science, Process Solutions, Merck Pte Ltd. (An Affiliate of Merck KGaA, Darmstadt, Germany), Singapore
| | - Masum Patel
- Life Science, Process Solutions, Merck Life Sciences Pvt. Ltd. (An Affiliate of Merck KGaA, Darmstadt, Germany), Bangalore, India
| | - Lance Chen
- Life Science, Process Solutions, Merck Pte Ltd. (An Affiliate of Merck KGaA, Darmstadt, Germany), Singapore
| | - Yuki Tsunakawa
- Life Science, Process Solutions, Merck Ltd. (An Affiliate of Merck KGaA, Darmstadt, Germany), Tokyo, Japan
| | - Byunghyun Park
- Life Science, Process Solutions, Merck Ltd. (An Affiliate of Merck KGaA, Darmstadt, Germany), Seoul, South Korea
| | - Subhasis Banerjee
- Life Science, Process Solutions, Merck Life Sciences Pvt. Ltd. (An Affiliate of Merck KGaA, Darmstadt, Germany), Bangalore, India
| |
Collapse
|
2
|
Nadar S, Shooter G, Somasundaram B, Shave E, Baker K, Lua LHL. Intensified Downstream Processing of Monoclonal Antibodies Using Membrane Technology. Biotechnol J 2020; 16:e2000309. [PMID: 33006254 DOI: 10.1002/biot.202000309] [Citation(s) in RCA: 13] [Impact Index Per Article: 3.3] [Reference Citation Analysis] [Abstract] [Key Words] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/07/2022]
Abstract
The need to intensify downstream processing of monoclonal antibodies to complement the advances in upstream productivity has led to increased attention toward implementing membrane technologies. With the industry moving toward continuous operations and single use processes, membrane technologies show promise in fulfilling the industry needs due to their operational flexibility and ease of implementation. Recently, the applicability of membrane-based unit operations in integrating the downstream process has been explored. In this article, the major developments in the application of membrane-based technologies in the bioprocessing of monoclonal antibodies are reviewed. The recent progress toward developing intensified end-to-end bioprocesses and the critical role membrane technology will play in achieving this goal are focused upon.
Collapse
Affiliation(s)
- Sathish Nadar
- Australian Research Council Training Centre for Biopharmaceutical Innovation, Australian Institute for Bioengineering and Nanotechnology, The University of Queensland, Corner College and Cooper Roads, Brisbane, Queensland, 4072, Australia
| | - Gary Shooter
- Australian Research Council Training Centre for Biopharmaceutical Innovation, Australian Institute for Bioengineering and Nanotechnology, The University of Queensland, Corner College and Cooper Roads, Brisbane, Queensland, 4072, Australia
| | - Balaji Somasundaram
- Protein Expression Facility, The University of Queensland, Corner College and Cooper Roads, Brisbane, Queensland, 4072, Australia
| | - Evan Shave
- Australian Research Council Training Centre for Biopharmaceutical Innovation, Australian Institute for Bioengineering and Nanotechnology, The University of Queensland, Corner College and Cooper Roads, Brisbane, Queensland, 4072, Australia.,Pharma services group, Thermo Fisher Scientific, 37 Kent St, Woolloongabba, Brisbane, Queensland, 4102, Australia
| | - Kym Baker
- Pharma services group, Thermo Fisher Scientific, 37 Kent St, Woolloongabba, Brisbane, Queensland, 4102, Australia
| | - Linda H L Lua
- Australian Research Council Training Centre for Biopharmaceutical Innovation, Australian Institute for Bioengineering and Nanotechnology, The University of Queensland, Corner College and Cooper Roads, Brisbane, Queensland, 4072, Australia.,Protein Expression Facility, The University of Queensland, Corner College and Cooper Roads, Brisbane, Queensland, 4072, Australia
| |
Collapse
|
3
|
Investigating the combination of single‐pass tangential flow filtration and anion exchange chromatography for intensified mAb polishing. Biotechnol Prog 2019; 35:e2862. [DOI: 10.1002/btpr.2862] [Citation(s) in RCA: 15] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/14/2019] [Revised: 05/24/2019] [Accepted: 06/03/2019] [Indexed: 11/07/2022]
|
4
|
Sipple P, Nguyen T, Patel K, Jaffe N, Chen Y, Khetan A. Suitability of a generic virus safety evaluation for monoclonal antibody investigational new drug applications. Biotechnol Prog 2019; 35:e2850. [PMID: 31125511 DOI: 10.1002/btpr.2850] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/21/2018] [Revised: 05/05/2019] [Accepted: 05/06/2019] [Indexed: 11/07/2022]
Abstract
Biologics produced from CHO cell lines with endogenous virus DNA can produce retrovirus-like particles in cell culture at high titers, and other adventitious viruses can find their way through raw materials into the process to make a product. Therefore, it is the industry standard to have controls to avoid introduction of viruses into the production process, to test for the presence of viral particles in unclarified cell culture, and to develop purification procedures to ensure that manufacturing processes are robust for viral clearance. Data have been accumulated over the past four decades on unit operations that can inactivate and clear adventitious virus and provide a high degree of assurance for patient safety. During clinical development, biological products are traditionally tested at process set points for viral clearance. However, the widespread implementation of platform production processes to produce highly similar IgG antibodies for many indications makes it possible to leverage historical data and knowledge from representative molecules to allow for better understanding and control of virus safety. More recently, individualized viral clearance studies are becoming the rate-limiting step in getting new antibody molecules to clinic, particularly in Phase 0 and eIND situations. Here, we explore considerations for application of a generic platform virus clearance strategy that can be applied for relevant investigational antibodies within defined operational parameters in order to increase speed to the clinic and reduce validation costs while providing a better understanding and assurance of process virus safety.
Collapse
Affiliation(s)
- Patrick Sipple
- Product Development, Bristol-Myers Squibb, Princeton, New Jersey
| | - Tung Nguyen
- Product Development, Bristol-Myers Squibb, Princeton, New Jersey
| | - Krina Patel
- Product Development, Bristol-Myers Squibb, Princeton, New Jersey
| | - Neil Jaffe
- Product Development, Bristol-Myers Squibb, Princeton, New Jersey
| | - Yan Chen
- Product Development, Bristol-Myers Squibb, Princeton, New Jersey
| | - Anurag Khetan
- Product Development, Bristol-Myers Squibb, Princeton, New Jersey
| |
Collapse
|
5
|
Singh N, Herzer S. Downstream Processing Technologies/Capturing and Final Purification : Opportunities for Innovation, Change, and Improvement. A Review of Downstream Processing Developments in Protein Purification. ADVANCES IN BIOCHEMICAL ENGINEERING/BIOTECHNOLOGY 2019; 165:115-178. [PMID: 28795201 DOI: 10.1007/10_2017_12] [Citation(s) in RCA: 8] [Impact Index Per Article: 1.6] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 12/12/2022]
Abstract
Increased pressure on upstream processes to maximize productivity has been crowned with great success, although at the cost of shifting the bottleneck to purification. As drivers were economical, focus is on now on debottlenecking downstream processes as the main drivers of high manufacturing cost. Devising a holistically efficient and economical process remains a key challenge. Traditional and emerging protein purification strategies with particular emphasis on methodologies implemented for the production of recombinant proteins of biopharmaceutical importance are reviewed. The breadth of innovation is addressed, as well as the challenges the industry faces today, with an eye to remaining impartial, fair, and balanced. In addition, the scope encompasses both chromatographic and non-chromatographic separations directed at the purification of proteins, with a strong emphasis on antibodies. Complete solutions such as integrated USP/DSP strategies (i.e., continuous processing) are discussed as well as gains in data quantity and quality arising from automation and high-throughput screening (HTS). Best practices and advantages through design of experiments (DOE) to access a complex design space such as multi-modal chromatography are reviewed with an outlook on potential future trends. A discussion of single-use technology, its impact and opportunities for further growth, and the exciting developments in modeling and simulation of DSP rounds out the overview. Lastly, emerging trends such as 3D printing and nanotechnology are covered. Graphical Abstract Workflow of high-throughput screening, design of experiments, and high-throughput analytics to understand design space and design space boundaries quickly. (Reproduced with permission from Gregory Barker, Process Development, Bristol-Myers Squibb).
Collapse
Affiliation(s)
- Nripen Singh
- Bristol-Myers Squibb, Global Manufacturing and Supply, Devens, MA, 01434, USA.
| | - Sibylle Herzer
- Bristol-Myers Squibb, Global Manufacturing and Supply, Hopewell, NJ, 01434, USA
| |
Collapse
|
6
|
Singh N, Arunkumar A, Peck M, Voloshin AM, Moreno AM, Tan Z, Hester J, Borys MC, Li ZJ. Development of adsorptive hybrid filters to enable two-step purification of biologics. MAbs 2016; 9:350-363. [PMID: 27929735 PMCID: PMC5297532 DOI: 10.1080/19420862.2016.1267091] [Citation(s) in RCA: 14] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/27/2016] [Revised: 11/18/2016] [Accepted: 11/28/2016] [Indexed: 10/20/2022] Open
Abstract
Recent progress in mammalian cell culture process has resulted in significantly increased product titers, but also a substantial increase in process- and product-related impurities. Due to the diverse physicochemical properties of these impurities, there is constant need for new technologies that offer higher productivity and improved economics without sacrificing the process robustness required to meet final drug substance specifications. Here, we examined the use of new synthetic adsorptive hybrid filters (AHF) modified with the high binding capacity of quaternary amine (Emphaze™ AEX) and salt-tolerant biomimetic (Emphaze™ ST-AEX) ligands for clearance of process-related impurities like host cell protein (HCP), residual DNA, and virus. The potential to remove soluble aggregates was also examined. Our aim was to develop a mechanistic understanding of the interactions governing adsorptive removal of impurities during filtration by evaluating the effect of various filter types, feed streams, and process conditions on impurity removal. The ionic capacity of these filters was measured and correlated with their ability to remove impurities for multiple molecules. The ionic capacity of AHF significantly exceeded that of traditional adsorptive depth filters (ADF) by 40% for the Emphaze™ AEX and by 700% for the Emphaze™ ST-AEX, providing substantially higher reduction of soluble anionic impurities, including DNA, HCPs and model virus. Nevertheless, we determined that ADF with filter aid provided additional hydrophobic functionality that resulted in removal of higher molecular weight species than AHF. Implementing AHF demonstrated improved process-related impurity removal and viral clearance after Protein A chromatography and enabled a two-step purification process. The consequences of enhanced process performance are far reaching because it allows the downstream polishing train to be restructured and simplified, and chromatographic purity standards to be met with a reduced number of chromatographic steps.
Collapse
Affiliation(s)
- Nripen Singh
- Biologics Development, Global Manufacturing and Supply, Bristol-Myers Squibb Company, Devens, MA, USA
| | - Abhiram Arunkumar
- Biologics Development, Global Manufacturing and Supply, Bristol-Myers Squibb Company, Devens, MA, USA
| | - Michael Peck
- Biologics Development, Global Manufacturing and Supply, Bristol-Myers Squibb Company, Devens, MA, USA
| | - Alexei M. Voloshin
- Life Science Process Technologies, 3M Purification Inc., St Paul, MN, USA
| | - Angela M. Moreno
- Life Science Process Technologies, 3M Purification Inc., St Paul, MN, USA
| | - Zhijun Tan
- Biologics Development, Global Manufacturing and Supply, Bristol-Myers Squibb Company, Devens, MA, USA
| | - Jonathan Hester
- Life Science Process Technologies, 3M Purification Inc., St Paul, MN, USA
| | - Michael C. Borys
- Biologics Development, Global Manufacturing and Supply, Bristol-Myers Squibb Company, Devens, MA, USA
| | - Zheng Jian Li
- Biologics Development, Global Manufacturing and Supply, Bristol-Myers Squibb Company, Devens, MA, USA
| |
Collapse
|
7
|
Horner IJ, Kraut ND, Hurst JJ, Rook AM, Collado CM, Atilla-Gokcumen GE, Maziarz EP, Liu XM, Merchea MM, Bright FV. Effects of Polyhexamethylene Biguanide and Polyquaternium-1 on Phospholipid Bilayer Structure and Dynamics. J Phys Chem B 2015; 119:10531-42. [DOI: 10.1021/acs.jpcb.5b07162] [Citation(s) in RCA: 10] [Impact Index Per Article: 1.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/17/2023]
Affiliation(s)
- Ian J. Horner
- Department
of Chemistry, Natural Sciences Complex, SUNY-Buffalo, Buffalo, New York 14260-3000, United States
| | - Nadine D. Kraut
- PPG Industries
Inc., 440 College Park Dr., Monroeville, Pennsylvania 15146, United States
| | - Jerod J. Hurst
- Department
of Chemistry, Natural Sciences Complex, SUNY-Buffalo, Buffalo, New York 14260-3000, United States
| | - Alyssa M. Rook
- Department
of Chemistry, Natural Sciences Complex, SUNY-Buffalo, Buffalo, New York 14260-3000, United States
| | - Crystal M. Collado
- Department
of Chemistry, Natural Sciences Complex, SUNY-Buffalo, Buffalo, New York 14260-3000, United States
| | - G. Ekin Atilla-Gokcumen
- Department
of Chemistry, Natural Sciences Complex, SUNY-Buffalo, Buffalo, New York 14260-3000, United States
| | - E. Peter Maziarz
- Pfizer Consumer
Healthcare, 1211 Sherwood Ave., Richmond, Virginia 23220, United States
| | - X. Michael Liu
- Pfizer Consumer
Healthcare, 1211 Sherwood Ave., Richmond, Virginia 23220, United States
| | | | - Frank V. Bright
- Department
of Chemistry, Natural Sciences Complex, SUNY-Buffalo, Buffalo, New York 14260-3000, United States
| |
Collapse
|