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Buckland B, Sanyal G, Ranheim T, Pollard D, Searles JA, Behrens S, Pluschkell S, Josefsberg J, Roberts CJ. Vaccine process technology-A decade of progress. Biotechnol Bioeng 2024; 121:2604-2635. [PMID: 38711222 DOI: 10.1002/bit.28703] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/22/2023] [Revised: 03/04/2024] [Accepted: 03/14/2024] [Indexed: 05/08/2024]
Abstract
In the past decade, new approaches to the discovery and development of vaccines have transformed the field. Advances during the COVID-19 pandemic allowed the production of billions of vaccine doses per year using novel platforms such as messenger RNA and viral vectors. Improvements in the analytical toolbox, equipment, and bioprocess technology have made it possible to achieve both unprecedented speed in vaccine development and scale of vaccine manufacturing. Macromolecular structure-function characterization technologies, combined with improved modeling and data analysis, enable quantitative evaluation of vaccine formulations at single-particle resolution and guided design of vaccine drug substances and drug products. These advances play a major role in precise assessment of critical quality attributes of vaccines delivered by newer platforms. Innovations in label-free and immunoassay technologies aid in the characterization of antigenic sites and the development of robust in vitro potency assays. These methods, along with molecular techniques such as next-generation sequencing, will accelerate characterization and release of vaccines delivered by all platforms. Process analytical technologies for real-time monitoring and optimization of process steps enable the implementation of quality-by-design principles and faster release of vaccine products. In the next decade, the field of vaccine discovery and development will continue to advance, bringing together new technologies, methods, and platforms to improve human health.
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Affiliation(s)
- Barry Buckland
- National Institute for Innovation in Manufacturing Biopharmaceuticals, University of Delaware, Newark, Delaware, USA
| | - Gautam Sanyal
- Vaccine Analytics, LLC, Kendall Park, New Jersey, USA
| | - Todd Ranheim
- Advanced Analytics Core, Resilience, Chapel Hill, North Carolina, USA
| | - David Pollard
- Sartorius, Corporate Research, Marlborough, Massachusetts, USA
| | | | - Sue Behrens
- Engineering and Biopharmaceutical Processing, Keck Graduate Institute, Claremont, California, USA
| | - Stefanie Pluschkell
- National Institute for Innovation in Manufacturing Biopharmaceuticals, University of Delaware, Newark, Delaware, USA
| | - Jessica Josefsberg
- Merck & Co., Inc., Process Research & Development, Rahway, New Jersey, USA
| | - Christopher J Roberts
- National Institute for Innovation in Manufacturing Biopharmaceuticals, University of Delaware, Newark, Delaware, USA
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Ardakani MH, Rezadoost H, Norouzi HR. Sequential purification of cannabidiol by two-dimensional liquid chromatography combined with modeling and simulation of elution profiles. J Chromatogr A 2024; 1717:464702. [PMID: 38310701 DOI: 10.1016/j.chroma.2024.464702] [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: 09/02/2023] [Revised: 12/15/2023] [Accepted: 01/30/2024] [Indexed: 02/06/2024]
Abstract
Cannabidiol (CBD) has garnered significant attention for its neuroprotective properties, and research on its therapeutic effects has increased dramatically in recent years. However, the systematic purification of CBD through scalable processes has remained bottleneck due to the structural similarities of the cannabinoids. Although preparative chromatography is considered as a potential solution, it is usually time-consuming and expensive. Therefore, the development of scalable strategy via fast and accurate optimization approach is crucial. The present study aimed to develop a sequential process for the scalable purification of CBD through an eco-friendly ethanolic extraction using ultrasonic assisted extraction, decarboxylation of cannabidiolic acid optimized by response surface methodology, followed by the development of off-line two-dimensional semi-preparative chromatography, boosted with stacked injection overloading. In the first dimension, a column packed with macroporous resin allows to enrich the target substance and then, the behavior of resin column for scale-up procedure were predicted and optimized by developed mathematical model. A C18 column was used in the second dimension. The CBD purity and recovery obtained were 94.3 and 82.1 %, respectively. A robust and reliable method was employed for CBD enrichment/purification, which can be generalized to other bioactive compounds in complex matrices.
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Affiliation(s)
- Mohammad Hooshyari Ardakani
- Department of Phytochemistry, Medicinal Plants and Drugs Research Institute, Shahid Beheshti University, G.C., Evin, Tehran, Iran
| | - Hassan Rezadoost
- Department of Phytochemistry, Medicinal Plants and Drugs Research Institute, Shahid Beheshti University, G.C., Evin, Tehran, Iran.
| | - Hamid Reza Norouzi
- Center of Engineering and Multiscale Modeling of Fluid Flow (CEMF), Department of Chemical Engineering, Amirkabir University of Technology (Tehran Poly Technique), Tehran, Iran
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Pang JH, Guo CF, Hao PL, Meng SL, Guo J, Zhang D, Ji YQ, Ming PG. Evaluation of the Robustness Verification of Downstream Production Process for Inactivated SARS-CoV-2 Vaccine and Different Chromatography Medium Purification Effects. Vaccines (Basel) 2024; 12:56. [PMID: 38250869 PMCID: PMC10818994 DOI: 10.3390/vaccines12010056] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/21/2023] [Revised: 12/29/2023] [Accepted: 01/03/2024] [Indexed: 01/23/2024] Open
Abstract
BACKGROUND Large-scale vaccine production requires downstream processing that focuses on robustness, efficiency, and cost-effectiveness. METHODS To assess the robustness of the current vaccine production process, three batches of COVID-19 Omicron BA.1 strain hydrolytic concentrated solutions were selected. Four gel filtration chromatography media (Chromstar 6FF, Singarose FF, Bestarose 6B, and Focurose 6FF) and four ion exchange chromatography media (Maxtar Q, Q Singarose, Diamond Q, and Q Focurose) were used to evaluate their impact on vaccine purification. The quality of the vaccine was assessed by analyzing total protein content, antigen content, residual Vero cell DNA, residual Vero cell protein, and residual bovine serum albumin (BSA). Antigen recovery rate and specific activity were also calculated. Statistical analysis was conducted to evaluate process robustness and the purification effects of the chromatography media. RESULTS The statistical analysis revealed no significant differences in antigen recovery (p = 0.10), Vero HCP residue (p = 0.59), Vero DNA residue (p = 0.28), and BSA residue (p = 0.97) among the three batches of hydrolytic concentrated solutions processed according to the current method. However, a significant difference (p < 0.001) was observed in antigen content. CONCLUSIONS The study demonstrated the remarkable robustness of the current downstream process for producing WIBP-CorV vaccines. This process can adapt to different batches of hydrolytic concentrated solutions and various chromatography media. The research is crucial for the production of inactivated SARS-CoV-2 vaccines and provides a potential template for purifying other viruses.
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Affiliation(s)
- Jia-Hui Pang
- National Engineering Technology Research Center for Combined Vaccines, Wuhan 430207, China
- Wuhan Institute of Biological Products Co., Ltd., Wuhan 430207, China
| | - Chang-Fu Guo
- Wuhan Institute of Biological Products Co., Ltd., Wuhan 430207, China
| | - Peng-Liang Hao
- Wuhan Institute of Biological Products Co., Ltd., Wuhan 430207, China
| | - Sheng-Li Meng
- National Engineering Technology Research Center for Combined Vaccines, Wuhan 430207, China
- Wuhan Institute of Biological Products Co., Ltd., Wuhan 430207, China
| | - Jing Guo
- National Engineering Technology Research Center for Combined Vaccines, Wuhan 430207, China
- Wuhan Institute of Biological Products Co., Ltd., Wuhan 430207, China
| | - Dou Zhang
- Wuhan Institute of Biological Products Co., Ltd., Wuhan 430207, China
| | - Ya-Qi Ji
- Wuhan Institute of Biological Products Co., Ltd., Wuhan 430207, China
| | - Ping-Gang Ming
- Wuhan Institute of Biological Products Co., Ltd., Wuhan 430207, China
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Umasekar S, Virivinti N. Advances in modeling techniques for the production and purification of biomolecules: A comprehensive review. J Chromatogr B Analyt Technol Biomed Life Sci 2024; 1232:123945. [PMID: 38113723 DOI: 10.1016/j.jchromb.2023.123945] [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: 07/19/2023] [Revised: 10/17/2023] [Accepted: 11/28/2023] [Indexed: 12/21/2023]
Abstract
In response to the growing demand for therapeutic biomolecules, there is a need for continuous and cost-effective bio-separation techniques to enhance extraction yield and efficiency. Aqueous biphasic extractive fermentation has emerged as an integrated downstream processing technique, offering selective partitioning, high productivity, and preservation of biomolecule integrity. However, the dynamic nature of this technique requires a comprehensive understanding of the underlying separation mechanisms. Unfortunately, the analysis of parameters influencing this dynamic behavior can be challenging due to limited resources and time. To address this, mathematical modeling approaches can be employed to minimize the tedious trial-and-error experimentation process. This review article presents mathematical modeling approaches for both upstream and downstream processing techniques, focusing on the production of biomolecules which can be used in pharmaceutical industries in a cost-effective manner. By leveraging mathematical models, researchers can optimize the production and purification processes, leading to improved efficiency and processing cost reduction in biomolecule production.
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Affiliation(s)
- Srimathi Umasekar
- Department of Chemical Engineering, National Institute of Technology Tiruchirappalli, Tiruchirappalli, Tamil Nadu 620015, India
| | - Nagajyothi Virivinti
- Department of Chemical Engineering, National Institute of Technology Tiruchirappalli, Tiruchirappalli, Tamil Nadu 620015, India.
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Lothert K, Wolff MW. Affinity and Pseudo-Affinity Membrane Chromatography for Viral Vector and Vaccine Purifications: A Review. MEMBRANES 2023; 13:770. [PMID: 37755191 PMCID: PMC10537005 DOI: 10.3390/membranes13090770] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 07/21/2023] [Revised: 08/11/2023] [Accepted: 08/29/2023] [Indexed: 09/28/2023]
Abstract
Several chromatographic approaches have been established over the last decades for the production of pharmaceutically relevant viruses. Due to the large size of these products compared to other biopharmaceuticals, e.g., proteins, convective flow media have proven to be superior to bead-based resins in terms of process productivity and column capacity. One representative of such convective flow materials is membranes, which can be modified to suit the particular operating principle and are also suitable for economical single-use applications. Among the different membrane variants, affinity surfaces allow for the most selective separation of the target molecule from other components in the feed solution, especially from host cell-derived DNA and proteins. A successful membrane affinity chromatography, however, requires the identification and implementation of ligands, which can be applied economically while at the same time being stable during the process and non-toxic in the case of any leaching. This review summarizes the current evaluation of membrane-based affinity purifications for viruses and virus-like particles, including traditional resin and monolith approaches and the advantages of membrane applications. An overview of potential affinity ligands is given, as well as considerations of suitable affinity platform technologies, e.g., for different virus serotypes, including a description of processes using pseudo-affinity matrices, such as sulfated cellulose membrane adsorbers.
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Affiliation(s)
| | - Michael W. Wolff
- Institute of Bioprocess Engineering and Pharmaceutical Technology, Department Life Science Engineering, University of Applied Sciences Mittelhessen (THM), 35390 Giessen, Germany
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Song Y, Yang Y, Lin X, Zhao Q, Su Z, Ma G, Zhang S. Size exclusion chromatography using large pore size media induces adverse conformational changes of inactivated foot-and-mouth disease virus particles. J Chromatogr A 2022; 1677:463301. [DOI: 10.1016/j.chroma.2022.463301] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/08/2022] [Revised: 06/30/2022] [Accepted: 07/01/2022] [Indexed: 10/17/2022]
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Singh SM, Furman R, Singh RK, Balakrishnan G, Chennamsetty N, Tao L, Li Z. Size exclusion chromatography for the characterization and quality control of biologics. J LIQ CHROMATOGR R T 2021. [DOI: 10.1080/10826076.2021.1979582] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/18/2023]
Affiliation(s)
- Surinder M. Singh
- Analytical Development and Attribute Sciences, New Brunswick, NJ, USA
| | - Ran Furman
- Analytical Development and Attribute Sciences, New Brunswick, NJ, USA
| | - Rajesh K. Singh
- Analytical Development and Attribute Sciences, New Brunswick, NJ, USA
| | | | | | - Li Tao
- Analytical Development and Attribute Sciences, New Brunswick, NJ, USA
| | - Zhengjian Li
- Analytical Development and Attribute Sciences, New Brunswick, NJ, USA
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