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
|
Vitharana S, Stillahn JM, Katayama DS, Henry CS, Manning MC. Application of Formulation Principles to Stability Issues Encountered During Processing, Manufacturing, and Storage of Drug Substance and Drug Product Protein Therapeutics. J Pharm Sci 2023; 112:2724-2751. [PMID: 37572779 DOI: 10.1016/j.xphs.2023.08.003] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/14/2022] [Revised: 07/24/2023] [Accepted: 08/07/2023] [Indexed: 08/14/2023]
Abstract
The field of formulation and stabilization of protein therapeutics has become rather extensive. However, most of the focus has been on stabilization of the final drug product. Yet, proteins experience stress and degradation through the manufacturing process, starting with fermentaition. This review describes how formulation principles can be applied to stabilize biopharmaceutical proteins during bioprocessing and manufacturing, considering each unit operation involved in prepration of the drug substance. In addition, the impact of the container on stabilty is discussed as well.
Collapse
Affiliation(s)
| | - Joshua M Stillahn
- Legacy BioDesign LLC, Johnstown, CO 80534, USA; Department of Chemistry, Colorado State University, Fort Collins, CO 80523, USA
| | | | - Charles S Henry
- Department of Chemistry, Colorado State University, Fort Collins, CO 80523, USA
| | - Mark Cornell Manning
- Legacy BioDesign LLC, Johnstown, CO 80534, USA; Department of Chemistry, Colorado State University, Fort Collins, CO 80523, USA.
| |
Collapse
|
3
|
Dodkins R, Delaney JR, Overton T, Scholle F, Frias-De-Diego A, Crisci E, Huq N, Jordan I, Kimata JT, Findley T, Goldberg IG. A rapid, high-throughput, viral infectivity assay using automated brightfield microscopy with machine learning. SLAS Technol 2023; 28:324-333. [PMID: 37451651 DOI: 10.1016/j.slast.2023.07.003] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/11/2023] [Revised: 07/06/2023] [Accepted: 07/11/2023] [Indexed: 07/18/2023]
Abstract
Infectivity assays are essential for the development of viral vaccines, antiviral therapies, and the manufacture of biologicals. Traditionally, these assays take 2-7 days and require several manual processing steps after infection. We describe an automated viral infectivity assay (AVIATM), using convolutional neural networks (CNNs) and high-throughput brightfield microscopy on 96-well plates that can quantify infection phenotypes within hours, before they are manually visible, and without sample preparation. CNN models were trained on HIV, influenza A virus, coronavirus 229E, vaccinia viruses, poliovirus, and adenoviruses, which together span the four major categories of virus (DNA, RNA, enveloped, and non-enveloped). A sigmoidal function, fit between virus dilution curves and CNN predictions, results in sensitivity ranges comparable to or better than conventional plaque or TCID50 assays, and a precision of ∼10%, which is considerably better than conventional infectivity assays. Because this technology is based on sensitizing CNNs to specific phenotypes of infection, it has potential as a rapid, broad-spectrum tool for virus characterization, and potentially identification.
Collapse
Affiliation(s)
| | | | - Tess Overton
- Department of Biological Sciences North Carolina State University Raleigh, NC 27695, United States
| | - Frank Scholle
- Department of Biological Sciences North Carolina State University Raleigh, NC 27695, United States
| | - Alba Frias-De-Diego
- College of Veterinary Medicine, Department of Population Health and Pathobiology, North Carolina State University, Raleigh, NC 27695, United States
| | - Elisa Crisci
- College of Veterinary Medicine, Department of Population Health and Pathobiology, North Carolina State University, Raleigh, NC 27695, United States
| | - Nafisa Huq
- Melbec Microbiology Ltd, Rossendale, Lancashire, BB4 4QJ, United Kingdom
| | - Ingo Jordan
- ProBioGen AG, Goethestr. 54, 13086 Berlin, Germany
| | - Jason T Kimata
- Department of Molecular Virology and Microbiology, Baylor College of Medicine, Houston, TX, United States
| | | | | |
Collapse
|
4
|
Capito F, Flato H, Oeinck V, Dierl S, Berg A. Mimicking continuous capture chromatography for virus clearance using a single chromatography column model. Biotechnol J 2022; 17:e2100433. [PMID: 35089643 DOI: 10.1002/biot.202100433] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/10/2021] [Revised: 01/23/2022] [Accepted: 01/24/2022] [Indexed: 11/11/2022]
Abstract
Continuous chromatography is increasingly being used across the biotechnology industry due to its economic advantages. For adoption in commercial manufacturing, also models for virus clearance studies must be available. We demonstrate how for a virus clearance study for a multispecific antibody, the continuous protein A capture chromatography process, being run on multiple interconnected columns, can be mimicked with only a single column. With this mimicking small-scale model, resources and complexity can be minimized, when conducting virus clearance studies at a contract research organization (CRO) lab. Obtained log reduction values (LRV) for xMuLV and MVM virus, used as model viruses, are comparable to batch protein A chromatography and results described by other groups. The feasibility of this mimicking small-scale model helps to further reduce barriers to adoption when implementing continuous chromatography. This article is protected by copyright. All rights reserved.
Collapse
Affiliation(s)
- Florian Capito
- Purification Process Development, Industriepark Höchst, Sanofi-Aventis Deutschland GmbH, Frankfurt am Main, 65926, Germany
| | - Hendrik Flato
- Purification Process Development, Industriepark Höchst, Sanofi-Aventis Deutschland GmbH, Frankfurt am Main, 65926, Germany
| | - Verena Oeinck
- Purification Process Development, Industriepark Höchst, Sanofi-Aventis Deutschland GmbH, Frankfurt am Main, 65926, Germany
| | - Stefan Dierl
- Purification Process Development, Industriepark Höchst, Sanofi-Aventis Deutschland GmbH, Frankfurt am Main, 65926, Germany
| | - Annette Berg
- Purification Process Development, Industriepark Höchst, Sanofi-Aventis Deutschland GmbH, Frankfurt am Main, 65926, Germany
| |
Collapse
|
5
|
De Santis P, Meyer LE, Kara S. The rise of continuous flow biocatalysis – fundamentals, very recent developments and future perspectives. REACT CHEM ENG 2020. [DOI: 10.1039/d0re00335b] [Citation(s) in RCA: 73] [Impact Index Per Article: 18.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/18/2022]
Abstract
Very recent developments in the field of biocatalysis in continuously operated systems. Special attention on the future perspectives in this key emerging technological area ranging from process analytical technologies to digitalization.
Collapse
Affiliation(s)
- Piera De Santis
- Aarhus University
- Department of Engineering, Biological and Chemical Engineering Section
- Biocatalysis and Bioprocessing Group
- DK 8000 Aarhus
- Denmark
| | - Lars-Erik Meyer
- Aarhus University
- Department of Engineering, Biological and Chemical Engineering Section
- Biocatalysis and Bioprocessing Group
- DK 8000 Aarhus
- Denmark
| | - Selin Kara
- Aarhus University
- Department of Engineering, Biological and Chemical Engineering Section
- Biocatalysis and Bioprocessing Group
- DK 8000 Aarhus
- Denmark
| |
Collapse
|