1
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Aryal B, Lehtimaki M, Rao VA. Stress-mediated polysorbate 20 degradation and its potential impact on therapeutic proteins. Pharm Res 2024; 41:1217-1232. [PMID: 38740663 PMCID: PMC11196320 DOI: 10.1007/s11095-024-03700-7] [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: 01/04/2024] [Accepted: 04/07/2024] [Indexed: 05/16/2024]
Abstract
PURPOSE Polysorbates are the most commonly used surfactants in formulations to stabilize therapeutic proteins against interfacial stresses. Polysorbates can undergo oxidative or enzyme-mediated hydrolytic degradation to produce free fatty acids (FFAs) and subvisible particles in formulations. To determine which product related variables contribute to PS20 degradation, we investigated the effects of storage temperature, formulation, pH, presence of hydrolytic enzymes, and specific fatty acid composition on different grades of PS20 in relation to their PS20 degradation profile and consequently the quality of protein drug products. METHODS Bevacizumab and T-DM1 were reformulated in the freshly prepared therapeutic protein formulations containing either compendial PS20 or non-compendial PS20 with high % lauric acid and spiked with exogenous esterase or lipase. The release of FFAs and formation of particles were monitored at 4°C and 37°C. Protein quality was assessed for secondary structures, purity, and biological activity. RESULTS Hydrolytic release of FFAs and formation of subvisible particles were found to be dependent on grades of PS20, types of enzymes used, incubation temperature, and pH. Esterase- or lipase-mediated degradation of PS20 and formation of subvisible particles in drug formulation showed no significant impact on the biological activity and stability of therapeutic proteins against degradation or aggregation. CONCLUSIONS Our study suggests that degradation of PS20 and formation of FFA particles depend on the fatty acid composition of PS20, types of hydrolytic enzymes, pH, and temperature. The presence of FFA subvisible particles showed no significant impact on the purity and biological activity of the therapeutic proteins under the tested conditions.
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Affiliation(s)
- Baikuntha Aryal
- Laboratory of Applied Biochemistry, Division of Biotechnology Research and Review III, Office of Biotechnology Products, Office of Pharmaceutical Quality, Center for Drug Evaluation and Research, Food and Drug Administrations, Silver Spring, MD, 20993, USA
| | - Mari Lehtimaki
- Laboratory of Applied Biochemistry, Division of Biotechnology Research and Review III, Office of Biotechnology Products, Office of Pharmaceutical Quality, Center for Drug Evaluation and Research, Food and Drug Administrations, Silver Spring, MD, 20993, USA
| | - V Ashutosh Rao
- Laboratory of Applied Biochemistry, Division of Biotechnology Research and Review III, Office of Biotechnology Products, Office of Pharmaceutical Quality, Center for Drug Evaluation and Research, Food and Drug Administrations, Silver Spring, MD, 20993, USA.
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2
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Šprager E, Möller J, Lin Y, Reisinger V, Bratkovič T, Lunder M, Vašl J, Krajnc A. Identification of Acyl-Protein Thioesterase-1 as a Polysorbate-Degrading Host Cell Protein in a Monoclonal Antibody Formulation Using Activity-Based Protein Profiling. J Pharm Sci 2024:S0022-3549(24)00185-0. [PMID: 38772451 DOI: 10.1016/j.xphs.2024.05.013] [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: 03/18/2024] [Revised: 05/13/2024] [Accepted: 05/13/2024] [Indexed: 05/23/2024]
Abstract
Polysorbate (PS) degradation in monoclonal antibody (mAb) formulations poses a significant challenge in the biopharmaceutical industry. PS maintains protein stability during drug product's shelf life but is vulnerable to breakdown by low-abundance residual host cell proteins (HCPs), particularly hydrolytic enzymes such as lipases and esterases. In this study, we used activity-based protein profiling (ABPP) coupled with mass spectrometry to identify acyl-protein thioesterase-1 (APT-1) as a polysorbate-degrading HCP in one case of mAb formulation with stability problems. We validated the role of APT1 by matching the polysorbate degradation fingerprint in the mAb formulation with that of a recombinant APT1 protein. Furthermore, we found an agreement between APT1 levels and PS degradation rates in the mAb formulation, and we successfully halted PS degradation using APT1-specific inhibitors ML348 and ML211. APT1 was found to co-purify with a specific mAb via hitchhiking mechanism. Our work provides a streamlined approach to identifying critical HCPs in PS degradation, supporting quality-by-design principles in pharmaceutical development.
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Affiliation(s)
- Ernest Šprager
- University of Ljubljana, Faculty of Pharmacy, Ljubljana, Slovenia; Novartis Technical Research & Development, Biologics Technical Development Mengeš, Novartis Pharmaceutical Manufacturing LLC, Slovenia
| | - Jens Möller
- Novartis Technical Research & Development, Analytical Characterization, Novartis Pharmaceutical Manufacturing GmbH, Kundl, Austria
| | - Yuhsien Lin
- Novartis Technical Research & Development, Analytical Characterization, Novartis Pharmaceutical Manufacturing GmbH, Kundl, Austria
| | - Veronika Reisinger
- Novartis Technical Research & Development, Analytical Characterization, Novartis Pharmaceutical Manufacturing GmbH, Kundl, Austria
| | - Tomaž Bratkovič
- University of Ljubljana, Faculty of Pharmacy, Ljubljana, Slovenia
| | - Mojca Lunder
- University of Ljubljana, Faculty of Pharmacy, Ljubljana, Slovenia
| | - Jožica Vašl
- Novartis Technical Research & Development, Biologics Technical Development Mengeš, Novartis Pharmaceutical Manufacturing LLC, Slovenia
| | - Aleksander Krajnc
- Novartis Technical Research & Development, Biologics Technical Development Mengeš, Novartis Pharmaceutical Manufacturing LLC, Slovenia.
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3
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Dehghani A, Binder F, Zorn M, Feigler A, Fischer KI, Felix MN, Happersberger P, Reisinger B. Investigating pH Effects on Enzymes Catalyzing Polysorbate Degradation by Activity-Based Protein Profiling. J Pharm Sci 2024; 113:744-753. [PMID: 37758159 DOI: 10.1016/j.xphs.2023.09.013] [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: 06/23/2023] [Revised: 09/15/2023] [Accepted: 09/15/2023] [Indexed: 10/03/2023]
Abstract
Host cell proteins (HCPs) are process-related impurities that can negatively impact the quality of biotherapeutics. Some HCPs possess enzymatic activity and can affect the active pharmaceutical ingredient (API) or excipients such as polysorbates (PS). PSs are a class of non-ionic surfactants commonly used as excipients in biotherapeutics to enhance the stability of APIs. The enzyme activity of certain HCPs can result in the degradation of PSs, leading to particle formation and decreased shelf life of biotherapeutics. Identifying and characterizing these HCPs is therefore crucial. This study employed the Activity-Based Protein Profiling (ABPP) technique to investigate the effect of pH on the activity of HCPs that have the potential to degrade polysorbates. Two probes were utilized: the commercially available fluorophosphonate (FP)-Desthiobiotin probe and a probe based on the antiobesity drug, Orlistat. Over 50 HCPs were identified, showing a strong dependence on pH-milieu regarding their enzyme activity. These findings underscore the importance of accounting for pH variations in the ABPP method and other investigations of HCP activity. Notably, the Orlistat-based probe (OBP) enabled us to investigate the enzymatic activity of a wider range of HCPs, emphasizing the advantage of using more than one probe for ABPP. Finally, this study led to the discovery of previously unreported active enzymes, including three HCPs from the carboxylesterase enzyme family.
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Affiliation(s)
- Alireza Dehghani
- Boehringer Ingelheim Pharma GmbH & Co. KG, Birkendorfer Strasse 65, Biberach D-88397, Germany
| | - Florian Binder
- Boehringer Ingelheim Pharma GmbH & Co. KG, Birkendorfer Strasse 65, Biberach D-88397, Germany
| | - Michael Zorn
- Boehringer Ingelheim Pharma GmbH & Co. KG, Birkendorfer Strasse 65, Biberach D-88397, Germany
| | - Andreas Feigler
- Boehringer Ingelheim Pharma GmbH & Co. KG, Birkendorfer Strasse 65, Biberach D-88397, Germany
| | - Kathrin Inge Fischer
- Boehringer Ingelheim Pharma GmbH & Co. KG, Birkendorfer Strasse 65, Biberach D-88397, Germany
| | - Marius Nicolaus Felix
- Boehringer Ingelheim Pharma GmbH & Co. KG, Birkendorfer Strasse 65, Biberach D-88397, Germany
| | - Peter Happersberger
- Boehringer Ingelheim Pharma GmbH & Co. KG, Birkendorfer Strasse 65, Biberach D-88397, Germany
| | - Bernd Reisinger
- Boehringer Ingelheim Pharma GmbH & Co. KG, Birkendorfer Strasse 65, Biberach D-88397, Germany.
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4
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Maier M, Weiß L, Zeh N, Schmieder-Todtenhaupt V, Dehghani A, Felix MN, Heinzelmann D, Lindner B, Schmidt M, Studts J, Schulz P, Reisinger B, Otte K, Franzreb M, Lakatos D, Fischer S. Illuminating a biologics development challenge: systematic characterization of CHO cell-derived hydrolases identified in monoclonal antibody formulations. MAbs 2024; 16:2375798. [PMID: 38984665 PMCID: PMC11238916 DOI: 10.1080/19420862.2024.2375798] [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: 02/29/2024] [Accepted: 06/30/2024] [Indexed: 07/11/2024] Open
Abstract
Monoclonal antibodies (mAb) and other biological drugs are affected by enzymatic polysorbate (PS) degradation that reduces product stability and jeopardizes the supply of innovative medicines. PS represents a critical surfactant stabilizing the active pharmaceutical ingredients, which are produced by recombinant Chinese hamster ovary (CHO) cell lines. While the list of potential PS-degrading CHO host cell proteins (HCPs) has grown over the years, tangible data on industrially relevant HCPs are still scarce. By means of a highly sensitive liquid chromatography-tandem mass spectrometry method, we investigated seven different mAb products, resulting in the identification of 12 potentially PS-degrading hydrolases, including the strongly PS-degrading lipoprotein lipase (LPL). Using an LPL knockout CHO host cell line, we were able to stably overexpress and purify the remaining candidate hydrolases through orthogonal affinity chromatography methods, enabling their detailed functional characterization. Applying a PS degradation assay, we found nine mostly secreted, PS-active hydrolases with varying hydrolytic activity. All active hydrolases showed a serine-histidine-aspartate/glutamate catalytical triad. Further, we subjected the active hydrolases to pH-screenings and revealed a diverse range of activity optima, which can facilitate the identification of residual hydrolases during bioprocess development. Ultimately, we compiled our dataset in a risk matrix identifying PAF-AH, LIPA, PPT1, and LPLA2 as highly critical hydrolases based on their cellular expression, detection in purified antibodies, active secretion, and PS degradation activity. With this work, we pave the way toward a comprehensive functional characterization of PS-degrading hydrolases and provide a basis for a future reduction of PS degradation in biopharmaceutical drug products.
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Affiliation(s)
- Melanie Maier
- Bioprocess Development Biologicals, Boehringer Ingelheim Pharma GmbH & Co. KG, Biberach an der Riss, Germany
- Institute of Functional Interfaces, Karlsruhe Institute of Technology, Karlsruhe, Germany
| | - Linus Weiß
- Bioprocess Development Biologicals, Boehringer Ingelheim Pharma GmbH & Co. KG, Biberach an der Riss, Germany
- Institute for Applied Biotechnology, University of Applied Sciences Biberach, Biberach an der Riss, Germany
| | - Nikolas Zeh
- Bioprocess Development Biologicals, Boehringer Ingelheim Pharma GmbH & Co. KG, Biberach an der Riss, Germany
| | | | - Alireza Dehghani
- Analytical Development Biologicals, Boehringer Ingelheim Pharma GmbH & Co. KG, Biberach an der Riss, Germany
| | - Marius Nicolaus Felix
- Analytical Development Biologicals, Boehringer Ingelheim Pharma GmbH & Co. KG, Biberach an der Riss, Germany
| | - Daniel Heinzelmann
- Bioprocess Development Biologicals, Boehringer Ingelheim Pharma GmbH & Co. KG, Biberach an der Riss, Germany
| | - Benjamin Lindner
- Bioprocess Development Biologicals, Boehringer Ingelheim Pharma GmbH & Co. KG, Biberach an der Riss, Germany
| | - Moritz Schmidt
- Bioprocess Development Biologicals, Boehringer Ingelheim Pharma GmbH & Co. KG, Biberach an der Riss, Germany
| | - Joey Studts
- Bioprocess Development Biologicals, Boehringer Ingelheim Pharma GmbH & Co. KG, Biberach an der Riss, Germany
| | - Patrick Schulz
- Bioprocess Development Biologicals, Boehringer Ingelheim Pharma GmbH & Co. KG, Biberach an der Riss, Germany
| | - Bernd Reisinger
- Analytical Development Biologicals, Boehringer Ingelheim Pharma GmbH & Co. KG, Biberach an der Riss, Germany
| | - Kerstin Otte
- Institute for Applied Biotechnology, University of Applied Sciences Biberach, Biberach an der Riss, Germany
| | - Matthias Franzreb
- Institute of Functional Interfaces, Karlsruhe Institute of Technology, Karlsruhe, Germany
| | - Daniel Lakatos
- Bioprocess Development Biologicals, Boehringer Ingelheim Pharma GmbH & Co. KG, Biberach an der Riss, Germany
| | - Simon Fischer
- Bioprocess Development Biologicals, Boehringer Ingelheim Pharma GmbH & Co. KG, Biberach an der Riss, Germany
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5
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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.
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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.
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6
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Li X. Recent applications of quantitative mass spectrometry in biopharmaceutical process development and manufacturing. J Pharm Biomed Anal 2023; 234:115581. [PMID: 37494866 DOI: 10.1016/j.jpba.2023.115581] [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: 04/28/2023] [Revised: 06/27/2023] [Accepted: 07/12/2023] [Indexed: 07/28/2023]
Abstract
Biopharmaceutical products have seen rapid growth over the past few decades and continue to dominate the global pharmaceutical market. Aligning with the quality by design (QbD) framework and realization, recent advances in liquid chromatography-mass spectrometry (LC-MS) instrumentation and related techniques have enhanced biopharmaceutical characterization capabilities and have supported an increased development of biopharmaceutical products. Beyond its routine qualitative characterization, the quantitative feature of LC-MS has unique applications in biopharmaceutical process development and manufacturing. This review describes the recent applications and implications of the advancement of quantitative MS methods in biopharmaceutical process development, and characterization of biopharmaceutical product, product-related variants, and process-related impurities. We also provide insights on the emerging applications of quantitative MS in the lifecycle of biopharmaceutical product development including quality control in the Good Manufacturing Practice (GMP) environment and process analytical technology (PAT) practices during process development and manufacturing. Through collaboration with instrument and software vendors and regulatory agencies, we envision broader adoption of phase-appropriate quantitative MS-based methods for the analysis of biopharmaceutical products, which in turn has the potential to enable manufacture of higher quality products for patients.
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Affiliation(s)
- Xuanwen Li
- Analytical Research and Development, MRL, Merck & Co., Inc., 126 E. Lincoln Avenue, Rahway, NJ 07065, USA.
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7
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Zhang S, Zhao B, Adaniya S, Xiao H, Li N. Ultrasensitive Quantification Method for Understanding Biologically Relevant Concentrations of Host Cell Proteins in Therapeutics. Anal Chem 2023; 95:6002-6008. [PMID: 36977129 DOI: 10.1021/acs.analchem.3c00020] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 03/30/2023]
Abstract
Certain host cell proteins (HCPs) in biotherapeutic drugs may be detrimental to drug product quality even when they are present at the subppm level. Therefore, an analytical method that can reliably quantify trace amounts of HCPs is desirable. This study demonstrates a novel strategy to quantify HCPs present at subppm levels with ProteoMiner enrichment coupled with limited digestion followed by targeted analysis with nano-liquid chromatography-parallel reaction monitoring. The method can achieve LLOQ values as low as 0.06 ppm, with an accuracy of 85%-111% of the theoretical value, and inter-run and intrarun precision within 12% and 25%, respectively. The approach was applied to the quantification of five high-risk HCPs in drug products. The results indicated that 2.5 ppm lysosomal acid lipase, 0.14 ppm liver carboxylesterase, 1.8 ppm palmitoyl-protein thioesterase 1, and 1 ppm cathepsin D affected the stability of drug products, whereas drug products could safely contain 1.5 ppm lipoprotein lipase, 0.1 ppm lysosomal acid lipase, or 0.3 ppm cathepsin D. In combination with lipase activity analysis, the accurate quantification of lipases/esterases in drug products enables better understanding and comparison of the enzymatic activity of polysorbate degradation from endogenous proteins.
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Affiliation(s)
- Sisi Zhang
- Regeneron Pharmaceuticals Inc., 777 Old Saw Mill River Road, Tarrytown, New York 10591-6706, United States
| | - Bo Zhao
- Regeneron Pharmaceuticals Inc., 777 Old Saw Mill River Road, Tarrytown, New York 10591-6706, United States
| | - Stephanie Adaniya
- Regeneron Pharmaceuticals Inc., 777 Old Saw Mill River Road, Tarrytown, New York 10591-6706, United States
| | - Hui Xiao
- Regeneron Pharmaceuticals Inc., 777 Old Saw Mill River Road, Tarrytown, New York 10591-6706, United States
| | - Ning Li
- Regeneron Pharmaceuticals Inc., 777 Old Saw Mill River Road, Tarrytown, New York 10591-6706, United States
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8
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Characterization of Recombinantly-Expressed Hydrolytic Enzymes from Chinese Hamster Ovary Cells: Identification of Host Cell Proteins that Degrade Polysorbate. J Pharm Sci 2023; 112:1351-1363. [PMID: 36646283 DOI: 10.1016/j.xphs.2023.01.003] [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: 09/30/2022] [Revised: 01/03/2023] [Accepted: 01/03/2023] [Indexed: 01/15/2023]
Abstract
Enzymatic hydrolysis of polysorbate in drug products is a major challenge for the biopharmaceutical industry. Polysorbate hydrolysis caused by host cell proteins (HCPs) co-purified during bioprocessing can reduce the protective effects of the surfactant for the active pharmaceutical ingredient and cause the accumulation of low-solubility degradation products over the long-term storage. The identities of such HCPs are elusive due to their extremely low concentrations after the efficient purification processes of most biopharmaceuticals. In this work, 20 enzymes-selected for their known or putative hydrolytic activity and potential to degrade polysorbate-were recombinantly expressed, purified, and characterized via orthogonal methods. First, these recombinant HCPs were assessed for hydrolytic activity against a fluorogenic esterase substrate in a recently-developed, high-throughput assay. Second, these HCPs were screened for hydrolytic activity against polysorbate in a representative mAb formulation. Third, HCPs that displayed hydrolytic activities in the first two assays were subjected to more detailed characterization of their enzyme kinetics against polysorbates. Finally, these HCPs were evaluated for substrate specificity towards different sub-species of polysorbates. This work provides critical new insights for targeted LC-MS/MS approaches for identification of relevant polysorbate-degrading enzymes and supports improvements to remove such HCPs, including knockouts or targeted removal during purification.
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9
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Castañeda Ruiz AJ, Shetab Boushehri MA, Phan T, Carle S, Garidel P, Buske J, Lamprecht A. Alternative Excipients for Protein Stabilization in Protein Therapeutics: Overcoming the Limitations of Polysorbates. Pharmaceutics 2022; 14:pharmaceutics14122575. [PMID: 36559072 PMCID: PMC9781097 DOI: 10.3390/pharmaceutics14122575] [Citation(s) in RCA: 11] [Impact Index Per Article: 5.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/20/2022] [Revised: 11/11/2022] [Accepted: 11/15/2022] [Indexed: 11/25/2022] Open
Abstract
Given their safety and efficiency in protecting protein integrity, polysorbates (PSs) have been the most widely used excipients for the stabilization of protein therapeutics for years. In recent decades, however, there have been numerous reports about visible or sub-visible particles in PS-containing biotherapeutic products, which is a major quality concern for parenteral drugs. Alternative excipients that are safe for parenteral administration, efficient in protecting different protein drugs against various stress conditions, effective in protein stabilization in high-concentrated liquid formulations, stable under the storage conditions for the duration of the product's shelf-life, and compatible with other formulation components and the primary packaging are highly sought after. The aim of this paper is to review potential alternative excipients from different families, including surfactants, carbohydrate- and amino acid-based excipients, synthetic amphiphilic polymers, and ionic liquids that enable protein stabilization. For each category, important characteristics such as the ability to stabilize proteins against thermal and mechanical stresses, current knowledge related to the safety profile for parenteral administration, potential interactions with other formulation components, and primary packaging are debated. Based on the provided information and the detailed discussion thereof, this paper may pave the way for the identification or development of efficient excipients for biotherapeutic protein stabilization.
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Affiliation(s)
- Angel J. Castañeda Ruiz
- Department of Pharmaceutical Technology and Biopharmaceutics, University of Bonn, 53121 Bonn, Germany
| | | | - Tamara Phan
- Boehringer Ingelheim Pharma GmbH & Co. KG, Innovation Unit, PDB, Birkendorfer Straße 65, 88397 Biberach an der Riss, Germany
| | - Stefan Carle
- Boehringer Ingelheim Pharma GmbH & Co. KG, Innovation Unit, PDB, Birkendorfer Straße 65, 88397 Biberach an der Riss, Germany
| | - Patrick Garidel
- Boehringer Ingelheim Pharma GmbH & Co. KG, Innovation Unit, PDB, Birkendorfer Straße 65, 88397 Biberach an der Riss, Germany
| | - Julia Buske
- Boehringer Ingelheim Pharma GmbH & Co. KG, Innovation Unit, PDB, Birkendorfer Straße 65, 88397 Biberach an der Riss, Germany
- Correspondence: (J.B.); (A.L.); Tel.: +49-7351-54-145-398 (J.B.); +49-228-735-243 (A.L.)
| | - Alf Lamprecht
- Department of Pharmaceutical Technology and Biopharmaceutics, University of Bonn, 53121 Bonn, Germany
- Correspondence: (J.B.); (A.L.); Tel.: +49-7351-54-145-398 (J.B.); +49-228-735-243 (A.L.)
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10
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Wuchner K, Yi L, Chery C, Nikels F, Junge F, Crotts G, Rinaldi G, Starkey JA, Bechtold-Peters K, Shuman M, Leiss M, Jahn M, Garidel P, de Ruiter R, Richer SM, Cao S, Peuker S, Huille S, Wang T, Brun VL. Industry Perspective on the Use and Characterization of Polysorbates for Biopharmaceutical Products Part 2: Survey Report on Control Strategy Preparing for the Future. J Pharm Sci 2022; 111:2955-2967. [PMID: 36002077 DOI: 10.1016/j.xphs.2022.08.021] [Citation(s) in RCA: 17] [Impact Index Per Article: 8.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/14/2022] [Revised: 08/17/2022] [Accepted: 08/17/2022] [Indexed: 12/14/2022]
Abstract
Polysorbate (PS) 20 and 80 are the main surfactants used to stabilize biopharmaceutical products. Industry practices on various aspects of PS based on a confidential survey and following discussions by 16 globally acting major biotechnology companies is presented in two publications. Part 1 summarizes the current practice and use of PS during manufacture in addition to aspects like current understanding of the (in)stability of PS, the routine QC testing and control of PS, and selected regulatory aspects of PS.1 The current part 2 of the survey focusses on understanding, monitoring, prediction, and mitigation of PS degradation pathways in order to propose an effective control strategy. The results of the survey and extensive cross-company discussions are put into relation with currently available scientific literature.
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Affiliation(s)
- Klaus Wuchner
- Janssen R&D, DPDS BTDS Analytical Development, Hochstr. 201, 8200 Schaffhausen, Switzerland.
| | - Linda Yi
- Analytical Development, Biogen, Morrisville, NC 27709, USA
| | - Cyrille Chery
- UCB, Analytical Development Sciences for Biologicals, Chemin du Foriest, 1420 Braine-l'Alleud, Belgium
| | - Felix Nikels
- Boehringer Ingelheim Pharma GmbH & Co KG, Innovation Unit, Birkendorfer Str. 65, 88397 Biberach an der Riss, Germany
| | - Friederike Junge
- Analytical Research and Development, NBE Analytical R&D, AbbVie Deutschland GmbH& Co. KG, Knollstraße, 67061 Ludwigshafen, Germany
| | - George Crotts
- GlaxoSmithKline, 1250 S Collegeville Rd, Collegeville, PA 19426, USA
| | - Gianluca Rinaldi
- Merck Serono SpA, Guidonia Montecelio, Italy, an affiliate of Merck KGaA, Darmstadt, Germany
| | - Jason A Starkey
- Pfizer, Inc. Biotherapeutics Pharmaceutical Sciences, Analytical Research and Development 875 W. Chesterfield Parkway, Chesterfield, MO 63017, USA
| | | | - Melissa Shuman
- GlaxoSmithKline, 1250 S Collegeville Rd, Collegeville, PA 19426, USA
| | - Michael Leiss
- Pharma Technical Development Analytics, Roche Diagnostics GmbH, Nonnenwald 2, Penzberg, 82377, Germany
| | - Michael Jahn
- Lonza AG, Drug Product Services, Hochbergerstr. 60G, CH-4057 Basel, Switzerland
| | - Patrick Garidel
- Boehringer Ingelheim Pharma GmbH & Co KG, Innovation Unit, Birkendorfer Str. 65, 88397 Biberach an der Riss, Germany
| | - Rien de Ruiter
- Byondis B.V., Downstream Processing, Nijmegen, the Netherlands
| | - Sarah M Richer
- Bioproduct Research and Development, Lilly Research Laboratories, Eli Lilly and Company, Indianapolis, IN 46285, USA
| | - Shawn Cao
- Process Development, Amgen Inc., 1 Amgen Center Drive, Thousand Oaks, CA 91320, USA
| | - Sebastian Peuker
- Bayer AG, Product Supply, Analytical Development and Clinical QC for Biotech Products, Friedrich-Ebert-Str. 217-233, 42117 Wuppertal, Germany
| | - Sylvain Huille
- Sanofi R&D, Biologics Drug Products Development,13 quai Jules Guesde, 94403 Vitry-sur Seine, France
| | - Tingting Wang
- Bioproduct Research and Development, Lilly Research Laboratories, Eli Lilly and Company, Indianapolis, IN 46285, USA
| | - Virginie Le Brun
- Lonza AG, Drug Product Services, Hochbergerstr. 60G, CH-4057 Basel, Switzerland
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11
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Zhang S, Xiao H, Li N. The Characterization of Polysorbate. Curr Protoc 2022; 2:e489. [PMID: 35857882 DOI: 10.1002/cpz1.489] [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] [Indexed: 06/15/2023]
Abstract
Polysorbates (PSs), including PS20 and PS80, are non-ionic surfactants widely used in the pharmaceutical industry to enhance drug solubility and stability. Despite their wide application, PSs are prone to degradation by either hydrolysis or oxidation in drug formulations during storage; therefore, a PS characterization method assessing protein products is needed for stability testing and for understanding the degradation pathway. In this article, we detail our protocol for sample preparation for forced degradation study and our instrumentation setup for PS profiling and quantitation in protein samples. © 2022 Wiley Periodicals LLC. Basic Protocol 1: Sample preparation for forced degradation of polysorbate in protein samples Basic Protocol 2: Two-dimensional liquid chromatography coupled with charged aerosol detector or mass spectrometry to analyze polysorbate degradation.
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Affiliation(s)
- Sisi Zhang
- Regeneron Pharmaceuticals Inc., Tarrytown, New York
| | - Hui Xiao
- Regeneron Pharmaceuticals Inc., Tarrytown, New York
| | - Ning Li
- Regeneron Pharmaceuticals Inc., Tarrytown, New York
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12
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Industry perspective on the use and characterization of polysorbates for biopharmaceutical products Part 1: Survey report on current state and common practices for handling and control of polysorbates. J Pharm Sci 2022; 111:1280-1291. [PMID: 35192858 DOI: 10.1016/j.xphs.2022.02.009] [Citation(s) in RCA: 28] [Impact Index Per Article: 14.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/17/2021] [Revised: 02/16/2022] [Accepted: 02/16/2022] [Indexed: 11/20/2022]
Abstract
Polysorbates (PS) are widely used as a stabilizer in biopharmaceutical products. Industry practices on various aspects of PS are presented in this part 1 survey report based on a confidential survey and following discussions by 16 globally acting major biotechnology companies. The current practice and use of PS during manufacture across their global manufacturing sites are covered in addition to aspects like current understanding of the (in)stability of PS, the routine QC testing and control of PS, and selected regulatory aspects of PS. The results of the survey and extensive cross-company discussions are put into relation with currently available scientific literature. Part 2 of the survey report (upcoming) will focus on understanding, monitoring, prediction, and mitigation of PS degradation pathways to develop an effective control strategy.
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13
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Li X, Wang F, Li H, Richardson DD, Roush DJ. The measurement and control of high-risk host cell proteins for polysorbate degradation in biologics formulation. Antib Ther 2022; 5:42-54. [PMID: 35155990 PMCID: PMC8826928 DOI: 10.1093/abt/tbac002] [Citation(s) in RCA: 9] [Impact Index Per Article: 4.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/04/2021] [Revised: 12/21/2021] [Accepted: 01/02/2022] [Indexed: 11/13/2022] Open
Abstract
Nonionic surfactant polysorbates, including PS-80 and PS-20, are commonly used in the formulation of biotherapeutic products for both preventing surface adsorption and acting as stabilizer against protein aggregation. Trace levels of residual host cell proteins (HCPs) with lipase or esterase enzymatic activity have been shown to degrade polysorbates in biologics formulation. The measurement and control of these low abundance, high-risk HCPs for polysorbate degradation are an industry-wide challenge to achieve desired shelf life of biopharmaceuticals in liquid formulation, especially for high-concentration formulation product development. Here, we reviewed the challenges, recent advances, and future opportunities of analytical method development, risk assessment, and control strategies for polysorbate degradation during formulation development with a focus on enzymatic degradation. Continued efforts to advance our understanding of polysorbate degradation in biologics formulation will help develop high-quality medicines for patients.
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Affiliation(s)
- Xuanwen Li
- Analytical Research & Development, Merck & Co., Inc., 2000 Galloping Hill Road, Kenilworth, NJ 07033, USA
- To whom correspondence should be addressed: Xuanwen Li, Analytical Research & Development Mass Spectrometry, Merck & Co. Inc., 770 Sumneytown Pike, WPP042A-4015, West Point, PA 19486. Tel: 215-652-1829;
| | - Fengqiang Wang
- Analytical Research & Development, Merck & Co., Inc., 2000 Galloping Hill Road, Kenilworth, NJ 07033, USA
| | - Hong Li
- Biologics Process Research & Development, Merck & Co., Inc., 2000 Galloping Hill Road, Kenilworth, NJ 07033, USA
| | - Douglas D Richardson
- Analytical Research & Development, Merck & Co., Inc., 2000 Galloping Hill Road, Kenilworth, NJ 07033, USA
| | - David J Roush
- Biologics Process Research & Development, Merck & Co., Inc., 2000 Galloping Hill Road, Kenilworth, NJ 07033, USA
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14
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Zhang S, Riccardi C, Kamen D, Xiao H, Li N. Monitoring polysorbate hydrolysis in therapeutic proteins using an ultrasensitive extraction-free fatty acid quantitation method. Anal Biochem 2022; 637:114472. [PMID: 34801481 DOI: 10.1016/j.ab.2021.114472] [Citation(s) in RCA: 8] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/01/2021] [Revised: 11/10/2021] [Accepted: 11/11/2021] [Indexed: 01/15/2023]
Abstract
Polysorbates (PSs) are surfactants commonly added to therapeutic protein drug product formulations to protect proteins from denaturation and aggregation during storage, transportation, and delivery. However, enzymatic hydrolysis of PSs has been recognized as the primary route of PS degradation in monoclonal antibody formulations, resulting in the release of free fatty acids that drive undesired particulate formation. Here, we present a rapid lipase activity assay with optimized incubation conditions for accurate quantitation of free fatty acids without a fatty acid extraction step. This assay can detect low levels of PS degradation (0.000024% PS20 degradation) within 1 day with minimal sample preparation. The levels of released free fatty acids were found to strongly correlate with the degree of PS20 degradation. The case study described herein suggests that this approach can detect low levels of PS20 degradation caused by sub-ppm lipase levels within 1 day, compared with the duration of 14 days needed for PS degradation assays based on two-dimensional liquid chromatography-charge aerosol detection.
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Affiliation(s)
- Sisi Zhang
- Analytical Chemistry, Regeneron Pharmaceuticals, Tarrytown, NY, 10591, USA
| | - Caterina Riccardi
- Formulation Group, Regeneron Pharmaceuticals, Tarrytown, NY, 10591, USA
| | - Douglas Kamen
- Formulation Group, Regeneron Pharmaceuticals, Tarrytown, NY, 10591, USA
| | - Hui Xiao
- Analytical Chemistry, Regeneron Pharmaceuticals, Tarrytown, NY, 10591, USA.
| | - Ning Li
- Analytical Chemistry, Regeneron Pharmaceuticals, Tarrytown, NY, 10591, USA
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15
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Identification of the specific causes of polysorbate 20 degradation in monoclonal antibody formulations containing multiple lipases. Pharm Res 2022; 39:75-87. [PMID: 34981317 DOI: 10.1007/s11095-021-03160-3] [Citation(s) in RCA: 15] [Impact Index Per Article: 7.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/06/2021] [Accepted: 12/21/2021] [Indexed: 01/22/2023]
Abstract
PURPOSE Polysorbates (PS) are excipients used in the biotech industry to stabilize monoclonal antibody (mAb) protein products. However, PS in drug product formulations can be degraded during storage and lead to particle formation because of the limited solubility of the free fatty acids released through the enzymatic hydrolysis of PS-a process driven by residual host cell proteins, especially lipases, that are co-purified with the drugs. When multiple lipases are present, it is very difficult to know the cause for PS degradation. In this study, we aim to determine the cause of PS degradation from two lipases, lysosomal acid lipase (LAL) and lipoprotein lipase (LPL). METHODS PS degradation pattern of the drug product was compared with those induced by recombinant lipases. Correlations between the concentration of LPL or LAL and PS20 loss were compared. Specific inhibitors, LAL inhibitor lalistat2 and LPL inhibitor GSK264220A, were used to differentiate their degradation of PS in the drug products. RESULTS The complete inhibition of PS20 degradation by lalistat2 suggested that LAL, rather than LPL, was responsible for the PS20 degradation. In addition, LAL was more strongly correlated than LPL with the percentage of PS20 degradation. No PS20 degradation was observed for several mAbs containing similar levels of LPL (0.5-1.5 ppm) in the absence of LAL, suggesting that LPL concentrations below 1.5 ppm does not degrade PS20 in drug products. CONCLUSIONS LAL was determined to be the cause of the PS20 degradation. This study provides a practical strategy to determine the root cause of PS degradation.
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16
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Hecht ES, Mehta S, Wecksler AT, Aguilar B, Swanson N, Phung W, Dubey Kelsoe A, Benner WH, Tesar D, Kelley RF, Sandoval W, Sreedhara A. Insights into ultra-low affinity lipase-antibody noncovalent complex binding mechanisms. MAbs 2022; 14:2135183. [PMID: 36284469 PMCID: PMC9621051 DOI: 10.1080/19420862.2022.2135183] [Citation(s) in RCA: 6] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/31/2022] Open
Abstract
Detection of host cell protein (HCP) impurities is critical to ensuring that recombinant drug products, including monoclonal antibodies (mAbs), are safe. Mechanistic characterization as to how HCPs persist in drug products is important to refining downstream processing. It has been hypothesized that weak lipase-mAb interactions enable HCP lipases to evade drug purification processes. Here, we apply state-of-the-art methods to establish lipase-mAb binding mechanisms. First, the mass spectrometry (MS) approach of fast photochemical oxidation of proteins was used to elucidate putative binding regions. The CH1 domain was identified as a conserved interaction site for IgG1 and IgG4 mAbs against the HCPs phospholipase B-like protein (PLBL2) and lysosomal phospholipase A2 (LPLA2). Rationally designed mutations in the CH1 domain of the IgG4 mAb caused a 3- to 70-fold KD reduction against PLBL2 by surface plasmon resonance (SPR). LPLA2-IgG4 mutant complexes, undetected by SPR and studied using native MS collisional dissociation experiments, also showed significant complex disruption, from 16% to 100%. Native MS and ion mobility (IM) determined complex stoichiometries for four lipase-IgG4 complexes and directly interrogated the enrichment of specific lipase glycoforms. Confirmed with time-course and exoglycosidase experiments, deglycosylated lipases prevented binding, and low-molecular-weight glycoforms promoted binding, to mAbs. This work demonstrates the value of integrated biophysical approaches to characterize micromolar affinity complexes. It is the first in-depth structural report of lipase-mAb binding, finding roles for the CH1 domain and lipase glycosylation in mediating binding. The structural insights gained offer new approaches for the bioengineering of cells or mAbs to reduce HCP impurity levels.Abbreviations: CAN, Acetonitrile; AMAC, Ammonium acetate; BFGS, Broyden-Fletcher-Goldfarb-Shanno; CHO, Chinese Hamster Ovary; KD, Dissociation constant; DTT, Dithiothreitol; ELISA, Enzyme-linked immunosorbent assay; FPOP, Fast photochemical oxidation of proteins; FA, Formic acid; F(ab'), Fragment antibodies; HCP, Host cell protein; IgG, Immunoglobulin; IM, Ion mobility; LOD, Lower limit of detection; LPLA2, Lysosomal phospholipase A2; Man, Mannose; MS, Mass spectrometry; MeOH, Methanol; MST, Microscale thermophoresis; mAbs, Monoclonal antibodies; PPT1, Palmitoyl protein thioesterase; ppm, Parts per million; PLBL2, Phospholipase B-like protein; PLD3, Phospholipase D3; PS-20, Polysorbate-20; SP, Sphingomyelin phosphodiesterase; SPR, Surface plasmon resonance; TFA, Trifluoroacetic acid.
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Affiliation(s)
- Elizabeth Sara Hecht
- Microchemistry, Proteomics, and Lipidomics, Genentech, IncSouth San Francisco, CA, USA
| | - Shrenik Mehta
- Pharmaceutical Development, Genentech, IncSouth San Francisco, CA, USA
| | - Aaron T. Wecksler
- Protein Analytical Chemistry, Genentech, IncSouth San Francisco, CA, USA
| | | | - Nathaniel Swanson
- Pharmaceutical Development, Genentech, IncSouth San Francisco, CA, USA
| | - Wilson Phung
- Microchemistry, Proteomics, and Lipidomics, Genentech, IncSouth San Francisco, CA, USA
| | | | | | - Devin Tesar
- Pharmaceutical Development, Genentech, IncSouth San Francisco, CA, USA
| | - Robert F. Kelley
- Pharmaceutical Development, Genentech, IncSouth San Francisco, CA, USA
| | - Wendy Sandoval
- Microchemistry, Proteomics, and Lipidomics, Genentech, IncSouth San Francisco, CA, USA,CONTACT Wendy Sandoval Microchemistry, Proteomics, and Lipidomics, Genentech, Inc South San Francisco, CA, USA
| | - Alavattam Sreedhara
- Pharmaceutical Development, Genentech, IncSouth San Francisco, CA, USA,Alavattam Sreedhara Pharmaceutical Development, Genentech, Inc, 1 DNA Way, South San Francisco, CA94080, USA
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17
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Degradation of Polysorbate 20 by Sialate O-Acetylesterase in Monoclonal Antibody Formulations. J Pharm Sci 2021; 110:3866-3873. [PMID: 34487744 DOI: 10.1016/j.xphs.2021.09.001] [Citation(s) in RCA: 22] [Impact Index Per Article: 7.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/30/2021] [Revised: 09/01/2021] [Accepted: 09/01/2021] [Indexed: 11/22/2022]
Abstract
Polysorbates (PS) are surfactants commonly added in biologics formulations that can protect proteins from denaturation and aggregation. However, decreases in polysorbate 20 (PS20) content have been observed in some monoclonal antibody formulations, causing the formation of visible and/or subvisible particles that ultimately compromise the quality and stability of the therapeutic protein products. It was determined that the particles are mainly composed of free fatty acid, suggesting enzymatic hydrolysis of PS is responsible for the degradation of PS. Enrichment of host cell proteins (HCPs) by immunoprecipitation followed by shotgun proteomics have been utilized to identify the HCPs that can hydrolyze PS20. One HCP, sialate O-acetylesterase (SIAE), demonstrated strong enzymatic activity for PS20 degradation even at low concentration (<5 ppm level). Incubation of recombinant SIAE with PS20 resulted in a unique degradation pattern where the hydrolysis of monoester with short fatty acid chain (C12, C14) was observed but not the monoester with long fatty acid chain (C16, C18) or higher-order esters. SIAE was detected and quantitated in several formulated mAbs, and the amount of SIAE was positively correlated to PS20 degradation in these mAbs during incubation. Additional experiments also showed that when SIAE was depleted, PS20 degradation was diminished, suggesting a causality between SIAE and PS20 degradation. The lipase activity of SIAE is specific to PS20, but not to PS 80 (PS80), which contains monoesters with long chain fatty acid (C18) and higher-order esters. The specific esterase activity of SIAE on PS20 suggests a possible solution of using PS80 over PS20 to eliminate surfactant degradation in mAb products.
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18
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Liu H, Jin Y, Menon R, Laskowich E, Bareford L, de Vilmorin P, Kolwyck D, Yeung B, Yi L. Characterization of Polysorbate 80 by Liquid Chromatography-Mass Spectrometry to Understand Its Susceptibility to Degradation and Its Oxidative Degradation Pathway. J Pharm Sci 2021; 111:323-334. [PMID: 34416271 DOI: 10.1016/j.xphs.2021.08.017] [Citation(s) in RCA: 17] [Impact Index Per Article: 5.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/24/2021] [Revised: 08/15/2021] [Accepted: 08/15/2021] [Indexed: 10/20/2022]
Abstract
A liquid chromatography-mass spectrometry (LC-MS) method was developed to provide a fingerprint of polysorbate 80 (PS80) subspecies that enables identification of PS80 degradation pathway. The developed method demonstrates unique monoester peak profile of PS80 from different vendors, attributed by differences in relative abundance of the fatty acid monoesters. The LC-MS method was also applied to examine the susceptibility of PS80, at different grades, to auto-oxidation and hydrolysis. PS80 oxidative degradation induced by iron or occurred in open bottle without nitrogen overlay was found to follow the same pathway, but at a much faster rate in the former scenario. The oxidation preferentially occurs at the double bond of fatty acid chains, thus providing explanation on the faster degradation observed in PS80 at Chinese Pharmacopia (ChP) grade than at multi-compendial (MC) grade. In contrast, the difference in susceptibility of MC and ChP grade PS80 against esterase-induced hydrolysis in placebo was not pronounced. The method was also able to provide a fingerprint to identify both PS80 hydrolysis and oxidation in mAb drug product stability samples, but it required a solid phase extraction step to remove protein prior to the analysis.
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Affiliation(s)
- Haiyan Liu
- Analytical Development, Biogen Inc., 5000 Davis Drive, RTP, NC 27709, United States
| | - Yutong Jin
- Analytical Development, Biogen Inc., 5000 Davis Drive, RTP, NC 27709, United States
| | - Rashmi Menon
- Analytical Development, Biogen Inc., 5000 Davis Drive, RTP, NC 27709, United States
| | - Erin Laskowich
- Analytical Development, Biogen Inc., 5000 Davis Drive, RTP, NC 27709, United States
| | - Lisa Bareford
- Materials Science, Biogen Inc., 5000 Davis Drive, RTP, NC 27709, United States
| | - Phil de Vilmorin
- Materials Science, Biogen Inc., 5000 Davis Drive, RTP, NC 27709, United States
| | - Dave Kolwyck
- Materials Science, Biogen Inc., 5000 Davis Drive, RTP, NC 27709, United States
| | - Bernice Yeung
- Analytical Development, Biogen Inc., 5000 Davis Drive, RTP, NC 27709, United States
| | - Linda Yi
- Analytical Development, Biogen Inc., 5000 Davis Drive, RTP, NC 27709, United States.
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19
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Graf T, Tomlinson A, Yuk IH, Kufer R, Spensberger B, Falkenstein R, Shen A, Li H, Duan D, Liu W, Wohlrab S, Edelmann F, Leiss M. Identification and Characterization of Polysorbate-Degrading Enzymes in a Monoclonal Antibody Formulation. J Pharm Sci 2021; 110:3558-3567. [PMID: 34224732 DOI: 10.1016/j.xphs.2021.06.033] [Citation(s) in RCA: 33] [Impact Index Per Article: 11.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/21/2021] [Revised: 06/28/2021] [Accepted: 06/29/2021] [Indexed: 11/29/2022]
Abstract
Degradation of polysorbate (PS) by hydrolytically active host cell proteins (HCPs) in drug products may impair the protein-stabilizing properties of PS and lead to the formation of particles due to the accumulation of poorly soluble free fatty acids upon long-term storage. The identification of the causative enzymes is challenging due to their low-abundance even when using state-of-the-art instrumentation and workflows. To overcome these challenges, we developed a rigorous enrichment strategy for HCPs, utilizing both Protein A and anti-HCP affinity chromatography, which facilitated the in-depth characterization of the HCP population in a monoclonal antibody formulation prone to PS hydrolysis. Based on the HCPs identified by liquid chromatography coupled to tandem mass spectrometry, a number of enzymes annotated as hydrolases were recombinantly expressed and characterized in terms of polysorbate degradation. Among the selected candidates, Lipoprotein Lipase, Lysosomal Acid Lipase (LIPA) and Palmitoyl-Protein Thioesterase 1 (PPT1) exhibited notable activity towards PS. To our knowledge, this is the first report to identify LIPA and PPT1 as residual HCPs that can contribute to PS degradation in a biological product.
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Affiliation(s)
- Tobias Graf
- Roche Diagnostics GmbH, Nonnenwald 2, 82377 Penzberg, Germany.
| | - Anthony Tomlinson
- Pharma Technical Development, Genentech, 1 DNA Way, South San Francisco, California, USA
| | - Inn H Yuk
- Pharma Technical Development, Genentech, 1 DNA Way, South San Francisco, California, USA
| | - Regina Kufer
- Roche Diagnostics GmbH, Nonnenwald 2, 82377 Penzberg, Germany
| | | | | | - Amy Shen
- Pharma Technical Development, Genentech, 1 DNA Way, South San Francisco, California, USA
| | - Hong Li
- Pharma Technical Development, Genentech, 1 DNA Way, South San Francisco, California, USA
| | - Dana Duan
- Pharma Technical Development, Genentech, 1 DNA Way, South San Francisco, California, USA
| | - Wenqiang Liu
- Pharma Technical Development, Genentech, 1 DNA Way, South San Francisco, California, USA
| | | | | | - Michael Leiss
- Roche Diagnostics GmbH, Nonnenwald 2, 82377 Penzberg, Germany
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20
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Jones M, Palackal N, Wang F, Gaza-Bulseco G, Hurkmans K, Zhao Y, Chitikila C, Clavier S, Liu S, Menesale E, Schonenbach NS, Sharma S, Valax P, Waerner T, Zhang L, Connolly T. "High-risk" host cell proteins (HCPs): A multi-company collaborative view. Biotechnol Bioeng 2021; 118:2870-2885. [PMID: 33930190 DOI: 10.1002/bit.27808] [Citation(s) in RCA: 54] [Impact Index Per Article: 18.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/14/2020] [Revised: 04/08/2021] [Accepted: 04/08/2021] [Indexed: 12/14/2022]
Abstract
Host cell proteins (HCPs) are process-related impurities that may copurify with biopharmaceutical drug products. Within this class of impurities there are some that are more problematic. These problematic HCPs can be considered high-risk and can include those that are immunogenic, biologically active, or enzymatically active with the potential to degrade either product molecules or excipients used in formulation. Some have been shown to be difficult to remove by purification. Why should the biopharmaceutical industry worry about these high-risk HCPs? What approach could be taken to understand the origin of its copurification and address these high-risk HCPs? To answer these questions, the BioPhorum Development Group HCP Workstream initiated a collaboration among its 26-company team with the goal of industry alignment around high-risk HCPs. The information gathered through literature searches, company experiences, and surveys were used to compile a list of frequently seen problematic/high-risk HCPs. These high-risk HCPs were further classified based on their potential impact into different risk categories. A step-by-step recommendation is provided for establishing a comprehensive control strategy based on risk assessments for monitoring and/or eliminating the known impurity from the process that would be beneficial to the biopharmaceutical industry.
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Affiliation(s)
- Marisa Jones
- GlaxoSmithKline, CMC Analytical, Structure & Function Characterization, Collegeville, Pennsylvania, USA
| | - Nisha Palackal
- Regeneron Pharmaceuticals Inc., Protein Biochemistry, Tarrytown, New York, USA
| | - Fengqiang Wang
- Merck & Co. Inc., Analytical Research & Development, Kenilworth, New Jersey, USA
| | | | - Karen Hurkmans
- AbbVie Bioresearch Center, Protein Analytics, Worcester, Massachusetts, USA
| | - Yiwei Zhao
- Takeda Pharmaceuticals, Pharmaceutical science, Cambridge, Massachusetts, USA
| | - Carmelata Chitikila
- Janssen R&D LLC, BioTherapeutics Development and Supply, Analytical Development, Bioassay Methods Development, Malvern, Pennsylvania, USA
| | - Severine Clavier
- Sanofi R&D, BioAnalytics, Biologics Development, Vitry-sur-seine, France
| | - Suli Liu
- Biogen, Analytical Development, Cambridge, Massachusetts, USA
| | - Emily Menesale
- Biogen, Analytical Development, Cambridge, Massachusetts, USA
| | - Nicole S Schonenbach
- Pfizer, Downstream Process Development, Bioprocess R&D, Chesterfield, Missouri, USA
| | - Satish Sharma
- Bristol Meyers Squibb, Analytical Development, New York, New York, USA
| | - Pascal Valax
- Merck KGaA, Global Healthcare Operations, Development and Launch, Biotech Process Sciences, Merck BioDevelopment, Martillac, France
| | - Thomas Waerner
- Boehringer Ingelheim Pharma, GmbH & Co. KG, Analytical Development, Biologicals, Biberach, Germany
| | - Lei Zhang
- Bristol Meyers Squibb, Analytical Development, New York, New York, USA
| | - Trish Connolly
- Development Group Phorum, BioPhorum, The Gridiron building, One Pancras Square, London, UK
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21
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Roy I, Patel A, Kumar V, Nanda T, Assenberg R, Wuchner K, Amin K. Polysorbate Degradation and Particle Formation in a High Concentration mAb: Formulation Strategies to Minimize Effect of Enzymatic Polysorbate Degradation. J Pharm Sci 2021; 110:3313-3323. [PMID: 34077768 DOI: 10.1016/j.xphs.2021.05.012] [Citation(s) in RCA: 24] [Impact Index Per Article: 8.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/17/2020] [Revised: 04/26/2021] [Accepted: 05/10/2021] [Indexed: 12/24/2022]
Abstract
Polysorbate (PS) 20 and 80 are the most common surfactants in monoclonal antibody (mAb) drug product (DP) formulations. Residual host cell proteins (HCP) present at extremely low concentrations in DP formulations can maintain enough enzymatic activity to degrade PS surfactants. Over time, the hydrolysis of surfactant causes the accumulation of minimally soluble free fatty acids resulting in precipitation and formation of subvisible and visible particulates. This manuscript summarizes the investigation of a batch of high concentration (>100 mg/mL) mAb DP where subvisible particles formed abruptly after prolonged storage at 5C°. The work also summarizes the effectiveness of different strategies for managing host cell proteins and fatty acid particles. The concentration and fatty acid composition of polysorbates were found to be significant factors in particle development. Solubilizers and alternative surfactants were all shown to be effective means of preventing particle formation. Lipase inhibitors proved to be a simple means to identify the problem but are more difficult to utilize as a solution.
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Affiliation(s)
- Ian Roy
- Drug Product Development, BioTherapeutics Development, Janssen Research & Development, 200 Great Valley Parkway, Malvern, PA 19355, USA.
| | - Ashaben Patel
- Drug Product Development, BioTherapeutics Development, Janssen Research & Development, 200 Great Valley Parkway, Malvern, PA 19355, USA
| | - Vineet Kumar
- Drug Product Development, BioTherapeutics Development, Janssen Research & Development, 200 Great Valley Parkway, Malvern, PA 19355, USA
| | - Tatiana Nanda
- Drug Product Development, BioTherapeutics Development, Janssen Research & Development, 200 Great Valley Parkway, Malvern, PA 19355, USA
| | - Rene Assenberg
- Analytical Development, BioTherapeutics Development, Janssen Research & Development, 200 Great Valley Parkway, Malvern, PA 19355, USA
| | - Klaus Wuchner
- Analytical Development, BioTherapeutics Development, Janssen Research & Development, 200 Great Valley Parkway, Malvern, PA 19355, USA
| | - Ketan Amin
- Drug Product Development, BioTherapeutics Development, Janssen Research & Development, 200 Great Valley Parkway, Malvern, PA 19355, USA
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22
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Li X, Chandra D, Letarte S, Adam GC, Welch J, Yang RS, Rivera S, Bodea S, Dow A, Chi A, Strulson CA, Richardson DD. Profiling Active Enzymes for Polysorbate Degradation in Biotherapeutics by Activity-Based Protein Profiling. Anal Chem 2021; 93:8161-8169. [PMID: 34032423 DOI: 10.1021/acs.analchem.1c00042] [Citation(s) in RCA: 23] [Impact Index Per Article: 7.7] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/25/2022]
Abstract
Polysorbate is widely used to maintain stability of biotherapeutic proteins in pharmaceutical formulation development. Degradation of polysorbate can lead to particle formation in drug products, which is a major quality concern and potential patient risk factor. Enzymatic activity from residual host cell enzymes such as lipases and esterases plays a major role for polysorbate degradation. Their high activity, often at very low concentration, constitutes a major analytical challenge in the biopharmaceutical industry. In this study, we evaluated and optimized the activity-based protein profiling (ABPP) approach to identify active enzymes responsible for polysorbate degradation. Using an optimized chemical probe, we established the first global profile of active serine hydrolases in harvested cell culture fluid (HCCF) for monoclonal antibodies (mAbs) production from two Chinese hamster ovary (CHO) cell lines. A total of eight known lipases were identified by ABPP with enzyme activity information, while only five lipases were identified by a traditional abundance-based proteomics (TABP) approach. Interestingly, phospholipase B-like 2 (PLBL2), a well-known problematic HCP was not found to be active in process-intermediates from two different mAbs. In a proof-of-concept study with downstream samples, phospholipase A2 group VII (PLA2G7) was only identified by ABPP and confirmed to contribute to polysorbate-80 degradation for the first time. The established ABBP approach is approved to be able to identify low-abundance host cell enzymes and fills the gap between lipase abundance and activity, which enables more meaningful polysorbate degradation investigations for biotherapeutic development.
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Affiliation(s)
- Xuanwen Li
- Analytical Research & Development Mass Spectrometry, Merck & Co., Inc., 2000 Galloping Hill Road, Kenilworth, New Jersey 07033, United States
| | - Divya Chandra
- Biologics Process Research & Development, Merck & Co., Inc., 2000 Galloping Hill Road, Kenilworth, New Jersey 07033, United States
| | - Simon Letarte
- Analytical Research & Development Mass Spectrometry, Merck & Co., Inc., 2000 Galloping Hill Road, Kenilworth, New Jersey 07033, United States
| | - Gregory C Adam
- Quantitative Biosciences, Merck & Co., Inc., 770 Sumneytown Pike, West Point, Pennsylvania 19486, United States
| | - Jonathan Welch
- Biologics Analytical Research & Development, Merck & Co., Inc., 2000 Galloping Hill Road, Kenilworth, New Jersey 07033, United States
| | - Rong-Sheng Yang
- Analytical Research & Development Mass Spectrometry, Merck & Co., Inc., 2000 Galloping Hill Road, Kenilworth, New Jersey 07033, United States
| | - Shannon Rivera
- Analytical Research & Development Mass Spectrometry, Merck & Co., Inc., 2000 Galloping Hill Road, Kenilworth, New Jersey 07033, United States
| | - Smaranda Bodea
- Chemical Biology, Merck & Co., Inc., 33 Avenue Louis Pasteur, Boston, Massachusetts 02115, United States
| | - Alex Dow
- Biologics Analytical Research & Development, Merck & Co., Inc., 2000 Galloping Hill Road, Kenilworth, New Jersey 07033, United States
| | - An Chi
- Chemical Biology, Merck & Co., Inc., 33 Avenue Louis Pasteur, Boston, Massachusetts 02115, United States
| | - Christopher A Strulson
- Biologics Analytical Research & Development, Merck & Co., Inc., 2000 Galloping Hill Road, Kenilworth, New Jersey 07033, United States
| | - Douglas D Richardson
- Analytical Research & Development Mass Spectrometry, Merck & Co., Inc., 2000 Galloping Hill Road, Kenilworth, New Jersey 07033, United States
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