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Helleckes LM, Wirnsperger C, Polak J, Guillén-Gosálbez G, Butté A, von Stosch M. Novel calibration design improves knowledge transfer across products for the characterization of pharmaceutical bioprocesses. Biotechnol J 2024; 19:e2400080. [PMID: 38997212 DOI: 10.1002/biot.202400080] [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: 02/12/2024] [Revised: 05/31/2024] [Accepted: 06/17/2024] [Indexed: 07/14/2024]
Abstract
Modern machine learning has the potential to fundamentally change the way bioprocesses are developed. In particular, horizontal knowledge transfer methods, which seek to exploit data from historical processes to facilitate process development for a new product, provide an opportunity to rethink current workflows. In this work, we first assess the potential of two knowledge transfer approaches, meta learning and one-hot encoding, in combination with Gaussian process (GP) models. We compare their performance with GPs trained only on data of the new process, that is, local models. Using simulated mammalian cell culture data, we observe that both knowledge transfer approaches exhibit test set errors that are approximately halved compared to those of the local models when two, four, or eight experiments of the new product are used for training. Subsequently, we address the question whether experiments for a new product could be designed more effectively by exploiting existing knowledge. In particular, we suggest to specifically design a few runs for the novel product to calibrate knowledge transfer models, a task that we coin calibration design. We propose a customized objective function to identify a set of calibration design runs, which exploits differences in the process evolution of historical products. In two simulated case studies, we observed that training with calibration designs yields similar test set errors compared to common design of experiments approaches. However, the former requires approximately four times fewer experiments. Overall, the results suggest that process development could be significantly streamlined when systematically carrying knowledge from one product to the next.
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Affiliation(s)
- Laura M Helleckes
- Institute of Bio- and Geosciences, IBG-1: Biotechnology, Forschungszentrum Jülich GmbH, Jülich, Germany
- Institute of Biotechnology, RWTH Aachen University, Aachen, Germany
| | | | | | - Gonzalo Guillén-Gosálbez
- Department of Chemistry and Applied Biosciences, Institute for Chemical and Bioengineering, ETH Zurich, Zurich, Switzerland
| | - Alessandro Butté
- DataHow AG, Zurich, Switzerland
- Department of Chemistry and Applied Biosciences, Institute for Chemical and Bioengineering, ETH Zurich, Zurich, Switzerland
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2
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Pastrana B, Culyba E, Nieves S, Sazinsky SL, Canto EI, Noda I. Streamlined Multi-Attribute Assessment of an Array of Clinical-Stage Antibodies: Relationship Between Degradation and Stability. APPLIED SPECTROSCOPY 2024:37028241231824. [PMID: 38419510 DOI: 10.1177/00037028241231824] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 03/02/2024]
Abstract
Clinical antibodies are an important class of drugs for the treatment of both chronic and acute diseases. Their manufacturability is subject to evaluation to ensure product quality and efficacy. One critical quality attribute is deamidation, a non-enzymatic process that is observed to occur during thermal stress, at low or high pH, or a combination thereof. Deamidation may induce antibody instability and lead to aggregation, which may pose immunogenicity concerns. The introduction of a negative charge via deamidation may impact the desired therapeutic function (i) within the complementarity-determining region, potentially causing loss of efficacy; or (ii) within the fragment crystallizable region, limiting the effector function involving antibody-dependent cellular cytotoxicity. Here we describe a transformative solution that allows for a comparative assessment of deamidation and its impact on stability and aggregation. The innovative streamlined method evaluates the intact protein in its formulation conditions. This breakthrough platform technology is comprised of a quantum cascade laser microscope, a slide cell array that allows for flexibility in the design of experiments, and dedicated software. The enhanced spectral resolution is achieved using two-dimensional correlation, co-distribution, and two-trace two-dimensional correlation spectroscopies that reveal the molecular impact of deamidation. Eight re-engineered immunoglobulin G4 scaffold clinical antibodies under control and forced degradation conditions were evaluated for deamidation and aggregation. We determined the site of deamidation, the overall extent of deamidation, and where applicable, whether the deamidation event led to self-association or aggregation of the clinical antibody and the molecular events that led to the instability. The results were confirmed using orthogonal techniques for four of the samples.
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Affiliation(s)
- Belinda Pastrana
- Research and Development, Protein Dynamic Solutions, Inc., Wakefield, Massachusetts, USA
| | - Elizabeth Culyba
- Research and Development, Protein Dynamic Solutions, Inc., Wakefield, Massachusetts, USA
- Antibody Discovery, Verseau Therapeutics, Inc., Bedford, Massachusetts, USA
| | - Sherly Nieves
- Research and Development, Protein Dynamic Solutions, Inc., Wakefield, Massachusetts, USA
| | - Stephen L Sazinsky
- Antibody Discovery, Verseau Therapeutics, Inc., Bedford, Massachusetts, USA
| | - Eduardo I Canto
- Translational Sciences, Auxilio BioLab, Auxilio Mutuo Hospital, San Juan, Puerto Rico, USA
| | - Isao Noda
- Infectious Disease Research, Department of Materials Sciences and Engineering, University of Delaware, Newark, Delaware, USA
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3
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Kelley B. The history and potential future of monoclonal antibody therapeutics development and manufacturing in four eras. MAbs 2024; 16:2373330. [PMID: 38946434 PMCID: PMC11218797 DOI: 10.1080/19420862.2024.2373330] [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: 05/07/2024] [Accepted: 06/24/2024] [Indexed: 07/02/2024] Open
Abstract
Therapeutic monoclonal antibody (mAb) development and the processes for manufacturing drug substance have evolved since the first approval of the mAb in 1986. As the past is often the prologue to the future, the history of these technologies has been classified here into three eras, leading to speculation about what the next era may hold with regard to development and manufacturing strategies, as well as the potential impacts to patients. The substantial increase in production culture titers and bioreactor production volumes and the availability of large-scale contract manufacturing facilities could translate into improved global access for these therapies and an expansion of indications for therapeutic antibodies.
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Affiliation(s)
- Brian Kelley
- Process & Product Development, Vir Biotechnology Inc, San Francisco, CA, USA
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4
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Marschall L, Gottimukkala CB, Kayal B, Veeraraghavan VM, Mandal SK, Bandyopadhyay S, Herwig C. Temperature Upshifts in Mammalian Cell Culture: A Suitable Strategy for Biosimilar Monoclonal Antibodies? Bioengineering (Basel) 2023; 10:1149. [PMID: 37892879 PMCID: PMC10603922 DOI: 10.3390/bioengineering10101149] [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: 08/22/2023] [Revised: 09/22/2023] [Accepted: 09/26/2023] [Indexed: 10/29/2023] Open
Abstract
Temperature downshifts are the gold standard when setting up control strategies for mammalian cell culture processes. These shifts are performed to prolong production phases and attain heightened levels of productivity. For the development of biosimilars, however, the bottleneck is in achieving a prespecified product quality. In a late-stage development project, we investigated the impact of temperature shifts and other process parameters with the aim of optimizing the glycosylation profile of a monoclonal antibody (mAb). We applied a design of experiments approach on a 3 L scale. The optimal glycosylation profile was achieved when performing a temperature upshift from 35.8 °C to 37 °C. Total afucosylated glycan (TAF) decreased by 1.2%, and galactosylated glycan species (GAL) increased by up to 4.5%. The optimized control strategy was then successfully taken to the manufacturing scale (1000 L). By testing two sets of set points at the manufacturing scale, we demonstrated that the statistical models predicting TAF and GAL trained with small-scale data are representative of the manufacturing scale. We hope this study encourages researchers to widen the screening ranges in process development and investigate whether temperature upshifts are also beneficial for other mAbs.
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Affiliation(s)
- Lukas Marschall
- TU Wien, Faculty of Technical Chemistry, Research Unit Biochemical Engineering, Gumpendorferstrasse 1a, 1060 Vienna, Austria
- Körber Pharma Austria GmbH, Mariahilfer Straße 88A/1/9, 1070 Vienna, Austria
| | - Chitti Babu Gottimukkala
- Dr. Reddy’s Laboratories Ltd., Biologics, Survey No. 47, Bachupally, Hyderabad 500090, India; (C.B.G.); (B.K.); (V.M.V.); (S.K.M.); (S.B.)
| | - Biswajit Kayal
- Dr. Reddy’s Laboratories Ltd., Biologics, Survey No. 47, Bachupally, Hyderabad 500090, India; (C.B.G.); (B.K.); (V.M.V.); (S.K.M.); (S.B.)
| | - Veerabhadra Madurai Veeraraghavan
- Dr. Reddy’s Laboratories Ltd., Biologics, Survey No. 47, Bachupally, Hyderabad 500090, India; (C.B.G.); (B.K.); (V.M.V.); (S.K.M.); (S.B.)
| | - Samir Kumar Mandal
- Dr. Reddy’s Laboratories Ltd., Biologics, Survey No. 47, Bachupally, Hyderabad 500090, India; (C.B.G.); (B.K.); (V.M.V.); (S.K.M.); (S.B.)
| | - Suman Bandyopadhyay
- Dr. Reddy’s Laboratories Ltd., Biologics, Survey No. 47, Bachupally, Hyderabad 500090, India; (C.B.G.); (B.K.); (V.M.V.); (S.K.M.); (S.B.)
| | - Christoph Herwig
- TU Wien, Faculty of Technical Chemistry, Research Unit Biochemical Engineering, Gumpendorferstrasse 1a, 1060 Vienna, Austria
- Körber Pharma Austria GmbH, Mariahilfer Straße 88A/1/9, 1070 Vienna, Austria
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5
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Ben Yahia B, Piednoir A, Dahomais T, Eggermont S, Paul W. "Organized stress" for robust scale-up of intensified production process with fed-batch seed bioreactor. Biotechnol Bioeng 2023; 120:2509-2522. [PMID: 37027375 DOI: 10.1002/bit.28396] [Citation(s) in RCA: 3] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/30/2022] [Revised: 03/17/2023] [Accepted: 03/27/2023] [Indexed: 04/08/2023]
Abstract
Process intensification has been widely used for many years in the mammalian biomanufacturing industry to increase productivity, agility and flexibility while reducing production costs. The most commonly used intensified processes are operated using a perfusion or fed-batch seed bioreactor enabling a higher than usual seeding density in the fed-batch production bioreactor. Hence, as part of the growth phase is shifted to the seed bioreactor, there is a lower split ratio, which increases the criticality of the seed bioreactor and could impact production performance. Therefore, such intensified processes should be designed and characterized for robust process scale-up. This research work is focused on intensified processes with high seeding density inoculated from seed bioreactor in fed-batch mode. The impact of the feeding strategy and specific power input (P/V) in the seed bioreactor and on the production step with two different cell lines (CL1 and CL2) producing two different monoclonal antibodies was investigated. Cell culture performance in the production bioreactor has been improved due to more stressful conditions for the cells in the seed bioreactor and the impact of the production bioreactor P/V on the production performance was limited. This is the first reported study highlighting a positive impact of cellular stress in seed bioreactors on intensified production bioreactor with the introduction of the "organized stress" concept.
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Affiliation(s)
- Bassem Ben Yahia
- Biologics Process Sciences, Biotech Sciences, UCB Pharma S.A., Avenue de l'Industrie, Brussels, Braine l'Alleud, Belgium
| | - Antoine Piednoir
- Biologics Process Sciences, Biotech Sciences, UCB Pharma S.A., Avenue de l'Industrie, Brussels, Braine l'Alleud, Belgium
| | - Thomas Dahomais
- Biologics Process Sciences, Biotech Sciences, UCB Pharma S.A., Avenue de l'Industrie, Brussels, Braine l'Alleud, Belgium
| | - Stefanie Eggermont
- Biologics Process Sciences, Biotech Sciences, UCB Pharma S.A., Avenue de l'Industrie, Brussels, Braine l'Alleud, Belgium
| | - Wolfgang Paul
- Biologics Process Sciences, Biotech Sciences, UCB Pharma S.A., Avenue de l'Industrie, Brussels, Braine l'Alleud, Belgium
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6
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Handlogten MW, Bosley S, Dunn S, Zhu J, Lee-O'Brien A, Li L, Therres J, Chakrabarti L, Khanal B, Mowery R, Arumugam S, Klover J, Taleb M, Reier J, Hatton D, Schmelzer A. Accelerated cell culture process development and characterization for cilgavimab/tixagevimab (AZD7442) for the prevention and treatment of COVID-19. Biotechnol Bioeng 2023. [PMID: 36722717 DOI: 10.1002/bit.28336] [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: 11/23/2022] [Revised: 01/20/2023] [Accepted: 01/21/2023] [Indexed: 02/02/2023]
Abstract
The global COVID-19 pandemic ignited an unprecedented race to develop vaccines and antibody therapeutics. AstraZeneca's pursuit to provide AZD7442 (EVUSHELD), two long-acting, SARS-CoV-2 spike receptor binding domain-specific neutralizing monoclonal antibodies, to individuals at risk on highly accelerated timelines challenged our traditional ways of process development and spurred the rapid adoption of novel approaches. Conventional upstream development processes were replaced by agile strategies that combined technological advances and highly accelerated workflows. With calculated business risks and close cross-functional collaborations, this process paved the way for hyper accelerated antibody development from discovery through manufacturing, process validation, emergency use authorization filing, and global regulatory approvals. The result was initiation of commercial manufacturing at a contract manufacturing organization less than 6 months from the selection of cilgavimab and tixagevimab-a process that historically has taken close to 10 years.
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Affiliation(s)
- Michael W Handlogten
- Cell Culture and Fermentation Sciences, BioPharmaceuticals R&D, AstraZeneca, Gaithersburg, Maryland, USA
| | - Stefanie Bosley
- Cell Culture and Fermentation Sciences, BioPharmaceuticals R&D, AstraZeneca, Gaithersburg, Maryland, USA
| | - Sarah Dunn
- Cell Culture and Fermentation Sciences, BioPharmaceuticals R&D, AstraZeneca, Cambridge, UK
| | - Jie Zhu
- Cell Culture and Fermentation Sciences, BioPharmaceuticals R&D, AstraZeneca, Gaithersburg, Maryland, USA
| | - Allison Lee-O'Brien
- Cell Culture and Fermentation Sciences, BioPharmaceuticals R&D, AstraZeneca, Gaithersburg, Maryland, USA
| | - Lina Li
- Cell Culture and Fermentation Sciences, BioPharmaceuticals R&D, AstraZeneca, Gaithersburg, Maryland, USA
| | - Jamy Therres
- Cell Culture and Fermentation Sciences, BioPharmaceuticals R&D, AstraZeneca, Gaithersburg, Maryland, USA
| | - Lina Chakrabarti
- Cell Culture and Fermentation Sciences, BioPharmaceuticals R&D, AstraZeneca, Gaithersburg, Maryland, USA
| | - Bijay Khanal
- Cell Culture and Fermentation Sciences, BioPharmaceuticals R&D, AstraZeneca, Gaithersburg, Maryland, USA
| | - Rachel Mowery
- Cell Culture and Fermentation Sciences, BioPharmaceuticals R&D, AstraZeneca, Gaithersburg, Maryland, USA
| | - Subhashini Arumugam
- Cell Culture and Fermentation Sciences, BioPharmaceuticals R&D, AstraZeneca, Gaithersburg, Maryland, USA
| | - Judith Klover
- Cell Culture and Fermentation Sciences, BioPharmaceuticals R&D, AstraZeneca, Gaithersburg, Maryland, USA
| | - Mohammed Taleb
- Cell Culture and Fermentation Sciences, BioPharmaceuticals R&D, AstraZeneca, Gaithersburg, Maryland, USA
| | - Jason Reier
- Cell Culture and Fermentation Sciences, BioPharmaceuticals R&D, AstraZeneca, Gaithersburg, Maryland, USA
| | - Diane Hatton
- Cell Culture and Fermentation Sciences, BioPharmaceuticals R&D, AstraZeneca, Cambridge, UK
| | - Albert Schmelzer
- Cell Culture and Fermentation Sciences, BioPharmaceuticals R&D, AstraZeneca, Gaithersburg, Maryland, USA
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7
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Tan KW, Ji P, Qian Z, Gao Q, Wang S, Li Q, Gu M, Zhang Q, Hou C, Huang Y, Lian D, Wang J, Zhang Z, Zhang S, Wu J, Zhou W. Rapidly accelerated development of neutralizing COVID-19 antibodies by reducing cell line and CMC development timelines. Biotechnol Bioeng 2022:10.1002/bit.28302. [PMID: 36482495 PMCID: PMC9877800 DOI: 10.1002/bit.28302] [Citation(s) in RCA: 9] [Impact Index Per Article: 4.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/02/2022] [Accepted: 12/06/2022] [Indexed: 12/13/2022]
Abstract
Since the Coronavirus Disease 2019 (COVID-19) outbreak, unconventional cell line development (CLD) strategies have been taken to enable development of severe acute respiratory syndrome coronavirus 2 (SARS-CoV-2)-neutralizing antibodies at expedited speed. We previously reported a novel chemistry, manufacturing, and control (CMC) workflow and demonstrated a much-shortened timeline of 3-6 months from DNA to investigational new drug (IND) application. Hereafter, we have incorporated this CMC strategy for many SARS-CoV-2-neutralizing antibody programs at WuXi Biologics. In this paper, we summarize the accelerated development of a total of seven antibody programs, some of which have received emergency use authorization approval in less than 2 years. Stable pools generated under good manufacturing practice (GMP) conditions consistently exhibited similar productivity and product quality at different scales and batches, enabling rapid initiation of phase I clinical trials. Clones with comparable product quality as parental pools were subsequently screened and selected for late-stage development and manufacturing. Moreover, a preliminary stability study plan was devised to greatly reduce the time required for final clone determination and next-generation sequencing-based viral testing was implemented to support rapid conditional release of the master cell bank for GMP production. The successful execution of these COVID-19 programs relies on our robust, fit for purpose, and continuously improving CLD platform. The speed achieved for pandemic-related biologics development may innovate typical biologics development timelines and become a new standard in the industry.
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Affiliation(s)
- Kee Wee Tan
- WuXi Biologics, Waigaoqiao Free Trade ZoneShanghaiChina
| | - Pengfei Ji
- WuXi Biologics, Waigaoqiao Free Trade ZoneShanghaiChina
| | - Zichen Qian
- WuXi Biologics, Waigaoqiao Free Trade ZoneShanghaiChina
| | - Qiao Gao
- WuXi Biologics, Waigaoqiao Free Trade ZoneShanghaiChina
| | - Shuai Wang
- WuXi Biologics, Waigaoqiao Free Trade ZoneShanghaiChina
| | - Qin Li
- WuXi Biologics, Waigaoqiao Free Trade ZoneShanghaiChina
| | - Mingzhu Gu
- WuXi Biologics, Waigaoqiao Free Trade ZoneShanghaiChina
| | - Qi Zhang
- WuXi Biologics, Waigaoqiao Free Trade ZoneShanghaiChina
| | - Chengjian Hou
- WuXi Biologics, Waigaoqiao Free Trade ZoneShanghaiChina
| | - Yang Huang
- WuXi Biologics, Waigaoqiao Free Trade ZoneShanghaiChina
| | - Dujuan Lian
- WuXi Biologics, Waigaoqiao Free Trade ZoneShanghaiChina
| | - Junghao Wang
- WuXi Biologics, Waigaoqiao Free Trade ZoneShanghaiChina
| | - Zheng Zhang
- WuXi Biologics, Waigaoqiao Free Trade ZoneShanghaiChina
| | - Sam Zhang
- WuXi Biologics, Waigaoqiao Free Trade ZoneShanghaiChina
| | - Jiansheng Wu
- WuXi Biologics, Waigaoqiao Free Trade ZoneShanghaiChina
| | - Weichang Zhou
- WuXi Biologics, Waigaoqiao Free Trade ZoneShanghaiChina
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8
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Kelley B, De Moor P, Douglas K, Renshaw T, Traviglia S. Monoclonal antibody therapies for COVID-19: lessons learned and implications for the development of future products. Curr Opin Biotechnol 2022; 78:102798. [PMID: 36179406 PMCID: PMC9436891 DOI: 10.1016/j.copbio.2022.102798] [Citation(s) in RCA: 16] [Impact Index Per Article: 8.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/11/2021] [Revised: 07/29/2022] [Accepted: 08/22/2022] [Indexed: 12/14/2022]
Abstract
Several companies were authorized to treat COVID-19 patients with monoclonal antibodies within 1-2 years of the start of the pandemic. These products were discovered, developed, manufactured, clinically tested, and approved under emergency-use authorization at unprecedented speed. Pandemic urgency led to novel development approaches that reduced the time to clinical trials by 75% or more without creating unacceptable patient or product-safety risks. Hundreds of thousands of patients now benefit from these therapeutics that have reduced the rates of hospitalization and death. The chemistry, manufacturing, and control development strategies set a new precedent of speed, safety, and demonstrated clinical benefit and will likely have a lasting impact on the development of future monoclonal antibody therapies for not only infectious diseases but also for oncology, inflammation, and rare diseases.
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