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Yang Z, Xu X, Silva CAT, Farnos O, Venereo-Sanchez A, Toussaint C, Dash S, González-Domínguez I, Bernier A, Henry O, Kamen A. Membrane Chromatography-Based Downstream Processing for Cell-Culture Produced Influenza Vaccines. Vaccines (Basel) 2022; 10:vaccines10081310. [PMID: 36016198 PMCID: PMC9414887 DOI: 10.3390/vaccines10081310] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/22/2022] [Revised: 08/10/2022] [Accepted: 08/11/2022] [Indexed: 11/18/2022] Open
Abstract
New influenza strains are constantly emerging, causing seasonal epidemics and raising concerns to the risk of a new global pandemic. Since vaccination is an effective method to prevent the spread of the disease and reduce its severity, the development of robust bioprocesses for producing pandemic influenza vaccines is exceptionally important. Herein, a membrane chromatography-based downstream processing platform with a demonstrated industrial application potential was established. Cell culture-derived influenza virus H1N1/A/PR/8/34 was harvested from benchtop bioreactor cultures. For the clarification of the cell culture broth, a depth filtration was selected as an alternative to centrifugation. After inactivation, an anion exchange chromatography membrane was used for viral capture and further processing. Additionally, two pandemic influenza virus strains, the H7N9 subtype of the A/Anhui/1/2013 and H3N2/A/Hong Kong/8/64, were successfully processed through similar downstream process steps establishing optimized process parameters. Overall, 41.3–62.5% viral recovery was achieved, with the removal of 86.3–96.5% host cell DNA and 95.5–99.7% of proteins. The proposed membrane chromatography purification is a scalable and generic method for the processing of different influenza strains and is a promising alternative to the current industrial purification of influenza vaccines based on ultracentrifugation methodologies.
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Affiliation(s)
- Zeyu Yang
- Viral Vectors and Vaccines Bioprocessing Group, Department of Bioengineering, McGill University, Montreal, QC H3A 0G4, Canada
| | - Xingge Xu
- Viral Vectors and Vaccines Bioprocessing Group, Department of Bioengineering, McGill University, Montreal, QC H3A 0G4, Canada
| | - Cristina A. T. Silva
- Viral Vectors and Vaccines Bioprocessing Group, Department of Bioengineering, McGill University, Montreal, QC H3A 0G4, Canada
- Department of Chemical Engineering, Polytechnique Montreal, Montreal, QC H3T 1J4, Canada
| | - Omar Farnos
- Viral Vectors and Vaccines Bioprocessing Group, Department of Bioengineering, McGill University, Montreal, QC H3A 0G4, Canada
| | - Alina Venereo-Sanchez
- Viral Vectors and Vaccines Bioprocessing Group, Department of Bioengineering, McGill University, Montreal, QC H3A 0G4, Canada
| | - Cécile Toussaint
- Viral Vectors and Vaccines Bioprocessing Group, Department of Bioengineering, McGill University, Montreal, QC H3A 0G4, Canada
| | - Shantoshini Dash
- Viral Vectors and Vaccines Bioprocessing Group, Department of Bioengineering, McGill University, Montreal, QC H3A 0G4, Canada
| | - Irene González-Domínguez
- Viral Vectors and Vaccines Bioprocessing Group, Department of Bioengineering, McGill University, Montreal, QC H3A 0G4, Canada
| | - Alice Bernier
- Viral Vectors and Vaccines Bioprocessing Group, Department of Bioengineering, McGill University, Montreal, QC H3A 0G4, Canada
| | - Olivier Henry
- Department of Chemical Engineering, Polytechnique Montreal, Montreal, QC H3T 1J4, Canada
| | - Amine Kamen
- Viral Vectors and Vaccines Bioprocessing Group, Department of Bioengineering, McGill University, Montreal, QC H3A 0G4, Canada
- Correspondence:
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Joshi PRH, Venereo-Sanchez A, Chahal PS, Kamen AA. Advancements in molecular design and bioprocessing of recombinant adeno-associated virus gene delivery vectors using the insect-cell baculovirus expression platform. Biotechnol J 2021; 16:e2000021. [PMID: 33277815 DOI: 10.1002/biot.202000021] [Citation(s) in RCA: 7] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/19/2020] [Revised: 11/27/2020] [Indexed: 01/23/2023]
Abstract
Despite rapid progress in the field, scalable high-yield production of adeno-associated virus (AAV) is still one of the critical bottlenecks the manufacturing sector is facing. The insect cell-baculovirus expression vector system (IC-BEVS) has emerged as a mainstream platform for the scalable production of recombinant proteins with clinically approved products for human use. In this review, we provide a detailed overview of the advancements in IC-BEVS for rAAV production. Since the first report of baculovirus-induced production of rAAV vector in insect cells in 2002, this platform has undergone significant improvements, including enhanced stability of Bac-vector expression and a reduced number of baculovirus-coinfections. The latter streamlining strategy led to the eventual development of the Two-Bac, One-Bac, and Mono-Bac systems. The one baculovirus system consisting of an inducible packaging insect cell line was further improved to enhance the AAV vector quality and potency. In parallel, the implementation of advanced manufacturing approaches and control of critical processing parameters have demonstrated promising results with process validation in large-scale bioreactor runs. Moreover, optimization of the molecular design of vectors to enable higher cell-specific yields of functional AAV particles combined with bioprocess intensification strategies may also contribute to addressing current and future manufacturing challenges.
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Affiliation(s)
- Pranav R H Joshi
- Department of Bioengineering, McGill University, Montréal, Quebec, Canada
| | | | - Parminder S Chahal
- Human Health Therapeutics Portfolio, National Research Council of Canada, Montréal, Quebec, Canada
| | - Amine A Kamen
- Department of Bioengineering, McGill University, Montréal, Quebec, Canada
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Venereo-Sanchez A, Simoneau M, Lanthier S, Chahal P, Bourget L, Ansorge S, Gilbert R, Henry O, Kamen A. Process intensification for high yield production of influenza H1N1 Gag virus-like particles using an inducible HEK-293 stable cell line. Vaccine 2017. [DOI: 10.1016/j.vaccine.2017.06.024] [Citation(s) in RCA: 22] [Impact Index Per Article: 3.1] [Reference Citation Analysis] [What about the content of this article? (0)] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/08/2023]
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Milián E, Julien T, Biaggio R, Venereo-Sanchez A, Montes J, Manceur AP, Ansorge S, Petiot E, Rosa-Calatrava M, Kamen A. Accelerated mass production of influenza virus seed stocks in HEK-293 suspension cell cultures by reverse genetics. Vaccine 2017; 35:3423-3430. [PMID: 28495315 DOI: 10.1016/j.vaccine.2017.04.065] [Citation(s) in RCA: 8] [Impact Index Per Article: 1.1] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/29/2017] [Revised: 04/14/2017] [Accepted: 04/23/2017] [Indexed: 01/20/2023]
Abstract
Despite major advances in developing capacities and alternative technologies to egg-based production of influenza vaccines, responsiveness to an influenza pandemic threat is limited by the time it takes to generate a Candidate Vaccine Virus (CVV) as reported by the 2015 WHO Informal Consultation report titled "Influenza Vaccine Response during the Start of a Pandemic". In previous work, we have shown that HEK-293 cell culture in suspension and serum free medium is an efficient production platform for cell culture manufacturing of influenza candidate vaccines. This report, took advantage of, recombinant DNA technology using Reverse Genetics of influenza strains, and advances in the large-scale transfection of suspension cultured HEK-293 cells. We demonstrate the efficient generation of H1N1 with the PR8 backbone reassortant under controlled bioreactor conditions in two sequential steps (transfection/rescue and infection/production). This approach could deliver a CVV for influenza vaccine manufacturing within two-weeks, starting from HA and NA pandemic sequences. Furthermore, the scalability of the transfection technology combined with the HEK-293 platform has been extensively demonstrated at >100L scale for several biologics, including recombinant viruses. Thus, this innovative approach is better suited to rationally engineer and mass produce influenza CVV within significantly shorter timelines to enable an effective global response in pandemic situations.
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Affiliation(s)
- Ernest Milián
- Department of Bioengineering, McGill University, Montréal, Québec, Canada; Vaccine Program, Human Health Therapeutics, National Research Council, Montréal, Québec, Canada
| | - Thomas Julien
- Virologie et Pathologie Humaine - VirPath Team, Centre International de Recherche en Infectiologie (CIRI), INSERM U1111, CNRS UMR5308, ENS Lyon, Université Claude Bernard Lyon 1, Université de Lyon, Lyon, France
| | - Rafael Biaggio
- Department of Bioengineering, McGill University, Montréal, Québec, Canada
| | - Alina Venereo-Sanchez
- Vaccine Program, Human Health Therapeutics, National Research Council, Montréal, Québec, Canada
| | - Johnny Montes
- Vaccine Program, Human Health Therapeutics, National Research Council, Montréal, Québec, Canada
| | - Aziza P Manceur
- Vaccine Program, Human Health Therapeutics, National Research Council, Montréal, Québec, Canada
| | - Sven Ansorge
- Vaccine Program, Human Health Therapeutics, National Research Council, Montréal, Québec, Canada
| | - Emma Petiot
- Virologie et Pathologie Humaine - VirPath Team, Centre International de Recherche en Infectiologie (CIRI), INSERM U1111, CNRS UMR5308, ENS Lyon, Université Claude Bernard Lyon 1, Université de Lyon, Lyon, France
| | - Manuel Rosa-Calatrava
- Virologie et Pathologie Humaine - VirPath Team, Centre International de Recherche en Infectiologie (CIRI), INSERM U1111, CNRS UMR5308, ENS Lyon, Université Claude Bernard Lyon 1, Université de Lyon, Lyon, France
| | - Amine Kamen
- Department of Bioengineering, McGill University, Montréal, Québec, Canada; Vaccine Program, Human Health Therapeutics, National Research Council, Montréal, Québec, Canada.
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Venereo-Sanchez A, Gilbert R, Simoneau M, Caron A, Chahal P, Chen W, Ansorge S, Li X, Henry O, Kamen A. Hemagglutinin and neuraminidase containing virus-like particles produced in HEK-293 suspension culture: An effective influenza vaccine candidate. Vaccine 2016; 34:3371-80. [PMID: 27155499 DOI: 10.1016/j.vaccine.2016.04.089] [Citation(s) in RCA: 37] [Impact Index Per Article: 4.6] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/17/2016] [Revised: 04/21/2016] [Accepted: 04/26/2016] [Indexed: 12/30/2022]
Abstract
Virus-like particles (VLPs) constitute a promising alternative as influenza vaccine. They are non-replicative particles that mimic the morphology of native viruses which make them more immunogenic than classical subunit vaccines. In this study, we propose HEK-293 cells in suspension culture in serum-free medium as an efficient platform to produce large quantities of VLPs. For this purpose, a stable cell line expressing the main influenza viral antigens hemagglutinin (HA) and neuraminidase (NA) (subtype H1N1) under the regulation of a cumate inducible promoter was developed (293HA-NA cells). The production of VLPs was evaluated by transient transfection of plasmids encoding human immunodeficiency virus (HIV) Gag or M1 influenza matrix protein. To facilitate the monitoring of VLPs production, Gag was fused to the green fluorescence protein (GFP). The transient transfection of the gag containing plasmid in 293HA-NA cells increased the release of HA and NA seven times more than its counterpart transfected with the M1 encoding plasmid. Consequently, the production of HA-NA containing VLPs using Gag as scaffold was evaluated in a 3-L controlled stirred tank bioreactor. The VLPs secreted in the culture medium were recovered by ultracentrifugation on a sucrose cushion and ultrafiltered by tangential flow filtration. Transmission electron micrographs of final sample revealed the presence of particles with the average typical size (150-200nm) and morphology of HIV-1 immature particles. The concentration of the influenza glycoproteins on the Gag-VLPs was estimated by single radial immunodiffusion and hemagglutination assay for HA and by Dot-Blot for HA and NA. More significantly, intranasal immunization of mice with influenza Gag-VLPs induced strong antigen-specific mucosal and systemic antibody responses and provided full protection against a lethal intranasal challenge with the homologous virus strain. These data suggest that, with further optimization and characterization the process could support mass production of safer and better-controlled VLPs-based influenza vaccine candidate.
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Affiliation(s)
- Alina Venereo-Sanchez
- Department of Chemical Engineering, Ecole Polytechnique de Montréal, Montréal, Québec, Canada; Vaccine Program, Human Health Therapeutics, National Research Council Canada, Montréal, Québec, Canada
| | - Renald Gilbert
- Vaccine Program, Human Health Therapeutics, National Research Council Canada, Montréal, Québec, Canada
| | - Melanie Simoneau
- Vaccine Program, Human Health Therapeutics, National Research Council Canada, Montréal, Québec, Canada
| | - Antoine Caron
- Vaccine Program, Human Health Therapeutics, National Research Council Canada, Montréal, Québec, Canada
| | - Parminder Chahal
- Vaccine Program, Human Health Therapeutics, National Research Council Canada, Montréal, Québec, Canada
| | - Wangxue Chen
- Human Health Therapeutics, National Research Council Canada, Ottawa, Ontario, Canada
| | - Sven Ansorge
- Vaccine Program, Human Health Therapeutics, National Research Council Canada, Montréal, Québec, Canada
| | - Xuguang Li
- Centre for Vaccine Evaluation, Biologics and Genetic Therapies Directorate, HPFB, Health Canada, Ottawa, Ontario, Canada
| | - Olivier Henry
- Department of Chemical Engineering, Ecole Polytechnique de Montréal, Montréal, Québec, Canada
| | - Amine Kamen
- Department of Bioengineering, McGill University, Montréal, Québec, Canada.
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Emmerling VV, Pegel A, Milian EG, Venereo-Sanchez A, Kunz M, Wegele J, Kamen AA, Kochanek S, Hoerer M. Rational plasmid design and bioprocess optimization to enhance recombinant adeno-associated virus (AAV) productivity in mammalian cells. Biotechnol J 2015; 11:290-7. [PMID: 26284700 DOI: 10.1002/biot.201500176] [Citation(s) in RCA: 28] [Impact Index Per Article: 3.1] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/07/2015] [Revised: 07/08/2015] [Accepted: 08/17/2015] [Indexed: 11/06/2022]
Abstract
Viral vectors used for gene and oncolytic therapy belong to the most promising biological products for future therapeutics. Clinical success of recombinant adeno-associated virus (rAAV) based therapies raises considerable demand for viral vectors, which cannot be met by current manufacturing strategies. Addressing existing bottlenecks, we improved a plasmid system termed rep/cap split packaging and designed a minimal plasmid encoding adenoviral helper function. Plasmid modifications led to a 12-fold increase in rAAV vector titers compared to the widely used pDG standard system. Evaluation of different production approaches revealed superiority of processes based on anchorage- and serum-dependent HEK293T cells, exhibiting about 15-fold higher specific and volumetric productivity compared to well-established suspension cells cultivated in serum-free medium. As for most other viral vectors, classical stirred-tank bioreactor production is thus still not capable of providing drug product of sufficient amount. We show that manufacturing strategies employing classical surface-providing culture systems can be successfully transferred to the new fully-controlled, single-use bioreactor system Integrity(TM) iCELLis(TM) . In summary, we demonstrate substantial bioprocess optimizations leading to more efficient and scalable production processes suggesting a promising way for flexible large-scale rAAV manufacturing.
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Affiliation(s)
- Verena V Emmerling
- Department of Gene Therapy, University of Ulm, Ulm, Baden-Württemberg, Germany. .,Development, Rentschler Biotechnologie GmbH, Laupheim, Baden-Württemberg, Germany.
| | - Antje Pegel
- Development, Rentschler Biotechnologie GmbH, Laupheim, Baden-Württemberg, Germany
| | - Ernest G Milian
- Human Health Therapeutics Portfolio, National Research Council of Canada, Montreal, QC, Canada
| | - Alina Venereo-Sanchez
- Human Health Therapeutics Portfolio, National Research Council of Canada, Montreal, QC, Canada
| | - Marion Kunz
- Development, Rentschler Biotechnologie GmbH, Laupheim, Baden-Württemberg, Germany
| | - Jessica Wegele
- Development, Rentschler Biotechnologie GmbH, Laupheim, Baden-Württemberg, Germany
| | - Amine A Kamen
- Department of Bioengineering, McGill University, Montreal, Quebec, Canada
| | - Stefan Kochanek
- Department of Gene Therapy, University of Ulm, Ulm, Baden-Württemberg, Germany
| | - Markus Hoerer
- Development, Rentschler Biotechnologie GmbH, Laupheim, Baden-Württemberg, Germany
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