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Powers AD, Drury JE, Hoehamer CF, Lockey TD, Meagher MM. Lentiviral Vector Production from a Stable Packaging Cell Line Using a Packed Bed Bioreactor. Mol Ther Methods Clin Dev 2020; 19:1-13. [PMID: 32995355 DOI: 10.1016/j.omtm.2020.08.010] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [What about the content of this article? (0)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 06/17/2020] [Accepted: 08/10/2020] [Indexed: 12/11/2022]
Abstract
Self-inactivating lentiviral vectors (LVVs) are used regularly for genetic modification of cells, including T cells and hematopoietic stem cells for cellular gene therapy. As vector demand grows, scalable and controllable methods are needed for production. LVVs are typically produced in HEK293T cells in suspension bioreactors using serum-free media or adherent cultures with serum. The iCELLis® is a packed-bed bioreactor for adherent or entrained cells with surface areas from 0.53 to 500 m2. Media are pumped through the fixed bed and overflows, creating a thin film that is replenished with oxygen and depleted of CO2 as media return to the reservoir. We describe the optimization and scale-up of the production of GPRTG-EF1α-hγc-OPT LVV using a stable packaging cell line in the iCELLis Nano 2-cm to the 10-cm bed height low compaction bioreactors (0.53 and 2.6 m2 surface area) and compare to the productivity and efficacy of GPRTG-EF1α-hγc-OPT LVV manufactured under current Good Manufacturing Practice (cGMP) using 10-layer cell factories for the treatment of X-linked severe combined immunodeficiency. By optimizing fetal bovine serum (FBS) concentration, pH post-induction, and day of induction, we attain viral yields of more than 2 × 107 transducing units/mL. We compared transduction efficiency between LVVs produced from the iCELLis Nano and cell factories on healthy, purified CD34+ cells and found similar results.
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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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