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Upstream and Downstream Solutions For AA
Upstream and Downstream Solutions For AA
Upstream and Downstream Solutions For AA
VECTOR CHANNEL:
SUSPENSION CULTURE SYSTEMS
INNOVATOR INSIGHT
With the advancement of gene delivery vectors and gene editing tech-
nologies, cell and gene therapies are a very real solution to many pre-
viously untreatable or difficult to treat diseases. With this heightened
interest in cell and gene therapies, the need for powerful, cost-effective,
and scalable methods to deliver these therapies has intensified. Whilst
here are a number of non-viral methods for delivery of gene therapies al-
ready being utilized, viral delivery remains the most commonly employed
method. This article discusses the current AAV manufacuring workflows
and identifies opportunities, both upstream and downstream, for process
optimisation to support the scalable manufacture of viral vectors to sup-
port the increasing demand.
DOI: 10.18609/cgti.2019.110
With the advancement of gene add, silence, replace, and edit genes interest in gene therapies has con-
delivery vectors and gene editing to treat diseases like neuromuscular tinued to rise with the number of
technologies, cell and gene thera- disorders, immunodeficiencies, and gene therapy clinical trials steadi-
pies are a very real solution to many ocular and liver diseases as well as ly increasing internationally since
previously untreatable or difficult to develop enhanced cells for the treat- the first approved trial in 1989
treat diseases. It is now possible to ment of diseases like cancer. The (Figure 1A) [1,2]. The FDA alone is
www.insights.bio 1017
CELL & GENE THERAPY INSIGHTS
f FIGURE 1
Gene therapy clinical trials by year and delivery mechanism from 1989 through December of 2018.
2018
2017
2016
2015
2014
2013
2012
2011
2010
2009
2008
2007
2006
2005
2004
2003
2002
2001
2000 Adeno-associated virus Naked/Plasmid DNA + Vaccinia virus
1999 Adenovirus Naked/Plasmid DNA + Vesicular stomatitis virus
1998 Adenovirus + Maraba virus Newcastle disease virus
Adenovirus + Modified vaccinia Ankara virus (MVA) Non-viral
1997 Adenovirus + Retrovirus PiggyBacTM (PB) Transposon
1996 Adenovirus + Sendai virus Poliovirus
1995 Adenovirus + Vaccinia virus Poxvirus
Alphavirus (VEE) Replicon Vaccine Poxvirus + Vaccinia virus
1994 Antisense oligonucleotide Retrovirus
1993 Bifidobacterium longum Retrovirus + Lentivirus
1992 CRISPR-Cas9 RNA transfer
E. coli RNA transfer + Naked/Plasmid DNA
1991 Flavivirus RNA virus
1990 Gene gun Saccharomyces cerevisiae
Herpes simplex virus Salmonella typhimurium
1989 Human Rhinovirus (RG-HRV16) Semliki forest virus
0 50 100 150 200 250 Lactococcus lactis Sendai virus
Lentivirus Shigella dysenteriae
Lipofection Simian virus
Listeria monocytogenes siRNA
Live Attenuated Salmonella Sleeping Beauty transposon
Measles virus Streptococcus mutans
Modified Vaccinia Ankara virus (MVA) Vaccinia virus
mRNA Electroporation Venezuelan equine encephalitis virus replicon
Naked/Plasmid DNA Vesicular stomatitis virus
Naked/Plasmid DNA + Adenovirus Vibrio cholerae
Naked/Plasmid DNA + Modified Vaccinia Ankara virus Unknown
Naked/Plasmid DNA + RNA transfer
(A) The number of gene therapy clinical trials approved internationally by year. (B) Breakdown of the different delivery mechanisms
used for gene therapy. ©Journal of Gene Medicine a Wiley Publication.
expecting to receive over 200 INDs and non-dividing cells, its ability to
per year by 2020 with the approval maintain long-term gene expression,
of 10–20 cell and gene therapies per and increased safety. In fact, AAV
year by 2025 [3]. vectors are particularly safe because
The heightened interest in cell infection is not pathogenic, AAV
and gene therapies has increased cannot replicate on its own, and the
the need for powerful, cost-effec- vector is maintained as an episome
tive, and scalable methods to deliver instead of directly integrating into
these therapies. There exists many a host genome. Furthermore, AAV
non-viral methods for delivery of can target different tissue or cell
gene therapies, including electro- types depending on the composition
poration and chemical-based sys- of its capsid proteins, making it an
tems; however, viral delivery is the attractive candidate for delivery of
most commonly employed method gene therapies in vivo [4]. By con-
(e.g., adenovirus, retrovirus, lenti- trast, lentivirus, retrovirus, and elec-
virus, and adeno-associated virus troporation are often used for ex vivo
[AAV]) (Figure 1B) [1]. AAV stands gene therapies [4]. AAV has already
out for its ability to infect dividing demonstrated efficacy as a method
f FIGURE 2
Upstream and downstream processes of the AAV workflow.
Expression
vector
development
Harvest media
Finished batch
Concentration
of active substance
Cell banks
Mycoplasma
quantitation
Residual DNA
quantitation
Affinity
Viral plasmid
chromatography
transfection
purification
The upstream processes include cell line development, cell culture, and viral harvest. The downstream processes include purification,
formulation, and filling.
money, having confidence in every small and large scale, product release
step through QA/QC protocols, and stability testing, analytical qual-
and generating a pure, high-titer ification, process qualification, and
product. Luckily, advances in the commercial supply. Brammer Bio
technologies used throughout the is therefore able to support compa-
AAV manufacturing process have nies with both their upstream and
greatly improved viral production. downstream AAV manufacturing
Furthermore, CDMOs can help workflow for pre-clinical through to
companies develop an effective vi- commercial-scale production. With
ral production workflow for IND the development of new technolo-
filings. For example, Brammer Bio gies for viral production and puri-
has extensive experience as a viral fication, it is becoming easier and
vector manufacturer for gene ther- more cost-effective to produce virus
apies and provides such services as for gene therapies whether devel-
process and QC analytical valida- oping viral production in-house or
tion, cGMP manufacturing at both contracting out to a CDMO.
f TABLE 1
Percentage binding of different AAV serotypes using
the AAVX resin in a static binding assay.
POROS™ CaptureSelect™ AAVX resin.
AAV serotype Binding % (in eluate)
AAV1 99.63
AAV2 97.8
AAV2_HSPG 98.33
AAV4 98.05
AAV5 97.88
AAV6 97.45
AAV6.2 98.93
AAV7 98.37
AAV8 97.76
AAV9 98.43
AAVrh10 96.28
AAVrh32.33 99.29
AAV9PHPB 98.51
AAV7m8 98.39
Clarified lysates containing AAV was mixed with AAVX resin for ten minutes. AAV was
then eluted using acidic elution buffer at pH 2 (0.1M citric acid). Percentage binding
was determined by qPCR. Data kindly provided by Genethon.
f FIGURE 4
Comparison of the AVB Sepharose High Performance resin with the POROS CaptureSelect AAV8, AAV9,
and AAVX resins.
Percentage of binding for several AAV serotypes on 4 affinity resins
100
90 AVB Sepharose
80 (GE Healthcare)
Binding efficiency (%)
POROS™ AAV8
70
POROS™ AAV9
60 POROS™ AAVX
50
40
30
20
10
0
AAV8 AAV9 Rh10 Synth 1 Synth 2 Synth 3 Synth 4 Synth 5 Synth 6 Synth 7 Synth 8
AAV serotypes
These data were generated from purification of AAV8, 9, 10, and 8 synthetic capsids using 25 µL of resin in a 96-well plate format.
Data kindly provided by Genethon
Elution
Filtered
Elution
Filtered
elution
elution
elution
QA/QC protocols must be imple-
mented to help ensure the regula-
tory approval of the cell or gene
therapy. Two such regulations,
important for the viral production
process are the absence of Myco-
plasma in the cell culture and the
absence of residual DNA follow-
ing virus harvest and purification.
New analytics to ensure regulato-
ry compliance were required with
(A) Percentage elution recovery for each the advent of gene therapies. For
of the different flow rates. (B) SDS-PAGE example, traditionally, Mycoplas-
gel indicating AAV purity. The three
strong bands indicate each of the three ma detection required a 28-day
viral capsid proteins. (cmh = cm/hr) culture-based test; however, fast-
er detection methods are needed
as they contribute no benefit to because of the quick turnaround
the therapy and may even increase times required for cell and gene
the immunogenetic potential [14]. therapies. To fill this need, rapid,
The separation of empty and full qPCR-based tests were developed
capsids can be accomplished by a by a number of different compa-
separate polishing step following nies. Therefore, to identify the best
affinity chromatography. Since kit on the market, Duguid et al.
empty and full viral capsids have reviewed 21 different commercial
only a slight difference in isoelec- kits and ranked them based on
tric points (pIs), only high-reso- critical risk attributes. They used
lution anion exchange resins can their ranked list to select three kits
effectively separate empty and full to test for specificity, sensitivity,
capsids (e.g., Thermo Scientific™ and ease of use and identified the
POROS™ HQ (Figure 6) [11,15– Applied Biosystems™ MycoSEQ™
17]. Together the POROS Cap- Mycoplasma Detection Kit as the
tureSelect AAVX Affinity Resin best kit according to all three met-
and POROS ion exchange resins rics (Table 2) [18].
Conductivity (mS)
Absorbance (AU)
f TABLE 2
Results of a side-by-side study of three different qPCR kits for the detection of
Mycoplasma.
Criteria qPCR Kit 1 qPCR Kit 2 qPCR Kit 3
Specificity Un-spiked samples Negative Negative Negative
PC-spiked samples Positive Mixed Mixed
Organisms Wide range Wide range 8
detected
Cross-reactivity None detected S. pyogenes N/A
Sensitivity Minimum detected 4 copies 0.016 mL PC 50 copies
(0.004 mL PC) (0.25 mL PC)
Minimum 8 copies 0.03 mL PC 50 copies
reproduced (0.008 mL PC) (0.25 mL PC)
Other Sample preparation Optimized None <5% recovery
Kit Stability >1 month >1 month <1 month
Complexity Least Most N/A
Optimized for vari- Yes Yes No
ous instruments
Delivery TBD 2 wk – 2+ 1 day
mo
Logistics None Difficult None
Issues are in bold.
(Figure 8 & Table 3). The resDNA- that efficient and cost-effective
SEQ kit can therefore be used to strategies for viral production are
qualify products for lot release. necessary to meet market needs.
Recent technological advances
have significantly improved the
AAV production workflow. This
CONCLUSIONS includes technologies like se-
With the increased interest in gene rum-free HEK293 cell lines capa-
and cell therapies, it is apparent ble of growing to high confluency
f TABLE 3
DNA quantitation by the resDNASEQ Human DNA Residual DNA Quantitation Kit
from samples prepared using the PrepSEQ Residual DNA Sample Preparation.
Test sample 100 pg Spike 10 pg Spike 1 pg Spike
Buffer pg DNA % CV pg DNA % CV pg DNA %
recovered recovered recovered CV
Assay 1 75.2 11% 7 7% 0.65 5%
Assay 2 65.4 6.2 0.69
Assay 3 61.9 6.1 0.63
Assay 4 58.3 6.3 0.63
Assay 5 55 5.9 0.66
Assay 6 60 7.1 0.72
Average 62.63 6.43 0.66
Six samples were spiked with 100 pg, 10 pg, and 1 pg of human standard DNA respectively. The average and percent coefficient of
variation (%) were calculated for each DNA amount tested.
0.160
0.120
Derivative
0.080
M. arginini
Discriminatory
control
0.040
0.000
-0.040
60 65 70 75 80 85 90 95
Temperature (C)
Melting curves for Mycoplasma arginini and an unaltered positive control are shown
in blue and red respectively. The melting curve for the modified positive control is
shown in green.
f FIGURE 8
Amplification plot of a 10-fold serial dilution of human DNA using the resDNASEQ Human DNA Residu-
al DNA Quantitation Kit.
0.1
3 30 pg
0.01 4 3 pg
0.001 5 300 fg
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40
Cycle
Acknowledgements: The authors wish to thank Genethon for the provision of data contained within this article.
Disclosure and potential conflicts of interest: The authors are employees of Thermo Fisher Scientific. The authors declare
that they have no conflicts of interest.
Funding declaration: The authors received no financial support for the research, authorship and/or publication of this article.
Attribution: Copyright © 2019 Poling B & Kate G. Published by Cell and Gene Therapy Insights under Creative Commons
License Deed CC BY NC ND 4.0.
Submitted for peer review: 24 June 2019; Revised manuscript received: 26 July 2019; Publication date: 7 August 2019.
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