Protein Expression in CHO cells: Comparison of GPEx to a Traditional Cell Line Engineering Technology

Transcription

1 Protein Expression in CHO cells: Comparison of GPEx to a Traditional Cell Line Engineering Technology

2 Why is GPEx Technology Unique and Differentiated? Versatile Works on any mammalian cell line, and many eukaryotic cell lines High Yields Gene inserts target active regions of the cell genome, allowing for high levels of antibody production from the cell pools and lines Shortened Timelines Antibiotic selection or traditional gene amplification is not required, resulting in shorter clonal cell line development timelines Complex Molecules Time & Cost Savings High transduction efficiency, coupled with no antibiotic selection requirement, allows easy titration of multiple genes to the correct gene ratio to yield maximum recombinant protein production and efficient protein formation The technology inserts each copy of the transgene at a different genomic location producing very stable gene insertions and stable expression from both pooled and clonal selected cell lines.

3 GPEx : Cell Line Engineering GPEx (Gene Product Expression): An Operating System for Mammalian Cell Line Development Retrovector Transduction Any Mammalian Cell Integrase RNA genome Reverse Transcriptase Replication Incompetent Retrovector * Regulatory acceptance with >40 clinical trials globally 2

4 GPEx : Retrovector Production 293GP Cells Vector Initial Production Process VSV-G Transgen e Vector Transient Co-Transfection Transient Co-Transfection Concentrated High Titer Retrovector Integrase RNA genome Reverse Transcriptase

5 GPEx : Platform Processes Retrovector Transduction of Cells Repeat Transductions to Increase Gene Copy # Limited Dilution Cell Cloning Clonal Cell Line Mammalian Cell Line Pool of Recombinant Protein Producing Cell Lines Clonal Cell Line Selection Recombinant Protein Recombinant Protein Production for Screening (mg-grams) Process Development and Optimization LC Retrovector Transduction of Cells HC Retrovector Transduction of Cells Repeat Transductions to Increase Gene Copy # Limited Dilution Cell Cloning Clonal Cell Line Mammalian Cell Line Pool of LC Expressing Cell Lines Pool of Antibody Producing Cell Lines Clonal Cell Line Selection Antibody Antibody Production for Screening (mg-grams) 3 Months Process Development and Optimization 4 Months

6 FISH Analysis of Antibody Expressing Cell Line Produced using Traditional Method (Amplification) Metaphase Interphase Heavy Chain Gene = Red Light Chain Gene = Green

7 FISH Analysis of Antibody Expressing Cell Line Produced using GPEx Metaphase Interphase Heavy Chain Gene = Red Light Chain Gene = Green

8 Genetic Stability Analysis of GPEx Master Cell Banks The 17 stability studies were perform over 40 to 60 cell generations Each cell bank is producing a different protein A master cell bank vial (B) was compared to cells that completed the cell generations in culture (E)

9 mrna Index mrna Index GPEx : HC and LC mrna Expression Stability (Real-Time PCR Analysis) 9 8 HC Generation 0 Generation 60 0 Antibody B Antibody C Antibody E Antibody F Antibody G Antibody H Antibody I 14 LC Generation 0 Generation 60 0 Antibody B Antibody C Antibody E Antibody F Antibody G Antibody H Antibody I

10 GCHO Cell Line Development: Recent Antibody Case Study GCHO cell transductions were performed Pooled cell line was expanded to evaluate production in non-optimized fedbatch culture and produce initial protein for characterization Limited dilution cell cloning was performed in 96 well plates using the pooled cell line as the starting material Media was collected from the plates after 14 days and the clones were ranked by antibody titer The top 24 clones were selected and produced between 44 and 100 mg/l during the 14 days of culture Each of the 24 clones were put through limited dilution cloning a second time to insure clonality with 18 clones surviving the process The remaining 18 clones were grown in duplicate 500 ml shake flasks using generic fed-batch culture conditions

11 GPEx (GCHO): Pooled Cell Line Shake-Flask Production Levels (Non-Optimized Fed-Batch Conditions) Product Titer at Harvest (mg/l) Antibody II 833 Antibody JJ 649 Antibody KK 701 Antibody LL 423 Antibody MM 672 Antibody NN 699 Antibody PP 813 Antibody QQ 400 Antibody RR 1170 Antibody TT 633 Antibody UU 1069 Antibody VV 686 Antibody WW 1073 Antibody XX 664 Antibody YY 534 Antibody ZZ 623 Antibody A Antibody B Antibody C1 499 Antibody D Antibody E1 568 Antibody F Antibody G Recombinant Protein Recombinant Protein Recombinant Protein CASE STUDY 1174

12 Clonal Cell Line Titers and Specific Productivities (Generic Fed-Batch Culture Conditions) Clonal Cell Line Final Titer (g/l) Specific Cell Productivity (p/c/d) Clonal Average

13 Clonal Cell Line Process Development A matrix of 3 different media (serum and protein-free), two different culture conditions and five different clones were evaluated in shake flask culture Cultures were terminated on Day 17 or when cell viabilities reached 50% Antibody titers were determined by Protein A HPLC analysis Results available 6 months after project start Protein (mg/l) Media 1 Media 2 Media 3 Clone # Condition 1 Condition 2 Condition 1 Condition 2 Condition 1 Condition * *

14 GPEx : Fed-Batch Shake Flask Antibody Productivity Before and After One PD Cycle Cell Line Initial Titer (g/l) Titer After PD (g/l) Initial P/C/D P/C/D After PD Antibody AA Antibody BB Antibody CC Antibody DD Antibody SS Antibody YY Antibody ZZ Antibody A Antibody B

15 Antibody Titer (mg/l) GPEx : Various Runs of the Antibody YY (IgG4) Optimized Cell Line Process at Different Scale Integral of Viable Cell Concentration Shake Flask (42 P/C/D) 100L Run #1 (49 P/C/D) 100L Run #2 (51 P/C/D) 100L Run #3 (55 P/C/D) 100L Run #4 (62 P/C/D) 100L Run #5 (46 P/C/D) 100L Run #6 (61 P/C/D) 200L Run #1 (49 P/C/D) 200L Run #2 (63 P/C/D) 200L Run #3 (63 P/C/D)

16 Antibody Cell Line Production All Antibodies (IgG1 + IgG4)

17 Fc-Fusion Cell Line Production 4 FC-Fusion Programs Taken Through USPD Product Titer at Harvest (g/l) Fc-fusion example Fc-fusion example Fc-fusion example Fc-fusion example 4 2.8

18 GPEx Exceeds Traditional Methods of Cell Line Development Large Pharma Company (CX) was interested in evaluating the GPEx technology GPEx developed cell lines were compared to cell lines developed by CX using their standard method which is a more traditional process for cell line engineering Proteins that were successful and not successful in CX s system were evaluated GPEx cell pools for each protein produced were developed by Catalent and provided to CX for clonal selection and evaluation Traditional cell pools were developed by CX using their standard methodologies All data was generated by CX and provided to Catalent

19 Products Evaluated in the Study Three antibody products and one Fc-Fusion product were identified for evaluation Antibody 1: Customer produced a good expressing cell line, but had difficulty producing a stable good expressing cell line Antibody 2: Customer could not produce a good expressing cell line Antibody 3: Customer did not have problems producing good expressing stable cell line (Control antibody) Fc-fusion: Customer had difficulty producing a good expressing cell line

20 Antibody #1 Titer and Specific Productivity Comparison of Clones Isolated from each Cell Line Development Method (Primary Screen) Cloning from cell pools was done using random selection using a ClonePix system 360 clonal cell lines were selected 10,000 cells were seeded in 96-well plates (static culture) Cell counts were performed on day 0 and 7 using Alamar Blue Titer was determined on day 7

21 Fc-Fusion #1 Titer and Specific Productivity Comparison of Clones Isolated from each Cell Line Development Method (Primary Screen) Cloning from cell pools was done using random selection using a ClonePix system 360 clonal cell lines were selected 10,000 cells were seeded in 96-well plates (static culture) Cell counts were performed on day 0 and 7 using Alamar Blue Titer was determined on day 7

22 Antibody #1 Titer and Specific Productivity Comparison of Clones Isolated from each Cell Line Development Method (Secondary Screen) Top 36 clones from the primary screen were selected based on titer and primary productivity (titer/final cell number/7 days) The top 36 clones were screened in fedbatch shaking 6-well culture Cultures were fed on day 3 Cells were seeded in 4 ml working volume at 1x105 cells/ml Cell counts were performed on days 0 and 7 (Guava) Titer was determined on day 7

23 Fc-Fusion #1 Titer and Specific Productivity Comparison of Clones Isolated from each Cell Line Development Method (Secondary Screen) Top 36 clones from the primary screen were selected based on titer and primary productivity (titer/final cell number/7 days) The top 36 clones were screened in fedbatch shaking 6-well culture Cultures were fed on day 3 Cells were seeded in 4 ml working volume at 1x105 cells/ml Cell counts were performed on days 0 and 7 (Guava) Titer was determined on day 7

24 Fed-Batch Titer Analysis of Top 10 Antibody #1 and Fc- Fusion Clones Produced using each Method Clones were analyzed in small scale spin tubes ph was adjusted Feeds were performed on days 4, 7 and 9 of culture A temperature shift was performed on day 4 of the culture

25 Antibody Titer (g/l) Antibody Titer (g/l) Antibody #2 and#3 Clone Comparison Between Cell Line Development Methods Antibody #2 2.5 Clonal cell lines producing Antibody 2 (difficult to produce molecule) and Antibody 3 (easy to produce molecule (Control Antibody)) were analyzed at larger scale Top GPEx clones were compare to traditional clones using fed-batch conditions in benchtop bioreactors Traditional Clone Antibody #3 GPEx Clone Traditional Clone GPEx Clone

26 Stability Study Outline and Results The top 12 GPEx clones producing each of the products were cultured for 100 generations and compared to the traditional clones that were examined in the same manner Definition of protein expression instability was a greater than 50% drop in specific productivity over the 100 generations Average specific productivity from passages 2-8 was compared to the average specific productivity from passages The percentage drop in specific productivity was calculated from those numbers Project Number of Traditional Clones Evaluated Number of Traditional Clones with >50% Expression Loss Number of GPEx Clones Evaluated Number of GPEx Clones with >50% Expression Loss Antibody Antibody (51% and 68%) Antibody (52%) Fc-Fusion (54%)

27 GPEx Cell Line Development Conclusions The GPEx process efficiently produces high expressing cell lines for numerous different types of proteins High expression and gene stability are consistently observed Some molecules show much higher expression in GPEx cell lines compared to more traditional methods

28 discover more. CATALENT PHARMA SOLUTIONS 14 SCHOOLHOUSE ROAD SOMERSET, NJ