"Small and large molecules bioproduction by mammalian and microbial fermentation"

Transcription

1 "Small and large molecules bioproduction by mammalian and microbial fermentation" H.-P. Meyer Bio/PharMOS March 2004 Symposium B Business Diversification in Life Science

2 "Small and large molecules bioproduction by mammalian and microbial fermentation" 107 years of diversification & change Initial focus focus today? Reasons for change? The in vivo production methods? Innovations and their impact? Future trends?

3 Diversification over the last 107 years Microbial Production of Therapeutic Proteins Mammalian Production Therapeutic Proteins Fine Chemicals Intermediates Food, Feed Pharma & Biotechnology Fine Chemicals Petroleum Cracker Diketene/Pyridines/Hydrogen Cyanide Fertilizer Mixture Ammonia/Nitric Acid/Ammonium Nitrate Acetaldehyde/Acetic Acid/Calcium Cyanamide Calcium Carbide /1907 START

4 107 years of change From a local end user to a market driven fine chemicals producer to a company focussing on biotechnology. Pills & Capsules Syringes CHF/kg Railway containers Drums Bags

5 Diversification in Biotechnology Microbial Production of Therapeutic Proteins In-house growth Mammalian Production Therapeutic Proteins Acquisition Fine Chemicals Intermediates Food, Feed Pharma & Biotechnology In-house growth & acquisition Fine Chemicals

6 The first important product L-Carnitine N + O O N + O SCoA N + O SCoA 4-butyrobetaine 4-butyrobetainyl-CoA crotonobetainyl-coa N + O O N + O O Carnitine dehydrogenase SCoA N + OH O SCoA betaine dehydrocarnityl-coa L-carnityl-CoA TCA cycle N + OH O O L-carnitine CO 2, H 2 O, Energy, Biomass

7 Reasons for a good start Integration Chemistry & Biotechnology 4,5 Cost Ecology Chemical production 3, , Biotechnological production 360 0,5 Waste for incineration in tons per ton of L-Carnitine TOC in the waste water in kg per ton of L-Carnitine Waste water in m 3 per ton of L-Carnitine Salts in tons per ton of L-Carnitine

8 Reasons for diversification in a nutshell Changing needs of the markets New business opportunities Use one technology platform to move to the next Establish bridges between the different technology platforms Use synergies chemistry - biology Use synergies within biotechnology Use synergies regulatory affairs

9 Biotechnological in vivo production systems Lonza offers the technology Sterile operatoin Regulatory Scalabiltiy Cost advantage Protein folding Glycosylation Thrapeutic proteins Small molecules Bacterial fermentation Yeast fermentation Fungal fermentation Transient plants Plant cell culture Transgenic plants Insect cell culture Transient mamm cell culture Mammalian cell culture Transgenic animals

10 Challenges in production Microbial Mammalian cell culture Increasing production efficiency Complying with (FDA) regulations The ultimate challenge for a commercial bioprocess is always directly or indirectly related to biological regulation. The cost of product recovery is inversely proportional to the logarithm of product concentration. The manufacturing precision of living microbial and mammalian cells is used, to create value.

11 Innovations and their impact? Scientific solutions to commercial issues Mammalian cell culture e.g. titer improvement, perfusion systems Titer improvement and cost implications for therapeutic proteins. Microbial expression and glycosylation Cost improvement for therapeutic proteins Access to non cultivable organisms New lead structures for small molecule APIs Chiral toolbox for biotransformations? Accessibility to commercially viable asymmetric synthesis for NCE

12 Biopharmaceuticals growth Microbial Mammalian cell culture USD bio mammalian microbial total E. & Y. 2000

13 Innovation: therapeutic proteins Cost implications of process optimisation (large molecules) Mammalian cell culture % Number of Batches Required % 60% 40% 20% Relative Fermentation Cost % Product Titre (g/l) 0% 2000L scale 5000L Scale Cost

14 Innovation: therapeutic proteins Process optimization for an antibody made in GS-CHO cells Mammalian cell culture Cell Line A Process 1 Antibody (mg/l) 139 A A B B

15 Innovation: therapeutic proteins Microbial Microbial Glycosylation Sugars on proteins are like accents on spoken word Goal: e.g. yeasts producing humanized glycosylated therapeutic proteins (e.g. large volume antibodies) cost advantage.

16 Innovation: small & large molecules Microbial gene Lonza microbial gen expression system Integration of a customer target gene into different expression systems to be able to decide as fast as possible (= 3 months) which strain has to be funelled into the fermentation and DSP development/optimization product

17 Innovation: secondary metabolites Microbial Non-cultivable organisms (small molecules) as a source of new leads. Plant cell culture for the production of high value fine chemicals and a source of new leads. Need for new antibiotics?

18 Innovation: biotransformation A strong annual growth of chiral products is still expected 8% - 15% annually). Chemically biotechnologically derived chiral products. Biotechnology is supposed to increasingly become a major source of innovation? Filling the gaps means new business opportunities!

19 Innovation: biotransformation 1. Oxidoreductases 25% 2. Transferases 5% 3. Hydrolases 60% 4. Lyases 5-10% 5. Isomerases <5% 6. Ligases 0% offer need GAP Enzymes for small and large scale applications

20 Innovation: biotransformation Availability and time-to-strain & enzyme must be radically improved. Every group is scrambling to develop its own data base change this: networking. Biotransformation must become textbook know-how. Bring some technologies into large scale (e.g. ISPR). Support of biotransformation development at the few remaining universities still active in the area.

21 Summary and outlook I The focus remains submersed in vivo systems for the production therapeutic proteins. Mammalian cell culture continues to be the method of choice for <1000 kg/year glycosylated therapeutic proteins. Microbial systems remain the preferred method for large volume and non-glycosylated therapeutic proteins, chiral small molecules and complex small molecules. Production of large volume therapeutic proteins with humanized glycosylation using yeast ev. bacteria in the future?

22 Summary and outlook II The other in vivo production methods will fullfil niche roles. For example transgenic plants for food/vaccine purposes? Transgenic plants for vaccines. Transgenic animals for vaccines or hormone production (no dedicated plant needed) The need for the simplification treatments and drugs in combination with a better understanding of pathological phenomena on a molecular level might lead to smaller, tailored molecules in the long run.