End-to-end process support, from development to industrialization

Adenoviral (AV) vectors are an efficient gene delivery system for a broad range of cell types and are one of the most commonly employed viral vectors for potential new therapies and vaccines. Much progress has been made in developing commercial production-scale processes for gene therapies and vaccines in recent decades, but challenges persist around cell associated virus and scalability due to purification recovery efficiency.  We offer a wide range of robust, scalable upstream and downstream solutions and have the technical knowledge and experience to support each step of the entire process. Most AV vector production follows the same basic process, with some variation as needed.

 

Upstream

     

 

 

Downstream

     

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  • An End-to-End Process for Large-Scale Adenovirus Manufacturing for Gene Therapy

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  • Industrialization of AdenoVirus Production and Purification with the iCELLis® 500 Single-Use Bioreactor (A4 Version)

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Want to learn more about Upstream &

Downstream Process workflows?

 

Adherent Cell Culture

As the therapies progress into clinical development, there is a requirement to increase quantity and quality of the virus produced.  Manufacturing virus from adherent cells using fixed-bed bioreactor technology allows for direct transfer of the 2D reference process, which minimizes risk and saves time. 

 

 

iCELLis® Bioreactor

 

The iCELLis bioreactor is a fully-integrated, high-cell density bioreactor designed to simplify processes involving adherent cells by combining the advantages of single-use technologies with the benefits of a bioreactors - reduced handling, footprint, labor, cost, and improved process assurance, robustness, and scalability. The iCELLis technology can be used at bench-scale (0.5 to 4 m2) and manufacturing-scale (66 to 500 m).

 

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  • Industrialization of AdenoVirus Production and Purification with the iCELLis® 500 Single-Use Bioreactor

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Clarification

The first process step after cell culture is the removal of cells, cell debris, and other impurities to reduce biological burden as much as possible. The easiest and most economical technology to clarify the cell culture is filtration. Low yield is a common challenge in this step, especially as cell densities increase upstream and sizes of viral particle increase. Our experienced technical team can help you achieve high throughput and yield by optimizing protocols and parameters for this step, in addition to selecting the best filter materials and size.

 

 

Stax™ Disposable Depth Filter Systems

 

This ready-to-use platform is scalable in size and performance to meet lab, pilot and process needs.  Stax disposable capsules are available in three interchangeable capsule sizes ranging from 0.25 m2 to 2.0 m2 (2.70 ft2 to 21.5 ft2). For commercial production scale, large Stax capsules with single-layer V100P media grade or dual-layer PDK11 offer high throughput and recoverability for manufacturing of viral vector products.

 

Supracap™ 100 Depth Filter Capsules

 

Supracap 100 capsules integrate seamlessly into any development process with its versatile configurations, sizes and available filter media. They offer easy scalability, and the fully disposable design eliminates any cleaning or handling concerns usually associated with housings, especially where biological and hazardous products are to be filtered. Supracap 100 with single-layer V100P media grade capsules offer high throughput and recoverability for viral vector products.

 

Supracap™ 50 Depth Filter Capsules with V100P Membrane

 

For smaller scale processes using the same membrane, Supracap 50 capsules are also available.

 

Bioburden Filtration

Reducing bioburden through a suitable grade 0.2 µm or 0.45 µm filter is usually the next step in this process.  The type of filter used here can vary based on the titer and volume of material, fouling properties of the fluid, and processing time requirements. 

 

 

Bioburden Reduction Filters

 

Our technologically innovative bioburden control filters reduce bacterial loads in process feeds to acceptably low levels for successful and cost-effective protection of processes from microbial and particulate contamination. Membranes are inert and have low protein and excipient binding properties suitable for all types of drug products. Available in a wide range of formats: cartridges for stainless steel installations and capsules for single-use systems.

 

All process development-scale filter formats are designed to scale directly to larger cGMP filter configurations for fast and easy production scale-up.

 

Purification (Chromatography)

This step removes empty capsids, DNA and host cell proteins (HCP). Adsorptive membrane technology offers an efficient and effective option for purifying gene therapy products.

 

 

Mustang® Q Membrane Chromatography Capsules

 

We have combined our competencies in membrane device design and chromatography to develop a range of high-performance, scalable Mustang Q XT membrane chromatography capsules. These capsules are reliable, easy to use and enable users to significantly improve their process economics through reduced buffer consumption, increased throughput and reduced capital expenditure.

 

Mustang Q XT Acrodisc

 

Disposable membrane chromatography units for scale-down process development. Mustang XT Acrodisc units, available in Q and S chemistries, are ideal for scale-down process development work in a variety of downstream process applications. A membrane volume of < 1 mL reduces the amount of sample required for evaluation, and the female luer lock inlet and outlet simplifies connection to typical low pressure chromatography systems.

 

UF/DF

Ultrafiltration/Diafiltration using Tangential Flow Filtration (TFF) membranes further concentrates the target molecule and exchanges buffers. Achieving high yield is a common challenge with TFF, but our technical experts can work with you to optimize your UF/DF unit operation based on experience and thorough testing.

 

 

Single-Use Tangential Flow Filtration (TFF) Modules

 

Single-use tangential flow filtration (SUTFF) modules are ready-to-use gamma-irradiated cassette modules that can be integrated into single-use TFF set-ups. Integrating the process-proven Omega™ polyethersulfone (PES) membrane, single-use TFF modules are available in scalable formats from 93 cm² up to 2.5 m² of membrane area.

 

T-Series TFF Cassettes with Omega Membrane

 

T-Series cassettes with Omega membrane are ideal for development, pilot, and production-scale TFF applications in diverse biological and biopharmaceutical processes. They are especially useful in vaccine and conjugate concentration and diafiltration, purification and recovery of monoclonal antibodies (mAb) or recombinant proteins, and blood plasma fractionation and purification.

 

T-Series TFF Cassette Holders

 

TFF cassette holders for the medium and large-scale production environment have a small footprint, yet still are capable of holding large areas of membrane. All stainless steel holders are engineered to precise specifications with a high standard internal and external surface finish and are available with either manual torque (MT) or auto torque (AT) compression systems for ease of use.

 

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  • Understanding Single-Pass Tangential Flow Filtration and the New Era of Bioprocessing

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Bulk Drug Substance Filtration

Manufacturing for clinical purposes requires the production of highly pure and biologically active vectors that meet regulatory requirements. A last sterilizing grade (0.2 µm) filtration step is usually needed before product is sent for final filling. 

 

 

Sterile Liquid Filtration

 

Optimized sterilizing-grade liquid filtration in your drug manufacturing process drives efficiencies while providing confidence in achieving drug critical quality attributes. Selecting the right sterile filter media and format, for your specific process helps to maximize yield and recovery of valuable drug product and ensure production efficiency. Our extensive range of sterilizing-grade liquid filters and formats enable us to offer filtration solutions for all applications and drug types, from mAbs, recombinant proteins, vaccines and gene therapies to small molecule drugs, and plasma derivatives.

 

Complementary Technologies

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Pall has a global team of over 300 experienced technical professionals to support your molecule from pre-clinical to commercial manufacturing. From process development services and end-to-end platforms, to on-site testing and applications support for specific process steps, Pall will help you find the best solution based on data and testing.