1. Érica A. SchulzeÉrica A. Schulze1,21,2, Parminder Chahal, Parminder Chahal33, Ricardo A. Medronho, Ricardo A. Medronho11,,
Leda R CastilhoLeda R Castilho22 Júlio FernandesJúlio Fernandes44 Amine KamenAmine Kamen33
Production of serotype 6Production of serotype 6--derivedderived
recombinantrecombinant adenoadeno--associated virusassociated virus
in serumin serum--free suspension culturesfree suspension cultures
of HEK 293 cellsof HEK 293 cells
Production of serotype 6Production of serotype 6--derivedderived
recombinantrecombinant adenoadeno--associated virusassociated virus
in serumin serum--free suspension culturesfree suspension cultures
of HEK 293 cellsof HEK 293 cells
11 Federal University of Rio de Janeiro, School of Chemistry,Federal University of Rio de Janeiro, School of Chemistry, CT, Bl.CT, Bl. E, 21941E, 21941--909 Rio de Janeiro/RJ, Brazil909 Rio de Janeiro/RJ, Brazil
22 Federal University of Rio de Janeiro, COPPE, Cell Culture Engineering Lab,Federal University of Rio de Janeiro, COPPE, Cell Culture Engineering Lab, CxCx. Postal 68502, 21941. Postal 68502, 21941--972 Rio de Janeiro/RJ, Brazil972 Rio de Janeiro/RJ, Brazil
33 Biotechnology Research Institute, National Research Council,Biotechnology Research Institute, National Research Council, 61006100 RoyalmountRoyalmount Avenue, H4P 2R2, Montréal/ QC, CanadaAvenue, H4P 2R2, Montréal/ QC, Canada
44 Centre deCentre de RechercheRecherche de l'Hôpital du Sacréde l'Hôpital du Sacré--Cœur de Montréal,Cœur de Montréal, 5400 Boulevard Gouin Ouest, H4J 1C5,5400 Boulevard Gouin Ouest, H4J 1C5, Montréal/QC, CanadaMontréal/QC, Canada
Leda R. CastilhoLeda R. Castilho22, Júlio Fernandes, Júlio Fernandes44, Amine Kamen, Amine Kamen33
HEKHEK 293293--SFSF--33FF66 cellscells suspensionsuspension cultivation,cultivation, usingusing 125125--mLmL
shakeshake flasksflasks ((2020--mLmL workingworking volume)volume) oror stirredstirred--tanktank
bioreactorsbioreactors ((22--LL workingworking volume)volume)
C ltC lt didi ff SFMSFM44 T FT F 293293 ((H lH l ))
METHODOLOGYMETHODOLOGYMETHODOLOGYMETHODOLOGY
RecombinantRecombinant adenoadeno--associatedassociated virusesviruses ((rAAVrAAV)) promisingpromising
genegene therapytherapy candidatecandidate vectorsvectors
KeyKey advantagesadvantages ofof rAAVrAAV vectorsvectors goodgood safetysafety profileprofile andand
b db d titi t it i th hth h thth ff diff tdiff t tt
INTRODUCTIONINTRODUCTIONINTRODUCTIONINTRODUCTION
CultureCulture mediummedium serumserum--freefree SFMSFM44 TransFxTransFx--293293 ((HycloneHyclone))
withwith 00..11%% PluronicPluronic FF6868 (Sigma(Sigma--Aldrich)Aldrich)
CellCell concentrationconcentration atat transfectiontransfection:: 11,, 11..55,, 22 andand 33 millionmillion
cells/cells/mLmL (Figure(Figure 11)) oror 11 millionmillion cells/cells/mLmL (Figures(Figures 22 andand 33))
TransfectionTransfection reagentreagent 2525--kDakDa linearlinear polyethyleniminepolyethylenimine (PEI)(PEI)
((PolysciencesPolysciences))
ThreeThree plasmidsplasmids werewere used,used, atat aa molarmolar ratioratio ofof 11::11::11 ::
PlasmidPlasmid ssITRCMVssITRCMV--EGFP,EGFP, containingcontaining thethe EGFPEGFP genegene flankedflanked
byby thethe AAVAAV ITRITR sequencessequences (single(single--strandedstranded DNA)DNA)
Rep/CapRep/Cap plasmidplasmid containingcontaining genesgenes associatedassociated toto replicationreplication
andand capsidcapsid formingforming proteinsproteins
broadbroad tissuetissue tropismtropism throughthrough thethe useuse ofof differentdifferent serotypesserotypes
MostMost commoncommon approachapproach forfor rAAVrAAV productionproduction transienttransient
transfectiontransfection ofof mammalianmammalian cellcell culturescultures
HEKHEK 293293 (human(human embryonicembryonic kidneykidney cells)cells) cellcell lineline usedused forfor
productionproduction ofof aa licensedlicensed recombinantrecombinant proteinprotein andand largelylargely
studiedstudied forfor thethe productionproduction ofof vaccinesvaccines andand genegene therapytherapy
vectorsvectors (specially(specially adenoviraladenoviral andand adenoadeno--associatedassociated viralviral
vectors)vectors)
HEKHEK 293293 advantagesadvantages relativelyrelatively easyeasy adaptationadaptation toto
suspensionsuspension cultivationcultivation inin serumserum-- andand animalanimal--derivedderived--
componentcomponent--freefree mediamedia (complying(complying withwith regulatoryregulatory needs)needs) andand andand capsidcapsid--formingforming proteinsproteins
HelperHelper plasmidplasmid containingcontaining adenovirusadenovirus genesgenes requiredrequired byby AAVAAV
TotalTotal plasmidplasmid DNADNA loadload:: 11 µgµg ofof plasmidplasmid DNADNA perper mLmL ofof cellcell
cultureculture
ResponsesResponses IVPIVP (infectious(infectious virusvirus particles)particles) andand VgVg (genomic(genomic
particles)particles)
pp ( p y g( p y g g yg y ))
highhigh transfectiontransfection efficienciesefficiencies withwith mostmost genegene transfertransfer vehiclesvehicles
TToo investigateinvestigate thethe effectseffects ofof differentdifferent cellcell densities,densities, DNADNA andand
transfectiontransfection reagentreagent (PEI)(PEI) concentrationsconcentrations onon rAAVrAAV yieldsyields
OBJECTIVE OF THE WORKOBJECTIVE OF THE WORKOBJECTIVE OF THE WORKOBJECTIVE OF THE WORK
RESULTSRESULTSRESULTSRESULTS
Evaluation of the effects of different DNA, PEI and cell concentrations on the production of AAVEvaluation of the effects of different DNA, PEI and cell concentrations on the production of AAV
Table 1Table 1 –– DNA and PEI concentrations andDNA and PEI concentrations and
PEIPEI--toto--DNA ratios in experiments of Figure 2.DNA ratios in experiments of Figure 2.
Table 1Table 1 –– DNA and PEI concentrations andDNA and PEI concentrations and
PEIPEI--toto--DNA ratios in experiments of Figure 2.DNA ratios in experiments of Figure 2.
Exp. #Exp. # DNADNA
(µg/mL)(µg/mL)
PEIPEI
(µg/mL)(µg/mL)
PEIPEI--toto--
DNADNA
ratioratio
11 0.20.2 4.004.00 20.0020.00
22 0.20.2 2.752.75 13.7513.75
1.0E+08
1.0E+09
1.0E+10
1.0E+11
1.0E+12
IVP (1/mL), Vg (1/mL)
IVP
Vg
1.0E+08
1.0E+09
1.0E+10
1.0E+11
1.0E+12
IVP (1/mL), Vg (1/mL)
IVP
Vg
Evaluation of process scalability to stirredEvaluation of process scalability to stirred--tank bioreactorstank bioreactors
FigureFigure 22 -- IVPIVP andand VgVg titerstiters obtainedobtained 4848 hh postpost--transfectiontransfection
inin experimentsexperiments ## 11--77,, wherewhere differentdifferent DNADNA andand PEIPEI
concentrationsconcentrations havehave beenbeen evaluatedevaluated (see(see TableTable 11 forfor DNADNA
andand PEIPEI values)values).. CellCell concentrationconcentration atat transfectiontransfection:: 11 millionmillion
cells/cells/mLmL..
FigureFigure 22 -- IVPIVP andand VgVg titerstiters obtainedobtained 4848 hh postpost--transfectiontransfection
inin experimentsexperiments ## 11--77,, wherewhere differentdifferent DNADNA andand PEIPEI
concentrationsconcentrations havehave beenbeen evaluatedevaluated (see(see TableTable 11 forfor DNADNA
andand PEIPEI values)values).. CellCell concentrationconcentration atat transfectiontransfection:: 11 millionmillion
cells/cells/mLmL..
FigureFigure 11 –– IVPIVP andand VgVg titerstiters obtainedobtained 4848 hh postpost--transfectiontransfection,,
withwith differentdifferent cellcell concentrationsconcentrations atat momentmoment ofof transfectiontransfection
((11,, 11..55,, 22 andand 33 millionmillion cells/cells/mLmL)).. TransfectionTransfection conditionsconditions::
11 µgµg ofof totaltotal plasmidplasmid DNADNA perper mLmL ofof cellcell culture,culture, 22 μμgg ofof PEIPEI
perper mLmL ofof cellcell culture,culture, PEIPEI--toto--DNADNA ratioratio ofof 22..00..
FigureFigure 11 –– IVPIVP andand VgVg titerstiters obtainedobtained 4848 hh postpost--transfectiontransfection,,
withwith differentdifferent cellcell concentrationsconcentrations atat momentmoment ofof transfectiontransfection
((11,, 11..55,, 22 andand 33 millionmillion cells/cells/mLmL)).. TransfectionTransfection conditionsconditions::
11 µgµg ofof totaltotal plasmidplasmid DNADNA perper mLmL ofof cellcell culture,culture, 22 μμgg ofof PEIPEI
perper mLmL ofof cellcell culture,culture, PEIPEI--toto--DNADNA ratioratio ofof 22..00..
33 0.60.6 2.752.75 4.584.58
44 0.60.6 2.502.50 4.174.17
55 0.60.6 1.601.60 2.672.67
66
77
1.01.0
1.01.0
1.801.80
1.201.20
1.801.80
1.201.20
1.0E+07
1.0 1.5 2.0 3.0
Cell concentration (106 cells/mL)
1.0E+07
1 (a‐c) 2 3 4 (a‐c) 5 6 7
Experiment number
p yp y
0.0
0.5
1.0
1.5
2.0
2.5
0
20
40
60
80
100
0 20 40 60 80
Totalcellconcentration(106/mL)
Viability(%),Diameter(µm)
Viability
Cell diameter
Total cells
(A)(A)(A)(A) (B)(B)(B)(B)
1.0E+06
1.0E+07
1.0E+08
1.0E+09
1.0E+10
1.0E+11
1.0E+12
24 48
IVP(1/mL),Vg(1/mL)
IVP
Vg
CONCLUSIONSCONCLUSIONSCONCLUSIONSCONCLUSIONS
rAAVrAAV productionproduction waswas slightlyslightly affectedaffected byby cellcell concentrationconcentration atat timetime ofof transfectiontransfection,, sincesince transfectiontransfection atat 33xx101066 cells/cells/mLmL resultedresulted inin
aa 22..55-- andand 33..55--foldfold increaseincrease inin IVPIVP andand Vg,Vg, respectively,respectively, whenwhen comparedcompared toto transfectiontransfection atat 11xx101066 cells/cells/mLmL..
FigureFigure 33 –– rAAVrAAV productionproduction inin aa stirredstirred--tanktank bioreactorbioreactor withwith 22--LL workingworking volumevolume.. TransfectionTransfection waswas donedone atat 2424 hh andand 11xx101066 cells/cells/mLmL,,
usingusing 11..66 µg/µg/mLmL PEIPEI andand 00..66 µg/µg/mLmL DNADNA (PEI(PEI::DNADNA==22..6767)).. (A)(A) KineticsKinetics ofof cellcell growth,growth, showingshowing ttotalotal cellcell concentration,concentration, cellcell viabilityviability
andand cellcell diameterdiameter fromfrom timetime ofof inoculationinoculation ((00 h)h) upup toto 4848 hh postpost--transfectiontransfection.. (B)(B) IVPIVP andand VgVg titerstiters 2424 hh andand 4848 hh postpost--transfectiontransfection..
FigureFigure 33 –– rAAVrAAV productionproduction inin aa stirredstirred--tanktank bioreactorbioreactor withwith 22--LL workingworking volumevolume.. TransfectionTransfection waswas donedone atat 2424 hh andand 11xx101066 cells/cells/mLmL,,
usingusing 11..66 µg/µg/mLmL PEIPEI andand 00..66 µg/µg/mLmL DNADNA (PEI(PEI::DNADNA==22..6767)).. (A)(A) KineticsKinetics ofof cellcell growth,growth, showingshowing ttotalotal cellcell concentration,concentration, cellcell viabilityviability
andand cellcell diameterdiameter fromfrom timetime ofof inoculationinoculation ((00 h)h) upup toto 4848 hh postpost--transfectiontransfection.. (B)(B) IVPIVP andand VgVg titerstiters 2424 hh andand 4848 hh postpost--transfectiontransfection..
0 20 40 60 80
Cultivation time (hours)
24 48
Time post-transfection (hours)
ACKNOWLEDGEMENTS:ACKNOWLEDGEMENTS: UniversitéUniversité de Montréal, BCEI/MAECI, NRCde Montréal, BCEI/MAECI, NRC--CNRCCNRC andand Bill & Melinda Gates FoundationBill & Melinda Gates FoundationACKNOWLEDGEMENTS:ACKNOWLEDGEMENTS: UniversitéUniversité de Montréal, BCEI/MAECI, NRCde Montréal, BCEI/MAECI, NRC--CNRCCNRC andand Bill & Melinda Gates FoundationBill & Melinda Gates Foundation
g,g, p y,p y, pp //
WhenWhen differentdifferent PEIPEI::DNADNA ratiosratios werewere tested,tested, IVPIVP variedvaried fromfrom 11..1919xx101088 IVP/IVP/mLmL toto 11..0303xx101099 IVP/IVP/mLmL,, whereaswhereas VgVg variedvaried fromfrom
33..0303xx101099 Vg/Vg/mLmL toto 33..3434xx10101111 Vg/Vg/mLmL.. TheThe resultsresults indicateindicate thatthat thethe individualindividual concentrationsconcentrations ofof PEIPEI andand DNADNA havehave aa moremore
pronouncedpronounced effecteffect onon IVPIVP andand VgVg titrestitres thanthan thethe ratioratio betweenbetween bothboth ofof themthem..
InIn stirredstirred--tanktank bioreactors,bioreactors, atat 4848 hourshours postpost--transfectiontransfection,, IVPIVP andand VgVg valuesvalues werewere higherhigher thanthan 22xx101088 IVP/IVP/mLmL andand 77xx10101010 Vg/Vg/mLmL,,
respectivelyrespectively.. AdoptingAdopting thethe methodologymethodology usedused inin thisthis work,work, assumingassuming thatthat similarsimilar virusvirus titerstiters cancan bebe obtainedobtained uponupon furtherfurther scalescale--upup
ofof thethe process,process, aa 10001000--LL bioreactorbioreactor couldcould produceproduce aa totaltotal amountamount ofof approximatelyapproximately 11xx10101414 IVPIVP andand 11xx10101616 VgVg particlesparticles.. AssumingAssuming anan
overalloverall downstreamdownstream processingprocessing recoveryrecovery ofof 5050%%,, thesethese quantitiesquantities shouldshould bebe sufficientsufficient forfor useuse inin largelarge clinicalclinical trialstrials..