Sterile filtration of a multi-serotype glycoconjugate vaccine drug product.

Glycoconjugate vaccines consisting of multiple serotypes of the bacterial capsular polysaccharide can provide strong protection against infection by significant pathogens. Previous studies of the sterile filtration behavior of these glycoconjugates have been limited to experiments with individual serotypes even though the formulated vaccines contain several different serotypes to provide broad immunization. The objective of this study was to explore the fouling behavior of a glycoconjugate vaccine drug product consisting of four different polysaccharide serotypes. Sterile filtration data were obtained with 0.22 µm Durapore® membranes at both constant flux and constant pressure for both the individual serotypes and the drug product containing multiple serotypes. Fouled membranes were examined by confocal microscopy, demonstrating that all four serotypes deposit in a narrow band near the filter inlet. The different ionic composition of the formulation buffer (compared to the buffers used with the drug substance) had a large effect on the fouling behavior. In addition, the fouling resistance associated with the drug product was greater than the sum of the resistances of the individual serotypes. These results provide important insights into the sterile filtration behavior of these multivalent glycoconjugate vaccines.

Pressure-dependent fouling behavior during sterile filtration of mRNA-containing lipid nanoparticles.

The COVID-19 pandemic has generated growing interest in the development of mRNA-based vaccines and therapeutics. However, the size and properties of the lipid nanoparticles (LNPs) used to deliver the nucleic acids can lead to unique phenomena during manufacturing that are not typical of other biologics. The objective of this study was to develop a more fundamental understanding of the factors controlling the performance of sterile filtration of mRNA-LNPs. Experimental filtration studies were performed with a Moderna mRNA-LNP solution using a commercially available dual-layer polyethersulfone sterile filter, the Sartopore 2 XLG. Unexpectedly, increasing the transmembrane pressure (TMP) from 2 to 20 psi provided more than a twofold increase in filter capacity. Also surprisingly, the effective resistance of the fouled filter decreased with increasing TMP, in contrast to the pressure-independent behavior expected for an incompressible media and the increase in resistance typically seen for a compressible fouling deposit. The mRNA-LNPs appear to foul the dual-layer filter by blocking the pores in the downstream sterilizing-grade membrane layer, as demonstrated both by scanning electron microscopy and derivative analysis of filtration data collected for the two layers independently. These results provide important insights into the mechanisms governing the filtration of mRNA-LNP vaccines and therapeutics.

Evaluation of a sterile filtration process for viral vaccines using a model nanoparticle suspension.

There is growing interest in the development of new vaccines based on live-attenuated viruses (LAVs) and virus-like particles. The large size of these vaccines, typically 100-400 nm, significantly complicates the use of sterile filtration. The objectives of this study are to examine the performance of several commercial sterile filters for filtration of a cytomegalovirus vaccine candidate (referred to as the LAV) and to develop and evaluate the use of a model nanoparticle suspension to perform a more quantitative assessment. Data obtained with a mixture of 200- and 300-nm fluorescent particles provided yield and pressure profiles that captured the behavior of the viral vaccine. This included the excellent performance of the Sartorius Sartobran P filter, which provided greater than 80% yield of both the vaccine and model particles even though the average particle size was more than 250 nm. The particle yield for the Sartobran P was independent of filtrate flux above 200 L/m2 /h, but increased with increasing particle concentration, varying from less than 10% at concentrations around 107 particles/ml to more than 80% at concentrations above 1010 particles/ml due to saturation of particle capture/binding sites within the filter. These results provide important insights into the factors controlling transmission and fouling during sterile filtration of large vaccine products.

Fouling Behavior during Sterile Filtration of Different Glycoconjugate Serotypes Used in Conjugate Vaccines.

PURPOSE: Sterile filtration can be a particular challenge when processing very large glycoconjugate vaccines. The objective of this study was to examine the sterile filtration performance of a series of glycoconjugate vaccines produced by coupling different polysaccharide serotypes to an immunogenic protein. METHODS: Sterile filtration was performed at constant filtrate flux using 0.22 µm pore size Durapore® polyvinylidene fluoride membranes. Glycoconjugates were characterized by dynamic light scattering, rheological measurements, and nanoparticle tracking analysis (NTA). Confocal microscopy was used to examine glycoconjugate capture profiles within the membrane. Transmembrane pressure data were analyzed using a recently developed fouling model. RESULTS: All glycoconjugates deposited in a narrow band near the entrance of the Durapore® membranes. The rate of fouling varied significantly for the different serotypes, with the fouling parameter correlated with the fraction of glycoconjugates larger than 200 nm in size. CONCLUSIONS: The fouling behavior and sterile filter capacity of the different glycoconjugate serotypes are determined primarily by the presence of large species (>200 nm in size) as determined by nanoparticle tracking analysis. The modified intermediate pore blockage model provides a framework for predicting the sterile filtration performance for these glycoconjugate vaccines.

Development of isoporous microslit silicon nitride membranes for sterile filtration applications.

The widely used 0.2/0.22 µm polymer sterile filters were developed for small molecule and protein sterile filtration but are not well-suited for the production of large nonprotein biological therapeutics, resulting in significant yield loss and production cost increases. Here, we report on the development of membranes with isoporous sub-0.2 µm rectangular prism pores using silicon micromachining to produce microslit silicon nitride (MSN) membranes. The very high porosity (~33%) and ultrathin (200 nm) nature of the 0.2 µm MSN membranes results in a dramatically different structure than the traditional 0.2/0.22 µm polymer sterile filter, which yielded comparable performance properties (including gas and hydraulic permeance, maximum differential pressure tolerance, nanoparticle sieving/fouling behavior). The results from bacteria retention tests, conducted according to the guidance of regulatory agencies, demonstrated that the 0.2 µm MSN membranes can be effectively used as sterile filters. It is anticipated that the results and technologies presented in this study will find future utility in the production of non-protein biological therapeutics and in other biological and biomedical applications.

Filtration of a multi-serotype glycoconjugate vaccine drug product through sterilizing grade 0.2/0.22 µm pore size filters.

Glycoconjugate vaccines containing multiple serotypes of a bacterial capsular polysaccharide can provide strong immune protection against pathogenic infections. Sterile filtration is an important component of the fill and finish operations in the preparation of these vaccines, with the capacity of the sterile filter limited by membrane fouling. The objective of this study was to examine the performance of a range of commercial 0.2/0.22 µm nominal pore size sterilizing grade filters with both single-layer and dual-layer structures during filtration of a glycoconjugate vaccine drug product consisting of four polysaccharide serotypes. The highly asymmetric Millipore Express showed much higher capacity than the more homogeneous filters, with the support structure of the Express acting as a prefilter that was able to remove foulants thereby protecting the small pores in the size-selective skin layer. This behavior was confirmed by performing experiments with different batch prefilters and by examining the location of foulant deposition within the sterile filters using confocal microscopy. These results provide important insights into the factors controlling fouling by these multiserotype vaccines as well as a framework for increasing the capacity of the sterile filter.

High yield sterile filtration process for highly concentrated lentiviral vectors.

The development and manufacture of biopharmaceuticals are subject to strict regulations that specify the required minimum quality of the products. A key measure to meet these quality requirements is the integration of a sterile filtration step into the commercial manufacturing process. Whereas common procedures for most biologics exist, this is challenging for lentiviral vector (LVV) production for ex vivo gene therapy. LVVs nominal size is more than half the pore size (0.2 µm) of filters used for sterile filtration. Hence, highly concentrated virus solutions are prone to filter clogging if aggregation of viruses occurs or impurities attach to the viruses. Several filters were screened aiming to identify those which allow filtering highly concentrated stocks of LVVs of up to 1E + 9 transducing units mL-1 , which corresponds to 4.5E + 12 particles mL-1 . In addition, the effect of endonuclease treatment upstream of the purification process on filter performance was studied. In summary, three suitable filters were identified in a small-scale study (<15 mL) with virus yields >80% and the process was successfully scaled-up to a final scale of 100 mL LVV stock solution.

Adaptation of an rVSV Ebola vaccine purification process for rapid development of a viral vaccine candidate for SARS-CoV-2.

During the COVID-19 pandemic, long development timelines typically associated with vaccines were challenged. The urgent need for a vaccine provided a strong driver to reevaluate existing vaccine development approaches. Innovative approaches to regulatory approval were realized, including the use of platform-based technology. In collaboration with the International AIDS Vaccine Initiative, Inc. (IAVI), Merck & Co., Inc., Rahway, NJ, USA rapidly advanced an investigational SARS-CoV-2 vaccine based on the recombinant vesicular stomatitis virus (rVSV) platform used for the Ebola vaccine ERVEBO (rVSV∆G-ZEBOV-GP). An rVSV∆G-SARS-CoV-2 vaccine candidate was generated using the SARS-CoV-2 spike protein to replace the VSV G protein. The purification process development for this vaccine candidate was detailed in this paper. Areas were highlighted where the ERVEBO platform process was successfully adopted and where additional measures were needed for the SARS-CoV-2 vaccine candidate. These included: (i) endonuclease addition directly into the bioreactor prior to harvest, (ii) inclusion of a core-shell chromatography step for improved purification, and (iii) incorporation of a terminal, sterile filtration step to eliminate the need for aseptic, closed processing. High infectious virus titers were achieved in Phase 3 clinical drug substance (>108 PFU mL-1 ), and process consistency was demonstrated across four large scale batches that were completed in 6 months from clone selection.

Challenges and solutions to manufacturing of low viscosity, ultra-high concentration IgG1 drug products: From late downstream process to final fill finish processing.

Challenges in manufacturing of high concentration antibody formulations have seldom been discussed. These are observed mainly form late downstream operations where antibody gets concentrated to its final strength, to final fill finish processing and containerization of the product. Present paper summarizes challenges typically observed in manufacturing and processing of high concentration antibody products and provides turnkey solutions to these typical challenges in order to have their consistent and robust manufacturing process. IgG1 has been used as model protein for studying the challenges and providing solutions to them. The late downstream challenges like increased viscosity limiting further concentration can be resolved by used of viscosity modifying agents in the formulation. Replacement of conventionally used 'A' screen membranes with 'D' screen or using single pass TFF can further provide advantage in targeting higher concentrations for same protein with lesser shear and aggregation. Using 0.5µm/0.2µm asymmetric or bilayered membrane instead of conventional 0.2µm membrane resulted in better flux while filtration of high concentration IgG1 formulation. In process holding time during filling operation was optimized to be <60min based on the nozzle drying time for high concentration IgG1 formulation. Appropriate control strategy of replacing filling nozzles and performing periodic fill weight check was proposed for fill finish process of high concentration IgG1 formulation.

Risk-based approach to setting sterile filtration microbial bioburden limits - Focus on biotech-derived products.

Holistic concepts should be applied that reduce risks prior to final bioburden testing and sterile filtration, based on enhanced process and product attribute understanding, which could be key to successful bioburden risk management. Key findings of this paper include.

Evaluation of Host Cell Impurity Effects on the Performance of Sterile Filtration Processes for Therapeutic Viruses.

Efficient downstream processing represents a significant challenge in the rapidly developing field of therapeutic viruses. While it is known that the terminal sterile filtration step can be a major cause of product loss, there is little known about the effect of host cell impurities (DNA and protein) on filtration performance. In this study, fractions of relatively pure Vero host cell protein and DNA were spiked into a highly pure preparation of vesicular stomatitis virus (VSV). Then, the resulting solutions were sterile filtered using two commercially available 0.22 µm rated microfiltration membranes. A combination of transmembrane pressure measurements, virus recovery measurements, and post-filtration microscopy images of the microfiltration membranes was used to evaluate the sterile filtration performance. It was found that increasing the amount of host cell protein from approximately 1 µg/mL (in the un-spiked VSV preparation) to 25 µg/mL resulted in a greater extent of membrane fouling, causing the VSV recovery to decrease from 89% to 65% in experiments conducted with the highly asymmetric Express PLUS PES membrane and to go as low as 48% in experiments conducted with the symmetric Durapore PVDF membrane. Similar effects were not seen when bovine serum albumin, a common model protein used in filtration studies, was spiked into the VSV preparation, which indicates that the sterile filtration performance is critically dependent on the complex composition of the mixture of host cell proteins rather than the presence of any protein. The results presented in this work provide important insights into the role of host cell impurities on the performance of sterile filtration processes for therapeutic viruses.

Scale-up issues during sterile filtration of glycoconjugate vaccines.

Several recent studies have provided important insights into the factors controlling the sterile filtration of glycoconjugate vaccines; however, this work has been limited to small-scale disk filters with very uniform flow distribution. The objective of this study was to examine the scale-up of the sterile filtration step using a glycoconjugate drug substance made from a single polysaccharide serotype. Experimental data were obtained during constant flux filtration through 0.22 µm Durapore® polyvinylidene difluoride (PVDF) membranes, both with small discs and with the Opticap® XL2 pleated cartridge. The transmembrane pressure increased rapidly during the glycoconjugate filtration due to membrane fouling, with the rate of pressure increase being more pronounced in the pleated cartridge. Additional insights into the fouling behavior were obtained using confocal microscopy by in situ labeling of the glycoconjugate captured within the filter media using an Alexa Fluor fluorescent dye. Glycoconjugate deposition occurred only within the first 5-15 µm of the 0.22 µm Durapore® membrane at both scales, with more variability in the deposition pattern observed for the pleated filter due to the non-uniform flow distribution in the Opticap® XL2 cartridge. These results provide important insights into the underlying fouling behavior during sterile filtration of glycoconjugate vaccines as well as a framework for the scale-up of the sterile filter step in glycoconjugate biomanufacturing.

Modified Bundle of Capillaries Approximation of Sterilizing Filter Membranes and its use for Filter Characterization and Filtration Process Optimization.

Sterilizing filtration is a common unit operation for the manufacture of parenteral drug products. However, filter performance can be impacted by properties of both the membrane material and the solution being filtered, requiring extensive multi-factor studies to optimize the filtration process for a given drug product. Here, we report the use of a modified bundle of capillaries approximation to predict filter performance. The model is directly applicable for both Newtonian and non-Newtonian solutions and does not require assumptions of steady state. Using a hydrophilic polyvinylidene difluoride (PVDF) filter as a test case, we show that the model fitting parameters align with expected values and both flux and shear are well predicted. Moreover, two case studies are presented to demonstrate the model's utility for filtration process optimization: 1) protein adsorption of an antibody formulation and 2) filter fouling of a 1% (w/v) carboxymethylcellulose (CMC) solution. In both cases, the model was able to accurately identify optimal filtration parameters to reduce the amount of adsorption or improve the filter capacity, respectively. This methodology can be easily extended to alternate filter types and provides an additional predictive tool to speed process development and minimize trial and error during filtration process design.

Prefiltration enhances performance of sterile filtration for glycoconjugate vaccines.

Recent studies have reported very low capacity during sterile filtration of glycoconjugate vaccines due to rapid fouling of the sterile filter. The objective of this study was to explore the potential for significantly increasing the capacity of the sterile filter through the use of an appropriate prefilter. Data were obtained using prefilters with different pore size and chemistry, with the sterile filtration performed at constant filtrate flux using 0.22 µm nominal pore size Durapore® polyvinylidene difluoride membranes. Prefiltration through 5 µm pore size Durapore® or Nylon prefilters nearly eliminated the fouling of the sterile filter, leading to more than a 100-fold reduction in the rate of pressure increase for the sterile filter. This dramatic improvement in sterile filter performance was due to the removal of large components (greater than 1 µm in size) as confirmed by dynamic light scattering. These results demonstrate the potential of using large pore size prefilters to significantly enhance the performance of the sterile filtration process for the production of important glycoconjugate vaccines.

Optical Density Value and Ratio as Novel Indexes for Nanoemulsion Sterile Filtration Process Control or Characterization.

Sterile filtration is an effective method to remove any microorganisms present during nanoemulsion preparation. However, it lacks effective control parameters. Here, we established a simple and rapid approach for the process control of nanoemulsion sterile filtration by utilizing optical density detection as a process control parameter. During sterile filtration, the optical density or optical density ratio of the filtrate were continuously monitored to explore the correlation between optical density and the emulsion content and the change in the optical density ratio before and after sterile filtration. In the emulsion stability test, the optical density ratio was determined. A good correlation was obtained between the optical density and the nanoemulsion content during sterile filtration, thereby reducing sterile filtration loss. The optical density ratio changed significantly after sterile filtration, indicating that it could be used as a process control parameter to monitor leakage during emulsion sterile filtration. The optical density ratio can be a characterization index for stability monitoring as it is more sensitive than particle size detection and more convenient than large particle detection. These parameters may be used for sterile filtration process control and as an index for nanoemulsion characterization. This approach overcomes the limitations of existing nanoemulsion characterization methods.

Liposome Sterile Filtration Characterization via X-ray Computed Tomography and Confocal Microscopy.

Two high resolution, 3D imaging techniques were applied to visualize and characterize sterilizing grade dual-layer filtration of liposomes, enabling membrane structure to be related with function and performance. Two polyethersulfone membranes with nominal retention ratings of 650 nm and 200 nm were used to filter liposomes of an average diameter of 143 nm and a polydispersity index of 0.1. Operating conditions including differential pressure were evaluated. X-ray computed tomography at a pixel size of 63 nm was capable of resolving the internal geometry of each membrane. The respective asymmetry and symmetry of the upstream and downstream membranes could be measured, with pore network modeling used to identify pore sizes as a function of distance through the imaged volume. Reconstructed 3D digital datasets were the basis of tortuous flow simulation through each porous structure. Confocal microscopy visualized liposome retention within each membrane using fluorescent dyes, with bacterial challenges also performed. It was found that increasing pressure drop from 0.07 MPa to 0.21 MPa resulted in differing fluorescent retention profiles in the upstream membrane. These results highlighted the capability for complementary imaging approaches to deepen understanding of liposome sterilizing grade filtration.

Scalability of Sterilizing-Grade Filters in Different Filtration Modes.

Scalability of filter throughput in normal flow filtration runs is an important consideration in the development of biopharmaceutical downstream processes. Depending on the filtration mode used, filter device geometry can significantly affect scalability. In this study, scaling of different polyethersulfone sterilizing-grade filters was performed in two filtration modes-at constant flow and at constant pressure-using a particulate model solution as well as a cell-free mAb solution as a representative example. Both filtration methods were compared regarding their practicability as well as their scalability of the final filter throughput and the filtration time. The pressure-dependent filter fouling that occurred with the mAb solution and the model solution showed that using different pressures for small- and process-scale filtration runs could potentially influence the predicted filter capacity. Overall, good scalability of the final filter throughput was determined for filters ranging from small-scale flat disc filters (4.5 cm2) to large pleated filter assemblies (5.4 m2) in filtration runs at constant flow as well as for filter capsules (0.6 m2) of up to 10" for filtration runs at constant pressure. Moreover, at constant flow, the filtration time could be accurately predicted because it was determined by the adjusted flow rate. However, at constant pressure, potential resistances in process-scale devices can result in lower fluid fluxes and, hence, a longer unpredictable filtration time compared with small-scale filter elements. This paper introduces a novel scaling method performed at constant pressure that compensates for the pressure losses resulting from process-scale device resistances. Improved scalability regarding final filter throughput and filtration time are shown here with this scaling method compared with scaling at constant pressure. Therefore, this study provides information essential in decision-making to achieve optimal scaling within biopharmaceutical process development.

Effect of exosome isolation methods on physicochemical properties of exosomes and clearance of exosomes from the blood circulation.

Exosomes, which are expected to be delivery systems for biomolecules such as nucleic acids, are collected by several methods. However, the effect of exosome isolation methods on the characteristics of exosomes as drug carriers, such as recovery efficiency after sterile filtration and pharmacokinetics, has not been investigated despite the importance of these characteristics for the development of exosome-based delivery systems. In the present study, exosomes collected from murine melanoma B16-BL6 cells by several methods were compared with respect to dispersibility, recovery rate after filtering, and clearance from the blood circulation in mice. The exosomes were collected by three ultracentrifugation-based methods: simple ultracentrifugation/pelleting (pelleting method), ultracentrifugation with an iodixanol cushion (cushion method), and ultracentrifugation on an iodixanol density gradient (gradient method). The isolation methods had little effect on the particle number of exosomes. In contrast, transmission electron microscopy observation and size distribution measurement using tunable resistive pulse sensing indicated that the exosomes of the gradient method were more dispersed than the others. The exosomes were labeled with Gaussia luciferase and intravenously injected into mice. Clearance of injected exosomes from the blood circulation did not significantly change with isolation methods. When the exosomes were filtered using a 0.2-µm filter, the recovery rate was 82% for the exosomes of the gradient method, whereas it was less than 50% for the others. These results indicate that the exosome isolation method markedly affects the dispersibility and filtration efficiency of the exosomes.

Microspectroscopic investigation of the membrane clogging during the sterile filtration of the growth media for mammalian cell culture.

Growth media for mammalian cell culture are very complex mixtures of several dozens of ingredients, and thus the preparation of qualified media is critical to viable cell density and final product titers. For liquid media prepared from powdered ingredients, sterile filtration is required prior to use to safeguard the cell culture process. Recently one batch of our prepared media failed to pass through the sterile filtration due to the membrane clogging. In this study, we report the root cause analysis of the failed sterile filtration based on the investigations of both the fouling media and the clogged membranes with multiple microspectroscopic techniques. Cellular particles or fragments were identified in the fouling media and on the surfaces of the clogged membranes, which were presumably introduced to the media from the bacterial contamination. This study demonstrated that microspectroscopic techniques may be used to rapidly identify both microbial particles and inorganic precipitates in the cell culture media.

Microscopic Characterization of Brevundimonas diminuta in the Hydrated State.

UNLABELLED: Brevundimonas diminuta is the organism most commonly used for challenge testing of sterilizing-grade filter membranes. ASTM F838-05 and PDA Technical Report 26 rely on B. diminuta ATCC #19146 for standard challenge tests used to designate sterilizing-grade filter performance. Despite the importance and widespread use of B. diminuta in filter testing and validation, information about this microorganism in its native hydrated state is limited. In this work, we measure, for the first time, the mechanical property of modulus for B. diminuta cultured in saline lactose broth (as described in ASTM F838-05) via wet atomic force microscopy. For comparison, we also imaged B. diminuta by the traditional method of electron microscopy after capture on a filter and chemical fixation. The modulus of hydrated B. diminuta cells was ∼193 mPa. To put this result into context, a simple model for pore penetration that correlates the role of the Young's modulus of hydrated cells to the penetration of sterilizing-grade filters is proposed. The model confirms the industry experience that pore size is an essential parameter in preventing the penetration of B. diminuta into sterilizing-grade filters. LAY ABSTRACT: The small microorganism Brevundimonas diminuta is used to characterize the performance of sterilizing-grade filter membranes used in the manufacturing of sterile drug products. Little is known about the size, shape, or elasticity of living bacterial cells, as it is easier to characterize bacteria after chemical fixation in a dry state. In this work, we use atomic force microscopy to determine the size, shape, and deformability of this important microorganism while it is alive and fully hydrated. Additionally, we compare the physical and mechanical properties of B. diminuta measured in wet and dry states. This information can be used to advance our understanding of how filter membranes remove these organisms from fluid streams.