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The life science business of Merck KGaA,
Darmstadt, Germany operates as
MilliporeSigma in the U.S. and Canada.
Platform Technologies to
Accelerate Novel Vaccine
Development and
Manufacturing
David Loong PhD
Senior Consultant, Novel Modalities, Asia Pacific,
BioProcessing Strategy
Josephine Cheng
Senior Consultant, Core Modalities, Asia Pacific,
BioProcessing Strategy
The life science business
of Merck KGaA, Darmstadt,
Germany operates as
MilliporeSigma in the U.S.
and Canada
Content
1
2
3
Vaccine Platform Technology & Benefits
Key platform introduction-Case studies
Comparison & summary
Vaccine Platform
Technology & Benefits
Eradication
of diseases such as
smallpox
3 million
deaths prevented
every year
Reduction
from 125 to 2 Polio endemic countries in 30 years
5
A preparation that is
administered to stimulate the
body's immune response against
a specific infectious agent or
disease
Introduction
Vaccines
5
Our mission
Enabling the industry to
produce
better faster safer
vaccines
to improve access,
globally
Vaccines are a major contribution to overall Global Health
6
Scalability
Need to be able to produce huge amount of doses in
a short time
Global vaccine manufacturing capacity may not be
sufficient for COVID19
Time
The typical vaccine paradigm doesn’t allow
adequate response to tackle outbreaks
Cost
Vaccine development & licensure requires
>$500 million
No guaranteed long-term market
Major Challenges in Vaccine manufacturing with Outbreak & Pandemic
A Paradigm Shift with Pandemics
7
A Paradigm Shift in Vaccine Manufacturing
Time is compressed, phases overlap
Phase 1
Target ID, development partner
selection & Pre-clinical trials
Phase 2a Phase 3 Licensure
Small-scale clinical trial material
Manufacturing scale-up,
commercial scale, process
validation
Large-scale
manufacturing
Clinical development
Target ID,
development
partner selection &
Pre-clinical trials
Safety/
Dose
selection
Safety/efficacy
Manufacturing development, scale up,
clinical lots, commercial scale,
validation of process
Large-scale manufacturing
Go or no-go
decision to invest in
candidate
First trial in
humans
Efficacy trial in
humans
Evaluation trial
in humans
Go or no-go
decision to
invest in
candidate
First in humans
(safety)
Regulatory pathway for
emergency authorization
Efficacy trial
Traditional
paradigm
+10years
Outbreak
paradigm
1-3 years
Adapted from NEJM, Lurie et al, March 30th, 2020
8
How they have influenced vaccine manufacturing
Pandemics and outbreaks
2021
9
• Global capacity is constrained to respond
to COVID19 need
• The “unknown” preparedness remain the
biggest challenge
• Next time, how can we minimize risks
and be better prepared?”
A Paradigm Shift
Lessons learned and Approaches
▪ Acceleration of development is
needed.
▪ Prepare for scalability once
vaccine is developed.
▪ Platform Technology to reduce
changes & increase production
capabilities.
10
Inactivated
virus
Vaccines compose of
dead virus
DNA
vaccines
Vaccines compose of
snippets of pathogen
genes
Vaccine by modalities
Traditional vaccine
Recombinant
protein
Vaccines with protein or a
protein fragment of the
pathogen, assembled to
closely resemble viruses
Conjugated
vaccine
Vaccines compose of
sugars that mimic bacteria
pathogen on a carrier
protein that increase
immune response
Viral vector
vaccine
Vaccines that use a virus
to deliver snippets of
pathogen genes into
human cells
Virus-like
particles
Vaccines with protein or
a protein fragment of
the pathogen, with a
structure closely
resemble the pathogen
Modern to cutting edge vaccine
Live attenuated
virus
Vaccines compose
of weakened virus
Toxoid
Vaccines compose
of inactivated toxin
Vaccines compose
of inactivated
bacteria
Whole bacteria
RNA
vaccines
Vaccines compose of
snippets of pathogen
genes
1921 1924 1945 1955 1986 - 2006 1986 - 1991 1987 - 1991 2019 2020 2021
« One bug – one drug » « One platform – multiple vaccines»
Improvements towards effective, safe, and affordable vaccine
A vaccine platform is any underlying technology,
a mechanism, delivery method, or cell line that
can be used to develop multiple vaccines.
Replication
incompetent
Replication
competent
Various expression
systems
Synthetic
mRNA
Self-amplifying
(saRNA)
11
Benefits
Supports
bioprocessing
standardization
1
Reduce process
development
time
2
3
4
Reduce
significant
manufacturing
changes
Ease of
regulatory
approval
12
Key platform introduction:
Case studies
- VLP, Viral Vector, pDNA,
mRNA
Protein Subunit vaccines/
VLP vaccines
14
A VLP has the shape of virus but no genetic materials, good immune
response & no risk of pathogenicity
Virus Like Particles – a versatile platform
• Virus-like particles (VLPs) are biological nanoparticles composed
of viral structural proteins, frequently major proteins in the capsid
or envelop.
• Contain repetitive high-density displays of viral surface proteins
that elicit strong immune responses.
• Self-assemble into structures morphologically resembling viruses.
• No genetic material – no replications, non-infectious.
• 20 to 200 nm in size and is similar to the size of the
corresponding viruses, allows them to be taken up by dendritic
cells (DCs) and antigen-presenting cells (APCs).
• Can be produced in a variety of cell culture systems, against
different strains of a virus other than those for which the vaccine
was formulated.
• They sometimes require adjuvants to increase their
immunogenicity
• Proven technology: Hepatitis B, Human Papillomavirus vaccines
15
VLPs are either non-enveloped or enveloped
VLPs can be divided into two groups:
Non-enveloped (“naked”) and Enveloped.
Each groups could be classified based on the
number of viral surface proteins.
Non-
enveloped
HBV, HPV
Enveloped
CMV
Source:Appl Microbiol Biotechnol (2015) 99:10415–10432
Transfus Med Hemother. 2010 Dec; 37(6): 365–375
VLP designs examples
(a) 1 layer - 1 proteins Hepatitis B
(b) 1 layer- 2 proteins SARS Coronavirus
VLPs
(c) 2 layers-2 proteins Papillomavirus L1
and L2
(d) 2 layers- multiple proteins FMDV-VLPs
(e) 3 layers- multiple proteins Bluetongue virus,
rotavirus
(f) 1 layer-1 protein Influenza virus
(g) 1 layer – 2 proteins Hantaviruses
(h) 2 layers- 2 proteins Hepatitis C
(j) 2 layers – multiple proteins SARS coronavirus
VLP
eVLP
16
Production & Purification of VLP-Based Vaccine
Insect Cell / Baculovirus VLP Production Platform
UF/DF
Baculovirus
Inactivation
Purification
Chromatography
Media and Inoculum
Preparation
Cell growth in
Bioreactor and
Virus Inoculation
Bioburden
Reduction
Primary
Clarification
Sterile
Filtration
Polishing
Chromatography
UF/DF
Removal
17
Bacteria Yeast Mammalian
Cell
Plants Insect Cell
VLP Type Non-
enveloped
Non-enveloped
Enveloped
Non-enveloped
Enveloped
Non-enveloped
Enveloped
Non-enveloped
Enveloped
Secretory
Expression
- + ++ + ++
Speed +++ +++ ++ ++ ++
Cost + + +++ ++ ++
Scalability +++ +++ ++ ++ ++
VLP Complexity + ++ ++ ++ +++
Yield +++ ++ + ++ ++
Reported Yields 4.38 g/L
Polyomavirus VP1
400 mg/L
Hepatitis B Surface
Antigen
500 mg/L
Adeno-associated
Virus
3 g/kg
Papillomavirus L1
662 mg/L
Rotavirus VP2, VP6
and VP7
Different VLP Production Systems
Source: Shiyu Dai et.al. Journal of Immunological Sciences (2018).
- No successful cases reported; + Low; ++ Medium; +++ High
Linda et al., Biotechnology and Bioengineering, Vol. 111, No. 3, March, 2014
18
VLP Technology
Challenges
1 pH, solubility, shear,
proteolytic
2 Adsorption
Shear
filtration
chromatography resolution
3
Endotoxin removal in bacterial
expression systems
Difficulties in baculovirus (BV)
removal (VLPs with similar sizes
and/or surface charge at a given
pH)
Stability
yields
Contaminant
Removal
19
Overall, depending on the expression platform of VLPs, the
production processes should be designed to accommodate the best
compromise between throughput, yield and quality needs meeting
the desired purity and potency, and the cost.
1. Disease Target: Hepatitis C
 170 million people infected, over 350,000
deaths/year
 Causes cirrhosis and liver cancer
 Current therapies only partially effective, costly
and poorly tolerated
 No vaccine currently exists
2. VLP produced in Sf9 insect cells co-infected with
MLV-GAG and HCV-E1E2 using baculovirus
Purification process optimization for VLP-based Vaccine
Case sharing collaboration with iBET
iBET: Instituto de Biologia Experimental e
Tecnológica, Oeiras, Portugal
Sf9
ANTIGENS
E1 and E2 envelope
glycoproteins from
Hepatitis C virus
STRUCTURE
Capsid and envelope
from retrovirus
(murine leukemia
virus)
20
21
Production & Purification of VLP-Based Vaccine
Process Challenges
Scalable production in bioreactor
Efficient purification
High recovery of VLP
Baculovirus clearance
VLP
Baculovirus
1
2
3
4
Production & Purification of VLP-Based Vaccine
Cell culture Optimization
Cell growth obtained using
Mobius® 3L Bioreactor
Western blot analysis of VLPs
using three markers
• Comparable cell and VLP properties between disposable and glass bioreactors.
• Increased agitation rate, increased cell density of inoculation, replacing the micro-
sparger with an open-pipe sparger improved the performance of the single-use
bioreactor.
• Reproducible performance of the disposable bioreactor.
22
Unlike centrifugation (CFG),
depth filtration resulted in ~70% DNA clearance
0% 20% 40% 60% 80% 100%
10 μm → 5 μm → 0.6 μm
10 μm → 0.6 μm
5 μm → 0.6 μm
5 μm → 0.3 μm
CFG → 0.6 μm
CFG → 0.3 μm
CFG
VLP recovery
HepC VLP clarification
Production & Purification of VLP-Based Vaccine
Clarification Optimization
Clarification
• Filter-only clarification train can be
used without compromising recovery
yield of VLPs.
• Filter cascade composed of a Polygard®
CN 5 μm filter followed by a 0.3 μm
depth filter showed the highest
recovery of HCV-VLP, improving on
centrifugation/2° depth filtration
• Moderate DNA removal with depth
filtration was seen
23
24
Virus-Like Paricle Vaccine Training
90%
35%
85%
80%
28%
91%
58%
90%
96%
38%
0%
25%
50%
75%
100%
HCV-VLP
recovery %
BV removal % Total Protein
removal %
DNA removal
%
HCP
removal%
Pellicon® (PES 100 kD) Pellicon® (CRC 300 kD)
Both membranes were fully retentive of the VLP
Better removal of
baculovirus, DNA,
and host-cell
protein!
Optimization of TFF for Concentration and Purification
Purification Results
UF/DF
Pellicon® cassette with 300
kD regenerated cellulose
membrane offered the best
combination of recovery
and purification
4-5X concentration
achieved
24
▪ Successfully purified VLPs using Fractogel®
TMAE commercial resins
▪ Yield of >60% with ~2 LRV baculovirus can
be achieved with a flow-through/wash
purification strategy
▪ Options to increase recovery or purification
depending on product value by varying process
conditions
Separation of VLP from Baculovirus
Anion Exchange Chromatography for VLP Purification
Higher flow rate
OR
Higher load conductivity
Recovery LRV
Flow rate (mL/min)
NaCl
(mM)
Higher recovery
AND
Lower BV LRV
Inputs: [NaCl] (100/200/300 mM) and flow rate (100/200/400 cm/hr)
Responses: % VLP recovery and Baculovirus LRV
Purification
Recovery
25
All components were
integrated in a templatable and
scalable process that made it
possible to achieve the desired
yield and recovery
Summary iBET collaboration
• A Mobius® 3L single-use bioreactor was
successfully used to produce a VLP-based
vaccine in an insect cell culture system
• Downstream processing was optimized using
Polygard® CN 5.0→0.3 μm depth filters, followed
by UF/DF using a Pellicon® cassette with
Ultracel® 300 kDa Membrane
• VLPs were purified using Fractogel® EMD TMAE
resins and Eshmuno® resin prototypes
26
Viral Vector
based vaccines
27
Viral Vectors shuffle genetic messages into cells for making target
antigens without getting human sick
A Trojan-horse Vaccine
1. A live vector vaccine is a a vaccine that uses a
weakened or harmless microorganism to transport
pieces of antigen in order to stimulate an immune
response.
2. Common viral vectors are adenovirus, canarypox,
lentivirus, and alphaviruses.
3. They transfect their own DNA into the host cell,
which is later expressed to produced new viral
particles.
4. Viral vectors are genetically modified to have non-
replicating viral vectors (e.g. adenovirus) and
replicating viral vectors (e.g. weakened Measles).
5. Benefits including strong immue response, possible
to encode several antigens (multi-diseases),
relatively inexpensive and stable to transport.
Widely used for vaccines and cancer drug.
6. Risk of reversion of virulence, potential cancerous
cell cancerous phenotype.
28
Adenovirus based vaccine pipelines
Adenovirus (AV) is most commonly used in vaccine development
Vaccine Target Type Company Approval year Comments
Ad5-
EBOV
Ebola Ad5
CanSino &
Beijing Institute
of Biotechnology,
China
2017
Lyophilized
1 dose
Zabdeno
®
Ad26.ZE
BOV
Ebola
AdVac®
(Ad26)
Johnson &
Johnson (Janssen
Vaccines)
2020
Liquid frozen
2 doses, boost:
Mvabea®
(MVA-
BN-Filo) with a
different vector
Vaccine Type Phase Company
AZD1222 Adenovirus EUA
AstraZeneca & University of
Oxford
Ad5-nCoV Adenovirus EUA CanSino & China’s military
research unit
Ad26COVS1 Adenovirus EUA Johnson & Johnson
Current approved adenovirus based vaccines
Current COVID-19 adenovirus*
*As of date July 2021
• Human adenoviruses and many
animal adenoviruses (monkeys,
cattle, sheep, swine, dogs),
belong to the genus
Mastadenovirus
• Adenovirus in its natural form
is a pathogen for common cold.
The AV used for vaccine
developments are specially
genetically modified NOT to
cause any diseases and
generally regarded as safe.
• Non-Enveloped viruses with a
ds-DNA, 70-90 nm in size,
small enough to go through
sterile filtration.
29
Schematic Adenovirus manufacturing process
Viral Vector Manufacturing
Raw materials Media prep Amplification &
inoculation
Cell culture Clarification
(I & II)
Bioburden
removal
Nucleic acid
digestion
Concentration
Bioburden
removal
AEX Chrom
Concentration
& Diafiltration
Formulation
Sterile
filtration
Final Filling
Lysis
SEC or
AEX chrom
Upstream Downstream
Formulation & Fill Finish Downstream
30
Viral Vector Technology
Challenges
1 Reaching sufficient viral
titers
2
3
Needs to meet regulatory
requirements
Recovery
Cost &
scalability
31
Titer
Ensure minimum
losses in downstream
4Purity &
Quality
Simian Adenovirus
platform for vaccines
32
Objectives:
• GMP process
• Easy to operate
• Single use
• >50% efficiency
• Phase 1 scale: >5x1013 VP (1000 doses)
• Readily scalable to 5x1014
• Vaccine candidate: Rabies vaccine
« ChAdOx2-RabGP »
Transition to a new manufacturing process
Reduced handling, compressed process
Benzonase®
Nuclease
Clarification
Millistak+®
filters
Concentration/
Diafiltration
Pellicon® 2
cassettes
Membrane
chromatography
Natrix®
membrane
Diafiltration/
Formulation
Pellicon® 2
cassettes
Final filtration
Durapore® filters
Mobius®
Bioreactor
Centrifugation Ultra-centrifugation
Shake flasks
33
Conclusion
Accelerating vaccine development & manufacturing is possible
GMP ready for
various
adenoviruses
Full single
use process
Project met
initial goals
>2000 doses/4L
culture
18 months
project
Collaboration
between
supplier/
manufacturer
is key
5 days process
time:
« outbreak »
ready
34
What is the advantage of a platform?
The Need to Platform
1. Supports bioprocessing standardization
2. Reduce process development time
3. Reduce significant manufacturing changes
4. Ease regulatory approval
At the Jenner Institute, in 2 months, process development was
done based on the previously developed platform
Optimization of critical unit operations were done hand in hand
with Merck engineers
35
Nucleic Acid Vaccine
– pDNA & mRNA
36
The rise of nucleic acid technologies
Nucleic acids require a delivery system to be effective
Naked Encapsulated
DNA RNA
Target gene
DNA
Plasmid DNA is the
common approach
mRNA
Lipid nanoparticles
formation using lipids
and/or polymers to
protect from nucleases &
endosomes
Intravenous or lymphatic
injection route
siRNA Antisense
RNA
Local administration
at target site
Rapid degradation
Intratumoral,
intranodal or subq
Other types of RNA
37
mRNA technology
Two types of mRNA constructs are being actively used
Non-Replicating mRNA (NRM) Self Amplifying mRNA (SAM)
Number of
nucleotides
2000 – 3000 nt ~ 10 000 nt
Type Single-stranded Single-stranded
Size 660 – 990 kDa 3300 kDa
Potency Low levels of proteins
High levels of proteins
Enhanced protein expression
Immunity
No theoretical risk of anti-vector immunity
with non-viral delivery systems
No anti-vector effect has been observed
yet
Potential interactions between encoded
non-structural proteins and host factors
require additional investigation.
Concentration
needed/dose
~50-200ug/dose ~1ug/dose
5’ UTR GOI 3’ UTR
5’ cap A A A A A A A A 5’ UTR GOI 3’ UTR
5’ cap A A A A A A A A
Replicase
38
mRNA technology
Advantages
1 RNA therapeutics are safer
than DNA therapeutics
(RNA does not integrate
into the Genom)
RNA is not infectious
RNA is produced using a
cell-free enzymatic
transcription reaction or
chemical synthesis
2 Production of RNA-
based vaccines is
faster compared to
production of
traditional vaccines
Good scalability
3
Producing RNA
vaccines is less
expensive than
producing the full
antigen protein
4
For any outbreak
RNA vaccines are
more flexibel, any
desired RNA for any
desired protein of
interest can be
prepared in short time
for each individual
patient (personalized
medicine)
Safety
Time
COst
Flexibility
39
39
mRNA technology
Challenges
1 Single stranded
Highly negatively charged
Rapid degradation of RNA
caused by endonucleases
Cold-chain
2 Exogenous mRNA is
immunostimulatory, as it is
recognized by a variety of
innate immune receptors
In applications such as
protein-replacement
therapies, activation of the
innate immune system by
toll-like receptors by IVT
mRNA is not desired
3 The in vivo Delivery of
RNA is very inefficient
RNA vaccines have a
lower immunogenicity
compared to traditional
vaccines, so higher doses
are needed
RNA instability
Immune modulation
Efficiency
40
40
Generate pDNA coding for the RNA polymerase promoter and the targeted mRNA construct
mRNA manufacturing starts with a plasmid template
Plasmid process
Fermentation Clarification Purification
with Chrom
(2-3 steps)
Final
Filtration
Concentration
and Diafiltration
(UF/DF)
Thaw cells
E.coli+pDNA
Cell Harvest Cell Lysis Concentration
and Diafiltration
(UF/DF)
Plasmid facility mRNA facility
pDNA
Non replicating mRNA
Self amplifying mRNA
pDNA
41
High-performing and single-use chromatography devices simplify the
process
Plasmid process
• Superior productivity and flexibility for multi-
product/multi-purpose manufacturing of plasmids
• Ideally suited for the capture of small and mid-sized
Plasmids (<20kbp)
• Yield: ≥80 % of ccc-form, >95 % RNA removal
• Short cycle time: 35 min
• Caustic stability enables efficient cleaning (1M NaOH)
• Re-use in rapid-cycling operation mode allows for cost
reduction
Natrix® Q Chromatography membrane
Plasmid
Size
Plasmid
Titer
µg/ml
Initial pDNA
Purity
A260 based
Operating
Capacity
mg/mL MV
Yield
%
pDNA Eluate
Purity
A260 based
5.7 kb 45 4.0 %  10 ≥ 80
≥ 80 %
pDNA
13 kb 33 2.4 %  4 ≥ 77
≥ 90 %
pDNA
20 kb 25 0.7 % 1 ≥ 65
≥ 62 %
pDNA
Case study
Feed characteristics
• Original E. coli lysates from alkaline lysis, clarified by
centrifugation/depth filtration, supplemented with optimal NaCl
to eliminate RNA interference, pH 5.0, finally 0.22 µm filtered
• Plasmids ranging from small to large size
• Varying initial pDNA purity ranging from 0.7% - 4%
Results
42
mRNA manufacturing
Scale-up considerations
Lab scale
• Solvent extraction
• Precipitation steps
• Hazardous solvents
• Scalability issues
• Lack of process development expertise
• Replace extraction & precipitation with chrom, TFF
• GMP compliance
• Risk assessment for Rnase-free biopharma materials,
process equipment, raw material & solutions
• Complex development of efficient & safe encapsulation
systems
• Challenges in sterile filtration of large mRNA complexes
• Cold-chain distribution to point of care
Manufacturing Scale
Make Purify Formulate
pDNA
Linearization
Chrom, UF/DF In vitro
Transcription
Chrom, UF/DF Enzymatic
capping
Chromatography UF/DF Encapsulation
& Formulation
Final Sterile
Filtration
43
mRNA manufacturing
Process objectives: quality
Make Purify Formulate
pDNA
Linearization
Chrom, UF/DF In vitro
Transcription
Chrom, UF/DF Enzymatic
capping
Chromatography UF/DF Encapsulation
& Formulation
Final Sterile
Filtration
mRNA
product
• mRNA Size/MW
• mRNA integrity, potency
• Encapsulation efficiency
• Capping efficiency
• Impurities: dsRNA, DNA template, nucleoside
triphosphates, RNA polymerase
• Appearance, pH, osmolality, subvisible
particles, elemental impurities and residual
solvents
Quality Control
Quality Attributes
mRNA structure
Purity
Low impurities promotes mRNA expression
• 5’ Cap: Affect innate sensing and protein
• UTRs: Maximize gene expression
• GOI or Coding Sequence Region Gene of Interest
• 3’ Poly-A-tail: Enhances translation & protects mRNA
Efficient delivery system (nanoparticle)
44
mRNA formulation
Encapsulation is crucial for mRNA stability and delivery efficiency
Drug Delivery Technologies
Lipids Lipid Nanoparticle
(LNP)
Polymers
Liposomes
Lipoplexes
Polyplexes
mRNA in
aqueous
solution
Sterile Filtration &
Fill and Finish
mRNA LNP
formation
LNP Formulation
UF/DF &
Final formulation
Encapsulation
Lipids in
organic
solvent
mRNA
LNP rug
product
LNP is most commonly
used for mRNA delivery
Each LNP consists of four different
lipids allowing the mRNA to be carried
in it and protected from degradation
45
Comparison &
summary
COVID pipeline analysis
(July.15,2021)
1
1
2
2
19
18
9
16
21
24
71
1
2
2
2
5
16
10
16
18
36
0 20 40 60 80 100 120
VVnr + Antigen Presenting Cell
Cellular based vaccine
Bacterial vector (Replicating)
VVr + Antigen Presenting Cell
Live attenuated bacterial vector
Live attenuated virus
Viral vector (Replicating)
Virus like particle
Inactivated virus
DNA based vaccine
Viral vector (Non-replicating)
RNA based vaccine
Protein subunit
Total Pipelines in COVID-19 Vaccine
Pre-Clinical Clinical Trials
PS > VV > mRNA > pDNA > IV > VLP
47
Summary
Platform technology can reduce the
development time and cost, whilst
minimizing process changes between
vaccines.
Platform technologies can provide high
level of flexibility and can be quickly
adjusted for variants especially in
pandemic and outbreaks.
Choosing which platform to use depends
on available assets and resources, overall
cost, targeted diseases, etc.
All products going forward needs to
approve safety and efficacy by the
regulatory authorities.
1
2
3
48
4
Fedosiuk et al.
Silva et al.
Peixoto et al.
Dr Anissa Boumlic
Elina Gousseinov
Claire Scanlan
Thomas Parker
Nargisse El Hajjami
Manuel Brantner
Matthieu Perret
Sandra Hon
Acknowlegement:
Thank you for listening!
49
Q&A
Platform Technologies to Accelerate Novel Vaccine Development and Manufacturing

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Platform Technologies to Accelerate Novel Vaccine Development and Manufacturing

  • 1. The life science business of Merck KGaA, Darmstadt, Germany operates as MilliporeSigma in the U.S. and Canada. Platform Technologies to Accelerate Novel Vaccine Development and Manufacturing David Loong PhD Senior Consultant, Novel Modalities, Asia Pacific, BioProcessing Strategy Josephine Cheng Senior Consultant, Core Modalities, Asia Pacific, BioProcessing Strategy
  • 2. The life science business of Merck KGaA, Darmstadt, Germany operates as MilliporeSigma in the U.S. and Canada
  • 3. Content 1 2 3 Vaccine Platform Technology & Benefits Key platform introduction-Case studies Comparison & summary
  • 5. Eradication of diseases such as smallpox 3 million deaths prevented every year Reduction from 125 to 2 Polio endemic countries in 30 years 5 A preparation that is administered to stimulate the body's immune response against a specific infectious agent or disease Introduction Vaccines 5
  • 6. Our mission Enabling the industry to produce better faster safer vaccines to improve access, globally Vaccines are a major contribution to overall Global Health 6
  • 7. Scalability Need to be able to produce huge amount of doses in a short time Global vaccine manufacturing capacity may not be sufficient for COVID19 Time The typical vaccine paradigm doesn’t allow adequate response to tackle outbreaks Cost Vaccine development & licensure requires >$500 million No guaranteed long-term market Major Challenges in Vaccine manufacturing with Outbreak & Pandemic A Paradigm Shift with Pandemics 7
  • 8. A Paradigm Shift in Vaccine Manufacturing Time is compressed, phases overlap Phase 1 Target ID, development partner selection & Pre-clinical trials Phase 2a Phase 3 Licensure Small-scale clinical trial material Manufacturing scale-up, commercial scale, process validation Large-scale manufacturing Clinical development Target ID, development partner selection & Pre-clinical trials Safety/ Dose selection Safety/efficacy Manufacturing development, scale up, clinical lots, commercial scale, validation of process Large-scale manufacturing Go or no-go decision to invest in candidate First trial in humans Efficacy trial in humans Evaluation trial in humans Go or no-go decision to invest in candidate First in humans (safety) Regulatory pathway for emergency authorization Efficacy trial Traditional paradigm +10years Outbreak paradigm 1-3 years Adapted from NEJM, Lurie et al, March 30th, 2020 8
  • 9. How they have influenced vaccine manufacturing Pandemics and outbreaks 2021 9
  • 10. • Global capacity is constrained to respond to COVID19 need • The “unknown” preparedness remain the biggest challenge • Next time, how can we minimize risks and be better prepared?” A Paradigm Shift Lessons learned and Approaches ▪ Acceleration of development is needed. ▪ Prepare for scalability once vaccine is developed. ▪ Platform Technology to reduce changes & increase production capabilities. 10
  • 11. Inactivated virus Vaccines compose of dead virus DNA vaccines Vaccines compose of snippets of pathogen genes Vaccine by modalities Traditional vaccine Recombinant protein Vaccines with protein or a protein fragment of the pathogen, assembled to closely resemble viruses Conjugated vaccine Vaccines compose of sugars that mimic bacteria pathogen on a carrier protein that increase immune response Viral vector vaccine Vaccines that use a virus to deliver snippets of pathogen genes into human cells Virus-like particles Vaccines with protein or a protein fragment of the pathogen, with a structure closely resemble the pathogen Modern to cutting edge vaccine Live attenuated virus Vaccines compose of weakened virus Toxoid Vaccines compose of inactivated toxin Vaccines compose of inactivated bacteria Whole bacteria RNA vaccines Vaccines compose of snippets of pathogen genes 1921 1924 1945 1955 1986 - 2006 1986 - 1991 1987 - 1991 2019 2020 2021 « One bug – one drug » « One platform – multiple vaccines» Improvements towards effective, safe, and affordable vaccine A vaccine platform is any underlying technology, a mechanism, delivery method, or cell line that can be used to develop multiple vaccines. Replication incompetent Replication competent Various expression systems Synthetic mRNA Self-amplifying (saRNA) 11
  • 13. Key platform introduction: Case studies - VLP, Viral Vector, pDNA, mRNA
  • 15. A VLP has the shape of virus but no genetic materials, good immune response & no risk of pathogenicity Virus Like Particles – a versatile platform • Virus-like particles (VLPs) are biological nanoparticles composed of viral structural proteins, frequently major proteins in the capsid or envelop. • Contain repetitive high-density displays of viral surface proteins that elicit strong immune responses. • Self-assemble into structures morphologically resembling viruses. • No genetic material – no replications, non-infectious. • 20 to 200 nm in size and is similar to the size of the corresponding viruses, allows them to be taken up by dendritic cells (DCs) and antigen-presenting cells (APCs). • Can be produced in a variety of cell culture systems, against different strains of a virus other than those for which the vaccine was formulated. • They sometimes require adjuvants to increase their immunogenicity • Proven technology: Hepatitis B, Human Papillomavirus vaccines 15
  • 16. VLPs are either non-enveloped or enveloped VLPs can be divided into two groups: Non-enveloped (“naked”) and Enveloped. Each groups could be classified based on the number of viral surface proteins. Non- enveloped HBV, HPV Enveloped CMV Source:Appl Microbiol Biotechnol (2015) 99:10415–10432 Transfus Med Hemother. 2010 Dec; 37(6): 365–375 VLP designs examples (a) 1 layer - 1 proteins Hepatitis B (b) 1 layer- 2 proteins SARS Coronavirus VLPs (c) 2 layers-2 proteins Papillomavirus L1 and L2 (d) 2 layers- multiple proteins FMDV-VLPs (e) 3 layers- multiple proteins Bluetongue virus, rotavirus (f) 1 layer-1 protein Influenza virus (g) 1 layer – 2 proteins Hantaviruses (h) 2 layers- 2 proteins Hepatitis C (j) 2 layers – multiple proteins SARS coronavirus VLP eVLP 16
  • 17. Production & Purification of VLP-Based Vaccine Insect Cell / Baculovirus VLP Production Platform UF/DF Baculovirus Inactivation Purification Chromatography Media and Inoculum Preparation Cell growth in Bioreactor and Virus Inoculation Bioburden Reduction Primary Clarification Sterile Filtration Polishing Chromatography UF/DF Removal 17
  • 18. Bacteria Yeast Mammalian Cell Plants Insect Cell VLP Type Non- enveloped Non-enveloped Enveloped Non-enveloped Enveloped Non-enveloped Enveloped Non-enveloped Enveloped Secretory Expression - + ++ + ++ Speed +++ +++ ++ ++ ++ Cost + + +++ ++ ++ Scalability +++ +++ ++ ++ ++ VLP Complexity + ++ ++ ++ +++ Yield +++ ++ + ++ ++ Reported Yields 4.38 g/L Polyomavirus VP1 400 mg/L Hepatitis B Surface Antigen 500 mg/L Adeno-associated Virus 3 g/kg Papillomavirus L1 662 mg/L Rotavirus VP2, VP6 and VP7 Different VLP Production Systems Source: Shiyu Dai et.al. Journal of Immunological Sciences (2018). - No successful cases reported; + Low; ++ Medium; +++ High Linda et al., Biotechnology and Bioengineering, Vol. 111, No. 3, March, 2014 18
  • 19. VLP Technology Challenges 1 pH, solubility, shear, proteolytic 2 Adsorption Shear filtration chromatography resolution 3 Endotoxin removal in bacterial expression systems Difficulties in baculovirus (BV) removal (VLPs with similar sizes and/or surface charge at a given pH) Stability yields Contaminant Removal 19 Overall, depending on the expression platform of VLPs, the production processes should be designed to accommodate the best compromise between throughput, yield and quality needs meeting the desired purity and potency, and the cost.
  • 20. 1. Disease Target: Hepatitis C  170 million people infected, over 350,000 deaths/year  Causes cirrhosis and liver cancer  Current therapies only partially effective, costly and poorly tolerated  No vaccine currently exists 2. VLP produced in Sf9 insect cells co-infected with MLV-GAG and HCV-E1E2 using baculovirus Purification process optimization for VLP-based Vaccine Case sharing collaboration with iBET iBET: Instituto de Biologia Experimental e Tecnológica, Oeiras, Portugal Sf9 ANTIGENS E1 and E2 envelope glycoproteins from Hepatitis C virus STRUCTURE Capsid and envelope from retrovirus (murine leukemia virus) 20
  • 21. 21 Production & Purification of VLP-Based Vaccine Process Challenges Scalable production in bioreactor Efficient purification High recovery of VLP Baculovirus clearance VLP Baculovirus 1 2 3 4
  • 22. Production & Purification of VLP-Based Vaccine Cell culture Optimization Cell growth obtained using Mobius® 3L Bioreactor Western blot analysis of VLPs using three markers • Comparable cell and VLP properties between disposable and glass bioreactors. • Increased agitation rate, increased cell density of inoculation, replacing the micro- sparger with an open-pipe sparger improved the performance of the single-use bioreactor. • Reproducible performance of the disposable bioreactor. 22
  • 23. Unlike centrifugation (CFG), depth filtration resulted in ~70% DNA clearance 0% 20% 40% 60% 80% 100% 10 μm → 5 μm → 0.6 μm 10 μm → 0.6 μm 5 μm → 0.6 μm 5 μm → 0.3 μm CFG → 0.6 μm CFG → 0.3 μm CFG VLP recovery HepC VLP clarification Production & Purification of VLP-Based Vaccine Clarification Optimization Clarification • Filter-only clarification train can be used without compromising recovery yield of VLPs. • Filter cascade composed of a Polygard® CN 5 μm filter followed by a 0.3 μm depth filter showed the highest recovery of HCV-VLP, improving on centrifugation/2° depth filtration • Moderate DNA removal with depth filtration was seen 23
  • 24. 24 Virus-Like Paricle Vaccine Training 90% 35% 85% 80% 28% 91% 58% 90% 96% 38% 0% 25% 50% 75% 100% HCV-VLP recovery % BV removal % Total Protein removal % DNA removal % HCP removal% Pellicon® (PES 100 kD) Pellicon® (CRC 300 kD) Both membranes were fully retentive of the VLP Better removal of baculovirus, DNA, and host-cell protein! Optimization of TFF for Concentration and Purification Purification Results UF/DF Pellicon® cassette with 300 kD regenerated cellulose membrane offered the best combination of recovery and purification 4-5X concentration achieved 24
  • 25. ▪ Successfully purified VLPs using Fractogel® TMAE commercial resins ▪ Yield of >60% with ~2 LRV baculovirus can be achieved with a flow-through/wash purification strategy ▪ Options to increase recovery or purification depending on product value by varying process conditions Separation of VLP from Baculovirus Anion Exchange Chromatography for VLP Purification Higher flow rate OR Higher load conductivity Recovery LRV Flow rate (mL/min) NaCl (mM) Higher recovery AND Lower BV LRV Inputs: [NaCl] (100/200/300 mM) and flow rate (100/200/400 cm/hr) Responses: % VLP recovery and Baculovirus LRV Purification Recovery 25
  • 26. All components were integrated in a templatable and scalable process that made it possible to achieve the desired yield and recovery Summary iBET collaboration • A Mobius® 3L single-use bioreactor was successfully used to produce a VLP-based vaccine in an insect cell culture system • Downstream processing was optimized using Polygard® CN 5.0→0.3 μm depth filters, followed by UF/DF using a Pellicon® cassette with Ultracel® 300 kDa Membrane • VLPs were purified using Fractogel® EMD TMAE resins and Eshmuno® resin prototypes 26
  • 28. Viral Vectors shuffle genetic messages into cells for making target antigens without getting human sick A Trojan-horse Vaccine 1. A live vector vaccine is a a vaccine that uses a weakened or harmless microorganism to transport pieces of antigen in order to stimulate an immune response. 2. Common viral vectors are adenovirus, canarypox, lentivirus, and alphaviruses. 3. They transfect their own DNA into the host cell, which is later expressed to produced new viral particles. 4. Viral vectors are genetically modified to have non- replicating viral vectors (e.g. adenovirus) and replicating viral vectors (e.g. weakened Measles). 5. Benefits including strong immue response, possible to encode several antigens (multi-diseases), relatively inexpensive and stable to transport. Widely used for vaccines and cancer drug. 6. Risk of reversion of virulence, potential cancerous cell cancerous phenotype. 28
  • 29. Adenovirus based vaccine pipelines Adenovirus (AV) is most commonly used in vaccine development Vaccine Target Type Company Approval year Comments Ad5- EBOV Ebola Ad5 CanSino & Beijing Institute of Biotechnology, China 2017 Lyophilized 1 dose Zabdeno ® Ad26.ZE BOV Ebola AdVac® (Ad26) Johnson & Johnson (Janssen Vaccines) 2020 Liquid frozen 2 doses, boost: Mvabea® (MVA- BN-Filo) with a different vector Vaccine Type Phase Company AZD1222 Adenovirus EUA AstraZeneca & University of Oxford Ad5-nCoV Adenovirus EUA CanSino & China’s military research unit Ad26COVS1 Adenovirus EUA Johnson & Johnson Current approved adenovirus based vaccines Current COVID-19 adenovirus* *As of date July 2021 • Human adenoviruses and many animal adenoviruses (monkeys, cattle, sheep, swine, dogs), belong to the genus Mastadenovirus • Adenovirus in its natural form is a pathogen for common cold. The AV used for vaccine developments are specially genetically modified NOT to cause any diseases and generally regarded as safe. • Non-Enveloped viruses with a ds-DNA, 70-90 nm in size, small enough to go through sterile filtration. 29
  • 30. Schematic Adenovirus manufacturing process Viral Vector Manufacturing Raw materials Media prep Amplification & inoculation Cell culture Clarification (I & II) Bioburden removal Nucleic acid digestion Concentration Bioburden removal AEX Chrom Concentration & Diafiltration Formulation Sterile filtration Final Filling Lysis SEC or AEX chrom Upstream Downstream Formulation & Fill Finish Downstream 30
  • 31. Viral Vector Technology Challenges 1 Reaching sufficient viral titers 2 3 Needs to meet regulatory requirements Recovery Cost & scalability 31 Titer Ensure minimum losses in downstream 4Purity & Quality
  • 32. Simian Adenovirus platform for vaccines 32 Objectives: • GMP process • Easy to operate • Single use • >50% efficiency • Phase 1 scale: >5x1013 VP (1000 doses) • Readily scalable to 5x1014 • Vaccine candidate: Rabies vaccine « ChAdOx2-RabGP »
  • 33. Transition to a new manufacturing process Reduced handling, compressed process Benzonase® Nuclease Clarification Millistak+® filters Concentration/ Diafiltration Pellicon® 2 cassettes Membrane chromatography Natrix® membrane Diafiltration/ Formulation Pellicon® 2 cassettes Final filtration Durapore® filters Mobius® Bioreactor Centrifugation Ultra-centrifugation Shake flasks 33
  • 34. Conclusion Accelerating vaccine development & manufacturing is possible GMP ready for various adenoviruses Full single use process Project met initial goals >2000 doses/4L culture 18 months project Collaboration between supplier/ manufacturer is key 5 days process time: « outbreak » ready 34
  • 35. What is the advantage of a platform? The Need to Platform 1. Supports bioprocessing standardization 2. Reduce process development time 3. Reduce significant manufacturing changes 4. Ease regulatory approval At the Jenner Institute, in 2 months, process development was done based on the previously developed platform Optimization of critical unit operations were done hand in hand with Merck engineers 35
  • 36. Nucleic Acid Vaccine – pDNA & mRNA 36
  • 37. The rise of nucleic acid technologies Nucleic acids require a delivery system to be effective Naked Encapsulated DNA RNA Target gene DNA Plasmid DNA is the common approach mRNA Lipid nanoparticles formation using lipids and/or polymers to protect from nucleases & endosomes Intravenous or lymphatic injection route siRNA Antisense RNA Local administration at target site Rapid degradation Intratumoral, intranodal or subq Other types of RNA 37
  • 38. mRNA technology Two types of mRNA constructs are being actively used Non-Replicating mRNA (NRM) Self Amplifying mRNA (SAM) Number of nucleotides 2000 – 3000 nt ~ 10 000 nt Type Single-stranded Single-stranded Size 660 – 990 kDa 3300 kDa Potency Low levels of proteins High levels of proteins Enhanced protein expression Immunity No theoretical risk of anti-vector immunity with non-viral delivery systems No anti-vector effect has been observed yet Potential interactions between encoded non-structural proteins and host factors require additional investigation. Concentration needed/dose ~50-200ug/dose ~1ug/dose 5’ UTR GOI 3’ UTR 5’ cap A A A A A A A A 5’ UTR GOI 3’ UTR 5’ cap A A A A A A A A Replicase 38
  • 39. mRNA technology Advantages 1 RNA therapeutics are safer than DNA therapeutics (RNA does not integrate into the Genom) RNA is not infectious RNA is produced using a cell-free enzymatic transcription reaction or chemical synthesis 2 Production of RNA- based vaccines is faster compared to production of traditional vaccines Good scalability 3 Producing RNA vaccines is less expensive than producing the full antigen protein 4 For any outbreak RNA vaccines are more flexibel, any desired RNA for any desired protein of interest can be prepared in short time for each individual patient (personalized medicine) Safety Time COst Flexibility 39 39
  • 40. mRNA technology Challenges 1 Single stranded Highly negatively charged Rapid degradation of RNA caused by endonucleases Cold-chain 2 Exogenous mRNA is immunostimulatory, as it is recognized by a variety of innate immune receptors In applications such as protein-replacement therapies, activation of the innate immune system by toll-like receptors by IVT mRNA is not desired 3 The in vivo Delivery of RNA is very inefficient RNA vaccines have a lower immunogenicity compared to traditional vaccines, so higher doses are needed RNA instability Immune modulation Efficiency 40 40
  • 41. Generate pDNA coding for the RNA polymerase promoter and the targeted mRNA construct mRNA manufacturing starts with a plasmid template Plasmid process Fermentation Clarification Purification with Chrom (2-3 steps) Final Filtration Concentration and Diafiltration (UF/DF) Thaw cells E.coli+pDNA Cell Harvest Cell Lysis Concentration and Diafiltration (UF/DF) Plasmid facility mRNA facility pDNA Non replicating mRNA Self amplifying mRNA pDNA 41
  • 42. High-performing and single-use chromatography devices simplify the process Plasmid process • Superior productivity and flexibility for multi- product/multi-purpose manufacturing of plasmids • Ideally suited for the capture of small and mid-sized Plasmids (<20kbp) • Yield: ≥80 % of ccc-form, >95 % RNA removal • Short cycle time: 35 min • Caustic stability enables efficient cleaning (1M NaOH) • Re-use in rapid-cycling operation mode allows for cost reduction Natrix® Q Chromatography membrane Plasmid Size Plasmid Titer µg/ml Initial pDNA Purity A260 based Operating Capacity mg/mL MV Yield % pDNA Eluate Purity A260 based 5.7 kb 45 4.0 %  10 ≥ 80 ≥ 80 % pDNA 13 kb 33 2.4 %  4 ≥ 77 ≥ 90 % pDNA 20 kb 25 0.7 % 1 ≥ 65 ≥ 62 % pDNA Case study Feed characteristics • Original E. coli lysates from alkaline lysis, clarified by centrifugation/depth filtration, supplemented with optimal NaCl to eliminate RNA interference, pH 5.0, finally 0.22 µm filtered • Plasmids ranging from small to large size • Varying initial pDNA purity ranging from 0.7% - 4% Results 42
  • 43. mRNA manufacturing Scale-up considerations Lab scale • Solvent extraction • Precipitation steps • Hazardous solvents • Scalability issues • Lack of process development expertise • Replace extraction & precipitation with chrom, TFF • GMP compliance • Risk assessment for Rnase-free biopharma materials, process equipment, raw material & solutions • Complex development of efficient & safe encapsulation systems • Challenges in sterile filtration of large mRNA complexes • Cold-chain distribution to point of care Manufacturing Scale Make Purify Formulate pDNA Linearization Chrom, UF/DF In vitro Transcription Chrom, UF/DF Enzymatic capping Chromatography UF/DF Encapsulation & Formulation Final Sterile Filtration 43
  • 44. mRNA manufacturing Process objectives: quality Make Purify Formulate pDNA Linearization Chrom, UF/DF In vitro Transcription Chrom, UF/DF Enzymatic capping Chromatography UF/DF Encapsulation & Formulation Final Sterile Filtration mRNA product • mRNA Size/MW • mRNA integrity, potency • Encapsulation efficiency • Capping efficiency • Impurities: dsRNA, DNA template, nucleoside triphosphates, RNA polymerase • Appearance, pH, osmolality, subvisible particles, elemental impurities and residual solvents Quality Control Quality Attributes mRNA structure Purity Low impurities promotes mRNA expression • 5’ Cap: Affect innate sensing and protein • UTRs: Maximize gene expression • GOI or Coding Sequence Region Gene of Interest • 3’ Poly-A-tail: Enhances translation & protects mRNA Efficient delivery system (nanoparticle) 44
  • 45. mRNA formulation Encapsulation is crucial for mRNA stability and delivery efficiency Drug Delivery Technologies Lipids Lipid Nanoparticle (LNP) Polymers Liposomes Lipoplexes Polyplexes mRNA in aqueous solution Sterile Filtration & Fill and Finish mRNA LNP formation LNP Formulation UF/DF & Final formulation Encapsulation Lipids in organic solvent mRNA LNP rug product LNP is most commonly used for mRNA delivery Each LNP consists of four different lipids allowing the mRNA to be carried in it and protected from degradation 45
  • 47. COVID pipeline analysis (July.15,2021) 1 1 2 2 19 18 9 16 21 24 71 1 2 2 2 5 16 10 16 18 36 0 20 40 60 80 100 120 VVnr + Antigen Presenting Cell Cellular based vaccine Bacterial vector (Replicating) VVr + Antigen Presenting Cell Live attenuated bacterial vector Live attenuated virus Viral vector (Replicating) Virus like particle Inactivated virus DNA based vaccine Viral vector (Non-replicating) RNA based vaccine Protein subunit Total Pipelines in COVID-19 Vaccine Pre-Clinical Clinical Trials PS > VV > mRNA > pDNA > IV > VLP 47
  • 48. Summary Platform technology can reduce the development time and cost, whilst minimizing process changes between vaccines. Platform technologies can provide high level of flexibility and can be quickly adjusted for variants especially in pandemic and outbreaks. Choosing which platform to use depends on available assets and resources, overall cost, targeted diseases, etc. All products going forward needs to approve safety and efficacy by the regulatory authorities. 1 2 3 48 4
  • 49. Fedosiuk et al. Silva et al. Peixoto et al. Dr Anissa Boumlic Elina Gousseinov Claire Scanlan Thomas Parker Nargisse El Hajjami Manuel Brantner Matthieu Perret Sandra Hon Acknowlegement: Thank you for listening! 49
  • 50. Q&A