Joe Orlando presented on Merck KGaA's platforms for robust and scalable upstream bioprocess development. Their CHOZN GS expression system provides a stable recombinant cell line, optimized media and feeds, and single-use bioreactors to efficiently develop and scale processes from shake flasks to 50L bioreactors. Using their TNFR Fc-fusion protein as an example, Merck demonstrated consistent titers, glycan profiles, and low aggregates across scales. Their turnkey solution aims to reduce development time and improve product quality and consistency throughout the upstream process.
4. Purpose
Platform Upstream
Bioprocess Development
• Foundation blocks
Cell line, DNA vector, cell culture media
& feeds, and bioreactors
• Unit operation integration
Turn-key solution for process
development and scale up
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5. Time consuming and resource
intensive processes
• Cell line development
• Bioreactor process development
Challenges to upstream process development
Process consistency
• Expected product titer and quality
• Equivalency at small and large
scale
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7. Comprehensive expression platform & services
Rapid and robust development
CHOZN® GS-/- cell line
GS auxotroph cell line with
clear IP path
Traceability
Documentation
Comprehensive cell line history
documentation to support
regulatory filing
Expression Vector
IP free GS expression vector
suitable for mAbs/recombinants
Process Guidance &
Protocols
Protocols for entire workflow
Media and Feeds
Fed batch & Perfusion media
produced under GMP
Technical Support
Comprehensive product and
process technical support to
ensure your success
CHOZN®
GS
Expression
Platform
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8. Optimized cell line development process
Balancing resources and performance
Transfect Selection
via “minipools”
Screen
minipools in
96-well plates
Scale-up
top producing
minipools
Screen
7-day shake
flask
Fed-batch
assay on top
minipools
(shake flask)
Single Cell
Cloning
200 pools 100 pools 100 pools 20 pools
3-4 weeks 1 week 2 weeks 1 week 2 weeks 10-12 weeks
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9. CHOZN® GS performance
Performance of 4 CHOZN® GS clones isolated from mini-pools
0
1000
2000
3000
4000
5000
Titer(mg/L)
Protein Expression
0
25
50
75
100
125
CellSpecificProductivity
pg/Cell/Day
Cell Specific Productivity (Qp)
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10. CHOZN® GS stability
75%75%
High stability
Studies performed on
top ten producing
clones from an
individual project.
80% of CHOZN®
clones are found to
have stable
productivity.
Confidence in consistent production
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12. • Robust and sustainable supply chain
• Proven manufacturability and
consistency
• Multisite manufacturing redundancy
• Scalable GMP ready products
• Animal component free
• High titers with CHOZN® GS and other
host cell lines
EX-CELL® Advanced™ cell culture media & feeds
Paired media for efficient production processes
12
13. EX-CELL Advanced cell culture media
Optimizing feed strategy
0
25
50
75
100
125
150
7 10 12 14
%ofcontrolpeaktiter
Days in culture
Control 5x5%
3x10%
1x5%, 4x7.5%
1x5%, 3x10%, 1x5%
10x3%
30% improvement
in peak titer
13
16. Limited number of bioreactor runs required for efficient scale up
Shake
Flask
Mobius® 50L
Single-use
bioreactor
Mobius® 3L Single-use
bioreactor
• Duplicate shake flasks were run in each study
• Cells seeded at 5x105 cells/ml
• EX-CELL® Advanced™ Feed schedule: 10% days 3, 5 and 7 & 5% day 10
• Glucose maintained at 5 or 6 g/L
• 3 duplicate runs evaluated
• Seed density and feed strategy consistent with shake flask
• Power 20 W/m3, pH 6.9, dissolved oxygen (DO) 30%, temp 36.8°C
• Parameters evaluated: gas transfer, pH dead band
• 2 single vessel runs evaluated
• Cells seeded and fed as shake flasks
• Equivalent energy dissipation or Power - primary scaling factor
• Power 20 W/m3, pH 6.9, DO 30%, temp 36.8°C
Scalability of the Mobius® Single-use Bioreactors
https://www.emdmillipore.com/Web-US-Site/en_CA/-/USD/ShowDocument-Pronet?id=201610.040
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17. Process scalability
Titers similar between bioreactor scales
0
5
10
15
20
25
- 3 6 9 12 15
VCDX1E6
Days
Viable Cell Density
SF
50L
3L
0
0.5
1
1.5
2
2.5
- 3 6 9 12 15
Titerg/L
Days
Titer
SF
50L
3L
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20. • A stable CHOZN® GS recombinant expressing
a TNFR Fc-fusion protein was subjected to
scale-up
• Shake flask, 3L, and 50 L bioreactor
conditions were identical to those used for the
benchmark recombinant cell line
• Near equivalent titers were achieved at all
three scales
• Future parameters to potentially address
• Seed density
• Power and agitator speed
• New feeds and strategies
Process consistency – Turn key platform
Scale-up of a recombinant cell line expressing a TNFR Fc-fusion protein
0
0.5
1
1.5
2
SF SF 3L 3L 50L
PeakTiterg/L20
21. Summary
and
Conclusions
Upstream Bioproduction
• Foundation blocks
Cell line, cell culture media & feeds, and
bioreactors
• Unit integration
Turnkey solution for clone selection,
process development, and scale up
• Speed
Platform development reduces the need for
extensive optimization
• Product consistency
Confidence in process performance and
product quality
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