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Manufacturing the COVID-
19 Pandemic Vaccine
Module Name & Code: Bioprocess (BIO62104)
Group Member Name & ID:
1. Kucheal Arivalagan (0341437)
2. DK Nur Farahiyah Pg Abd Rahman
(0340861)
3. Sharegga Sri Rengaam Saravanan
(0341782)
4. Aswintguru A/L Sivaguru (0341026)
Introduction
● SARS-CoV-2, also known as the COVID-19 pandemic, has been declared as such by the world health organization on
30th January 2020. Currently, there are a reported 1.2 million fatalities caused by the pandemic (World Health
Organisation n.d.).
● SARS-CoV-2 is a highly transmissible virus which contains a positive single stranded RNA producing flu-like
symptoms in infected hosts (Shereen et al. 2020).
● The coronavirus outbreak originated from the Wuhan Province, China.
● The main mode of transmission is from aerosols produced from the nose and the mouth by sneezing, coughing and
talking.
Symptoms, Contagion and Prevention
CONTAGION
Droplets
from
sneezing &
coughing
Hand contact
to eyes, nose
& mouth
Objects to
eye, nose,
mouth
PREVENTION
Wash/sanitize
hands
Wear a
face mask
(World Health Organization n.d.)
Avoid
contact and
social
distance
Fever
Dry cough
Tiredness
Loss of smell and taste
Breathing difficulty
Upper body pain
Vaccine Design for COVID-19
Coronaviruses have a 30kb+
positive ssRNA genome that’s
covered by helical nucleocapsid
and an outer envelope of matrix
protein, envelope protein and
spike proteins.
In SARS-CoV-2, spike proteins were
able to provide a neutralising
antibody and are a major target
antigen for developing a vaccine
(Koirala et al.).
Traditional vaccines have a
weakened pathogenic strand that is
introduced into the patient to
generate an immune response
(Vaccines. Gov n.d).
The latest technology (Pfizer vaccine) being used
to find a vaccine for COVID-19 is similar to a
traditional vaccine, except it uses mRNA to read
the spike protein of Sars-CoV-2 to be replicated
in the body and produce an immune response.
Crystallization
Chromatography
Precipitation
Purification
Downstream Process of Vaccine Production
Vacuum drying
Spray Drying
Freeze-Drying
DryingIsolation
Adsorption
Evaporation
Ion exchange resins
Membrane filtration
Extraction
Centrifugation
Flocculation
Filtration
Sedimentation
Mechanical
Physical
Chemical
Enzymatic
Cell
disruption
(vaccine europe 2020)
Industrial Manufacturing Process of Vaccine
Raw material are either
used in fermentation,
purification or a part of
the vaccine.
2 weeks on average 12 months
Raw material
reception
Active ingredient
manufacturing
A critical step in the
production of high
quality, safe and
efficacious vaccines.
(Gomez and Robinson 2020),
(Understanding the complexity of
vaccine manufacturing 2020)
• induce an immune response.
• generation of the pathogen or a
recombinant protein derived from the
pathogen
• a suitable host strain for antigen is
isolated in ampoules and stored at
-192˚C in liquid nitrogen
• growth of a feed culture in a pre-
fermenter that is then transferred to
the main fermenter
• this step may involve many unit
operations of column chromatography
and ultrafiltration
• the fermentation process is
supplemented by a nutrient solution
• nutrients are dissolved in a nutrient
tank and added to the fermentation
process after filtration
• release the antigen from the
substrate and isolate it
Industrial Manufacturing Process of Vaccine
Shipment and
distribution
2 weeks 8 months 18 weeks
Filling
Coupling and
formulation
Packaging and
lot release
2 weeks
During the formulation, the
antigen is coupled with
stabilizers and preservatives
to enhance the immune
response and ensure vaccine
stability.
Vaccines are filled
aseptically, in a vial
or a syringe, to
endure sterility.
After quality
assurance, a final
authorization is given
to release the product.
Maintenance of the cold
chain is essential for
preservation of the
vaccine.
(Gomez and Robinson 2020), (Understanding
the complexity of vaccine manufacturing
2020)
• if the vaccine is lyophilized, the
vial stoppers have to be
partially inserted to allow for
moisture to escape
• water is removed to ensure
stability and has to be
reintroduced before packaging
Figure 1: A summary on the vaccine manufacturing process (Sanofi Pasteur 2020).
Figure 2: Timeline of current influenza vaccine production using egg-based, cell-based and protein-based methods (Chen et al. 2020).
Pandemic vs Seasonal Flu
(CDC 2020)
Rarely occurs
Vaccine may not be available in the
early stages and two doses may be
needed
The population has little or no
immunity as they have not been
exposed to the virus
Vaccine available
Little to no impact on the
economy and people’s daily
lives
The population has some
immunity from previous
exposures
Seasonal Flu
Pandemic Hospitals and health care
institutions are able to cater to
patient’s sufficiently
Major impact on the economy and
people’s daily lives, hospitals are not
able to cater to patient’s sufficiently
Pandemic Vaccine vs Traditional Vaccine
● As minimal formulations are needed, it only
takes around 1 week to completely
manufacture a batch of the vaccine
● The RNA from the vaccine instructs the cell
to produce antigens that activate T-cell
and other immune responses that are able
to combat the virus (SARS-COV-2)
● Constructed using the virus’s genetic code,
thus no virus is needed
● Scalable and and standardisable
● Enables swapping coding sequence for the
protein of interest without any major
changes to the vaccine production process
● Entire process takes months to
complete as the virus has to be grown in
vitro in mammalian cells or chicken eggs
● Potentially hazardous due to the need of
large quantity of the virus
● Requires bespoke, tailor-made
processes
● Complex purification and testing
processes
● It is not possible to develop vaccines
when not grown in cell culture, cell
cultures are costly to maintain
● The overall yield of vaccines is very low
(Breakthroughs 2020)
a) Dead bacteria or
inactivated viruses.
b) Live non-virulent
or weakened
(attenuated)
bacteria/viruses
c) Viral fragments
or bacterial
molecules
Traditional VaccinesPandemic Vaccines (RNA Vaccine)
Current Developments
1
2
3
6
5
4
Pfizer and BioNTech were developing
mRNA based vaccine, BNT162 vaccine
encapsulated with LNP which targeted
the spike protein antigen.
The development of Sinopharm inactivated
vaccine which targeted the whole virus. The
vaccine does not cause the pathogen to
relapse.
Pfizer vaccine is currently under phase III stage
carried out in USA, Argentina and Brazil (What
We Know About COVID-19 Vaccine Development
2020).
There are about 43,583 people participated in
this study. Pfizer vaccine was reported to be
90% effective as 94 cases were identified. 164
cases were needed to finalised the analysis
(Callaway 2020).
The vaccine production does not required
cell culture. Hence, it is cost-effective with
short manufacturing cycle and high potency
of vaccines.
Some of the platforms used in developing
COVID-19 vaccines are; DNA/RNA vaccine,
inactivated vaccine and non-replicating
viral vector.
(Begum et al. 2020, Sharma et al. 2020)
Figure 3: The mechanism of Pfizer and BioNTech vaccine (Pfizer 2020).
Challenges
Limited distribution of vaccine worldwide
Pfizer vaccine needs to be stored at - 70°C. It is
challenging to maintain the temperature during
shipment (Johnson & Steckelberg 2020).
Insufficient information on the biological properties
RNA based vaccine was never commercialized before.
Moreover, the long term immunity after getting vaccinated
is still not known (Callaway 2020).
Antibody Dependent Enhancement
Incomplete neutralization of the viral particles
present in the vaccine may lead to the uptake
and the dissemination of the virus.
Vaccine Administration
Vaccine administration may influenced the vaccine
efficiency. Mucosal immunity may not be stimulated by
parenteral vaccination.
(Wang et al. 2020)
Conclusion
Accelerated production
of pandemic vaccines
as minimal vaccine
formulation is requiredSARS-CoV-2 vaccine
induce the immune
response by allowing the
spike protein to replicate.
While, the traditional
vaccine activates the
immune response by
introducing weak
pathogen.
A wide range of
demographics is needed to
determine the vaccination
outcome.
References
● Begum, J, Mir, N, Dev, K, Buyamayum, B, Wani, M & Raza, M 2020, ‘Challenges and prospects of COVID‐19 vaccine development based on the progress
made in SARS and MERS vaccine development’, Transboundary and Emerging Diseases, pp. 1-14.
● Breakthroughs 2020, ‘What Makes an RNA Vaccine Different From a Conventional Vaccine?’, viewed 18 November 2020,
<https://www.breakthroughs.com/advancing-medical-research/what-makes-rna-vaccine-different-conventional-vaccine>.
● Callaway, E 2020, 'What Pfizer's landmark COVID vaccine results mean for the pandemic', Nature, <https://www.nature.com/articles/d41586-020-03166-
8>, viewed 17 November 2020.
● CDC 2020, ‘How Is Pandemic Flu Different from Seasonal Flu?’, viewed 17 November 2020, <https://www.cdc.gov/flu/pandemic-
resources/basics/about.html>.
● Chen, JR, Liu, YM, Tseng, YC & Ma, Che 2020, ‘Better influenza vaccines: an industry perspective’, Journal of Biomedical Science, vol. 27, no. 33, viewed 19
November 2020, <https://doi.org/10.1186/s12929-020-0626-6>.
● Gomez, PL, Robinson, JM & Rogalewicz, JA 2013, ‘Vaccine manufacturing’, Vaccines, pp. 44.
● Johnson, C & Steckelberg, A 2020, ‘What you need to know about the Moderna and Pfizer coronavirus vaccines’, The Washington Post, viewed 18
November 2020, <https://www.washingtonpost.com/health/2020/11/17/covid-vaccines-what-you-need-to-know/?arc404=true>.
● Kaur, SP & Gupta, V 2020, ‘COVID-19 Vaccine: A comprehensive status report’, Virus Res, viewed 17 November 2020,
<https://www.ncbi.nlm.nih.gov/pmc/articles/PMC7423510/>.
● Koirala, A, Joo, YJ, Khatami, A, Chiu, C & Britton, PN 2020, ‘Vaccines for COVID-19: The current state of play’, Paediatr Respir Rev, viewed 17 November
2020, <https://www.ncbi.nlm.nih.gov/pmc/articles/PMC7301825/>.
References
● Pfizer, 'Pfizer and BioNTech Dose First Participants in the U.S. as Part of Global COVID-19 mRNA Vaccine Development Program', viewed 18 November
2020,
<https://www.pfizer.com/news/press-release/press-release-
detail/pfizer_and_biontech_dose_first_participants_in_the_u_s_as_part_of_global_covid_19_mrna_vaccine_development_program >.
● Sanofi Pasteur 2020, ‘Manufacturing vaccines is a complex journey’, viewed 19 November 2020, <https://www.sanofi.com/en/your-
health/vaccines/production>.
● Sharma, O, Sultan, A, Ding, H, Triggle, C 2020,'A Review of the Progress and Challenges of Developing a Vaccine for COVID-19', Frontiers in Immunology,
vol.11, viewed 15 November 2020, <https://www.frontiersin.org/articles/10.3389/fimmu.2020.585354/full#h11>.
● Shereen, MA, Khan, S, Kazmi, A, Bashir, N & Siddique, R 2020, ‘COVID-19 infection: Origin, transmission, and characteristics of human coronaviruses’,
viewed 17 November 2020, <https://www.sciencedirect.com/science/article/pii/S2090123220300540>.
● Vaccineseurope.eu. 2020, <https://www.vaccineseurope.eu/wp-content/uploads/2020/08/A4-VE-Infographic-Manufacturing-24062020.pdf>.
● Vaccines.gov n.d., ‘Vaccine Types’, U.S. Department of Health & Human Services, viewed 17 November 2020,
<https://www.vaccines.gov/basics/types>.
● Wang, J, Peng, Y, Xu, H, Cui, Z, Williams, RO III 20202,' The COVID-19 Vaccine Race: Challenges and Opportunities in Vaccine Formulation', AAPS
PharmSciTech, vol. 21, no. 6, pp. 225.
● What we know about COVID-19 vaccine development 2020, viewed 17 November 2020, <https://www.who.int/docs/default-source/coronaviruse/risk-
comms-updates/update37-vaccine-development.pdf?sfvrsn=2581e994_6>.
● World Health Organisation n.d., ‘WHO Coronavirus Disease (COVID-19) Dashboard’, viewed 17 November 2020,
<https://covid19.who.int/>.
Our Team
THANKS!

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Manufacturing the COVID-19 Pandemic Vaccine - Group 2

  • 1. Manufacturing the COVID- 19 Pandemic Vaccine Module Name & Code: Bioprocess (BIO62104) Group Member Name & ID: 1. Kucheal Arivalagan (0341437) 2. DK Nur Farahiyah Pg Abd Rahman (0340861) 3. Sharegga Sri Rengaam Saravanan (0341782) 4. Aswintguru A/L Sivaguru (0341026)
  • 2. Introduction ● SARS-CoV-2, also known as the COVID-19 pandemic, has been declared as such by the world health organization on 30th January 2020. Currently, there are a reported 1.2 million fatalities caused by the pandemic (World Health Organisation n.d.). ● SARS-CoV-2 is a highly transmissible virus which contains a positive single stranded RNA producing flu-like symptoms in infected hosts (Shereen et al. 2020). ● The coronavirus outbreak originated from the Wuhan Province, China. ● The main mode of transmission is from aerosols produced from the nose and the mouth by sneezing, coughing and talking.
  • 3. Symptoms, Contagion and Prevention CONTAGION Droplets from sneezing & coughing Hand contact to eyes, nose & mouth Objects to eye, nose, mouth PREVENTION Wash/sanitize hands Wear a face mask (World Health Organization n.d.) Avoid contact and social distance Fever Dry cough Tiredness Loss of smell and taste Breathing difficulty Upper body pain
  • 4. Vaccine Design for COVID-19 Coronaviruses have a 30kb+ positive ssRNA genome that’s covered by helical nucleocapsid and an outer envelope of matrix protein, envelope protein and spike proteins. In SARS-CoV-2, spike proteins were able to provide a neutralising antibody and are a major target antigen for developing a vaccine (Koirala et al.). Traditional vaccines have a weakened pathogenic strand that is introduced into the patient to generate an immune response (Vaccines. Gov n.d). The latest technology (Pfizer vaccine) being used to find a vaccine for COVID-19 is similar to a traditional vaccine, except it uses mRNA to read the spike protein of Sars-CoV-2 to be replicated in the body and produce an immune response.
  • 5. Crystallization Chromatography Precipitation Purification Downstream Process of Vaccine Production Vacuum drying Spray Drying Freeze-Drying DryingIsolation Adsorption Evaporation Ion exchange resins Membrane filtration Extraction Centrifugation Flocculation Filtration Sedimentation Mechanical Physical Chemical Enzymatic Cell disruption (vaccine europe 2020)
  • 6. Industrial Manufacturing Process of Vaccine Raw material are either used in fermentation, purification or a part of the vaccine. 2 weeks on average 12 months Raw material reception Active ingredient manufacturing A critical step in the production of high quality, safe and efficacious vaccines. (Gomez and Robinson 2020), (Understanding the complexity of vaccine manufacturing 2020) • induce an immune response. • generation of the pathogen or a recombinant protein derived from the pathogen • a suitable host strain for antigen is isolated in ampoules and stored at -192˚C in liquid nitrogen • growth of a feed culture in a pre- fermenter that is then transferred to the main fermenter • this step may involve many unit operations of column chromatography and ultrafiltration • the fermentation process is supplemented by a nutrient solution • nutrients are dissolved in a nutrient tank and added to the fermentation process after filtration • release the antigen from the substrate and isolate it
  • 7. Industrial Manufacturing Process of Vaccine Shipment and distribution 2 weeks 8 months 18 weeks Filling Coupling and formulation Packaging and lot release 2 weeks During the formulation, the antigen is coupled with stabilizers and preservatives to enhance the immune response and ensure vaccine stability. Vaccines are filled aseptically, in a vial or a syringe, to endure sterility. After quality assurance, a final authorization is given to release the product. Maintenance of the cold chain is essential for preservation of the vaccine. (Gomez and Robinson 2020), (Understanding the complexity of vaccine manufacturing 2020) • if the vaccine is lyophilized, the vial stoppers have to be partially inserted to allow for moisture to escape • water is removed to ensure stability and has to be reintroduced before packaging
  • 8. Figure 1: A summary on the vaccine manufacturing process (Sanofi Pasteur 2020).
  • 9. Figure 2: Timeline of current influenza vaccine production using egg-based, cell-based and protein-based methods (Chen et al. 2020).
  • 10. Pandemic vs Seasonal Flu (CDC 2020) Rarely occurs Vaccine may not be available in the early stages and two doses may be needed The population has little or no immunity as they have not been exposed to the virus Vaccine available Little to no impact on the economy and people’s daily lives The population has some immunity from previous exposures Seasonal Flu Pandemic Hospitals and health care institutions are able to cater to patient’s sufficiently Major impact on the economy and people’s daily lives, hospitals are not able to cater to patient’s sufficiently
  • 11. Pandemic Vaccine vs Traditional Vaccine ● As minimal formulations are needed, it only takes around 1 week to completely manufacture a batch of the vaccine ● The RNA from the vaccine instructs the cell to produce antigens that activate T-cell and other immune responses that are able to combat the virus (SARS-COV-2) ● Constructed using the virus’s genetic code, thus no virus is needed ● Scalable and and standardisable ● Enables swapping coding sequence for the protein of interest without any major changes to the vaccine production process ● Entire process takes months to complete as the virus has to be grown in vitro in mammalian cells or chicken eggs ● Potentially hazardous due to the need of large quantity of the virus ● Requires bespoke, tailor-made processes ● Complex purification and testing processes ● It is not possible to develop vaccines when not grown in cell culture, cell cultures are costly to maintain ● The overall yield of vaccines is very low (Breakthroughs 2020) a) Dead bacteria or inactivated viruses. b) Live non-virulent or weakened (attenuated) bacteria/viruses c) Viral fragments or bacterial molecules Traditional VaccinesPandemic Vaccines (RNA Vaccine)
  • 12. Current Developments 1 2 3 6 5 4 Pfizer and BioNTech were developing mRNA based vaccine, BNT162 vaccine encapsulated with LNP which targeted the spike protein antigen. The development of Sinopharm inactivated vaccine which targeted the whole virus. The vaccine does not cause the pathogen to relapse. Pfizer vaccine is currently under phase III stage carried out in USA, Argentina and Brazil (What We Know About COVID-19 Vaccine Development 2020). There are about 43,583 people participated in this study. Pfizer vaccine was reported to be 90% effective as 94 cases were identified. 164 cases were needed to finalised the analysis (Callaway 2020). The vaccine production does not required cell culture. Hence, it is cost-effective with short manufacturing cycle and high potency of vaccines. Some of the platforms used in developing COVID-19 vaccines are; DNA/RNA vaccine, inactivated vaccine and non-replicating viral vector. (Begum et al. 2020, Sharma et al. 2020)
  • 13. Figure 3: The mechanism of Pfizer and BioNTech vaccine (Pfizer 2020).
  • 14. Challenges Limited distribution of vaccine worldwide Pfizer vaccine needs to be stored at - 70°C. It is challenging to maintain the temperature during shipment (Johnson & Steckelberg 2020). Insufficient information on the biological properties RNA based vaccine was never commercialized before. Moreover, the long term immunity after getting vaccinated is still not known (Callaway 2020). Antibody Dependent Enhancement Incomplete neutralization of the viral particles present in the vaccine may lead to the uptake and the dissemination of the virus. Vaccine Administration Vaccine administration may influenced the vaccine efficiency. Mucosal immunity may not be stimulated by parenteral vaccination. (Wang et al. 2020)
  • 15. Conclusion Accelerated production of pandemic vaccines as minimal vaccine formulation is requiredSARS-CoV-2 vaccine induce the immune response by allowing the spike protein to replicate. While, the traditional vaccine activates the immune response by introducing weak pathogen. A wide range of demographics is needed to determine the vaccination outcome.
  • 16. References ● Begum, J, Mir, N, Dev, K, Buyamayum, B, Wani, M & Raza, M 2020, ‘Challenges and prospects of COVID‐19 vaccine development based on the progress made in SARS and MERS vaccine development’, Transboundary and Emerging Diseases, pp. 1-14. ● Breakthroughs 2020, ‘What Makes an RNA Vaccine Different From a Conventional Vaccine?’, viewed 18 November 2020, <https://www.breakthroughs.com/advancing-medical-research/what-makes-rna-vaccine-different-conventional-vaccine>. ● Callaway, E 2020, 'What Pfizer's landmark COVID vaccine results mean for the pandemic', Nature, <https://www.nature.com/articles/d41586-020-03166- 8>, viewed 17 November 2020. ● CDC 2020, ‘How Is Pandemic Flu Different from Seasonal Flu?’, viewed 17 November 2020, <https://www.cdc.gov/flu/pandemic- resources/basics/about.html>. ● Chen, JR, Liu, YM, Tseng, YC & Ma, Che 2020, ‘Better influenza vaccines: an industry perspective’, Journal of Biomedical Science, vol. 27, no. 33, viewed 19 November 2020, <https://doi.org/10.1186/s12929-020-0626-6>. ● Gomez, PL, Robinson, JM & Rogalewicz, JA 2013, ‘Vaccine manufacturing’, Vaccines, pp. 44. ● Johnson, C & Steckelberg, A 2020, ‘What you need to know about the Moderna and Pfizer coronavirus vaccines’, The Washington Post, viewed 18 November 2020, <https://www.washingtonpost.com/health/2020/11/17/covid-vaccines-what-you-need-to-know/?arc404=true>. ● Kaur, SP & Gupta, V 2020, ‘COVID-19 Vaccine: A comprehensive status report’, Virus Res, viewed 17 November 2020, <https://www.ncbi.nlm.nih.gov/pmc/articles/PMC7423510/>. ● Koirala, A, Joo, YJ, Khatami, A, Chiu, C & Britton, PN 2020, ‘Vaccines for COVID-19: The current state of play’, Paediatr Respir Rev, viewed 17 November 2020, <https://www.ncbi.nlm.nih.gov/pmc/articles/PMC7301825/>.
  • 17. References ● Pfizer, 'Pfizer and BioNTech Dose First Participants in the U.S. as Part of Global COVID-19 mRNA Vaccine Development Program', viewed 18 November 2020, <https://www.pfizer.com/news/press-release/press-release- detail/pfizer_and_biontech_dose_first_participants_in_the_u_s_as_part_of_global_covid_19_mrna_vaccine_development_program >. ● Sanofi Pasteur 2020, ‘Manufacturing vaccines is a complex journey’, viewed 19 November 2020, <https://www.sanofi.com/en/your- health/vaccines/production>. ● Sharma, O, Sultan, A, Ding, H, Triggle, C 2020,'A Review of the Progress and Challenges of Developing a Vaccine for COVID-19', Frontiers in Immunology, vol.11, viewed 15 November 2020, <https://www.frontiersin.org/articles/10.3389/fimmu.2020.585354/full#h11>. ● Shereen, MA, Khan, S, Kazmi, A, Bashir, N & Siddique, R 2020, ‘COVID-19 infection: Origin, transmission, and characteristics of human coronaviruses’, viewed 17 November 2020, <https://www.sciencedirect.com/science/article/pii/S2090123220300540>. ● Vaccineseurope.eu. 2020, <https://www.vaccineseurope.eu/wp-content/uploads/2020/08/A4-VE-Infographic-Manufacturing-24062020.pdf>. ● Vaccines.gov n.d., ‘Vaccine Types’, U.S. Department of Health & Human Services, viewed 17 November 2020, <https://www.vaccines.gov/basics/types>. ● Wang, J, Peng, Y, Xu, H, Cui, Z, Williams, RO III 20202,' The COVID-19 Vaccine Race: Challenges and Opportunities in Vaccine Formulation', AAPS PharmSciTech, vol. 21, no. 6, pp. 225. ● What we know about COVID-19 vaccine development 2020, viewed 17 November 2020, <https://www.who.int/docs/default-source/coronaviruse/risk- comms-updates/update37-vaccine-development.pdf?sfvrsn=2581e994_6>. ● World Health Organisation n.d., ‘WHO Coronavirus Disease (COVID-19) Dashboard’, viewed 17 November 2020, <https://covid19.who.int/>.