Development of process analytical tools for rapid monitoring of live virus vaccines in manufacturing
In the development of end-to-end large-scale live virus vaccine (LVV) manufacturing, process analytical technology (PAT) tools enable timely monitoring of critical process parameters (CPP) and significantly guide process development and characterization. In a commercial setting, these very same tool...
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Published in | Scientific reports Vol. 12; no. 1; p. 15494 |
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Main Authors | , , , , , , , , , , , |
Format | Journal Article |
Language | English |
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London
Nature Publishing Group UK
15.09.2022
Nature Publishing Group Nature Portfolio |
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Abstract | In the development of end-to-end large-scale live virus vaccine (LVV) manufacturing, process analytical technology (PAT) tools enable timely monitoring of critical process parameters (CPP) and significantly guide process development and characterization. In a commercial setting, these very same tools can enable real time monitoring of CPPs on the shop floor and inform harvest decisions, predict peak potency, and serve as surrogates for release potency assays. Here we introduce the development of four advanced PAT tools for upstream and downstream process monitoring in LVV manufacturing. The first tool explores the application of capacitance probes for real time monitoring of viable cell density in bioreactors. The second tool utilizes high content imaging to determine optimum time of infection in a microcarrier process. The third tool uses flow virometry (or nanoscale flow cytometry) to monitor total virus particle counts across upstream and downstream process steps and establishes a robust correlation to virus potency. The fourth and final tool explores the use of nucleic acid dye staining to discriminate between “good” and “damaged” virus particles and uses this strategy to also monitor virus aggregates generated sometimes during downstream processing. Collectively, these tools provide a comprehensive monitoring toolbox and represent a significantly enhanced control strategy for the manufacturing of LVVs. |
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AbstractList | In the development of end-to-end large-scale live virus vaccine (LVV) manufacturing, process analytical technology (PAT) tools enable timely monitoring of critical process parameters (CPP) and significantly guide process development and characterization. In a commercial setting, these very same tools can enable real time monitoring of CPPs on the shop floor and inform harvest decisions, predict peak potency, and serve as surrogates for release potency assays. Here we introduce the development of four advanced PAT tools for upstream and downstream process monitoring in LVV manufacturing. The first tool explores the application of capacitance probes for real time monitoring of viable cell density in bioreactors. The second tool utilizes high content imaging to determine optimum time of infection in a microcarrier process. The third tool uses flow virometry (or nanoscale flow cytometry) to monitor total virus particle counts across upstream and downstream process steps and establishes a robust correlation to virus potency. The fourth and final tool explores the use of nucleic acid dye staining to discriminate between “good” and “damaged” virus particles and uses this strategy to also monitor virus aggregates generated sometimes during downstream processing. Collectively, these tools provide a comprehensive monitoring toolbox and represent a significantly enhanced control strategy for the manufacturing of LVVs. Abstract In the development of end-to-end large-scale live virus vaccine (LVV) manufacturing, process analytical technology (PAT) tools enable timely monitoring of critical process parameters (CPP) and significantly guide process development and characterization. In a commercial setting, these very same tools can enable real time monitoring of CPPs on the shop floor and inform harvest decisions, predict peak potency, and serve as surrogates for release potency assays. Here we introduce the development of four advanced PAT tools for upstream and downstream process monitoring in LVV manufacturing. The first tool explores the application of capacitance probes for real time monitoring of viable cell density in bioreactors. The second tool utilizes high content imaging to determine optimum time of infection in a microcarrier process. The third tool uses flow virometry (or nanoscale flow cytometry) to monitor total virus particle counts across upstream and downstream process steps and establishes a robust correlation to virus potency. The fourth and final tool explores the use of nucleic acid dye staining to discriminate between “good” and “damaged” virus particles and uses this strategy to also monitor virus aggregates generated sometimes during downstream processing. Collectively, these tools provide a comprehensive monitoring toolbox and represent a significantly enhanced control strategy for the manufacturing of LVVs. Abstract In the development of end-to-end large-scale live virus vaccine (LVV) manufacturing, process analytical technology (PAT) tools enable timely monitoring of critical process parameters (CPP) and significantly guide process development and characterization. In a commercial setting, these very same tools can enable real time monitoring of CPPs on the shop floor and inform harvest decisions, predict peak potency, and serve as surrogates for release potency assays. Here we introduce the development of four advanced PAT tools for upstream and downstream process monitoring in LVV manufacturing. The first tool explores the application of capacitance probes for real time monitoring of viable cell density in bioreactors. The second tool utilizes high content imaging to determine optimum time of infection in a microcarrier process. The third tool uses flow virometry (or nanoscale flow cytometry) to monitor total virus particle counts across upstream and downstream process steps and establishes a robust correlation to virus potency. The fourth and final tool explores the use of nucleic acid dye staining to discriminate between “good” and “damaged” virus particles and uses this strategy to also monitor virus aggregates generated sometimes during downstream processing. Collectively, these tools provide a comprehensive monitoring toolbox and represent a significantly enhanced control strategy for the manufacturing of LVVs. |
ArticleNumber | 15494 |
Author | Vlasak, Josef Salovich, Daniel Ryan Davide, Joseph Bhat, Aditya Sehlin, Darrell Califano, Joseph Mukherjee, Malini Ha, Sha Yi, Sijia McCracken, Reilly Whitmer, Travis Ploeger, Kristin |
Author_xml | – sequence: 1 givenname: Sijia surname: Yi fullname: Yi, Sijia organization: Vaccines Process Development and Commercialization, Merck & Co., Inc – sequence: 2 givenname: Reilly surname: McCracken fullname: McCracken, Reilly organization: Vaccines Process Development and Commercialization, Merck & Co., Inc – sequence: 3 givenname: Joseph surname: Davide fullname: Davide, Joseph organization: Vaccines Process Development and Commercialization, Merck & Co., Inc – sequence: 4 givenname: Daniel Ryan surname: Salovich fullname: Salovich, Daniel Ryan organization: Vaccines Process Development and Commercialization, Merck & Co., Inc – sequence: 5 givenname: Travis surname: Whitmer fullname: Whitmer, Travis organization: Vaccines Process Development and Commercialization, Merck & Co., Inc – sequence: 6 givenname: Aditya surname: Bhat fullname: Bhat, Aditya organization: Aber Instruments Inc – sequence: 7 givenname: Josef surname: Vlasak fullname: Vlasak, Josef organization: Vaccines Analytical Development, Merck & Co., Inc – sequence: 8 givenname: Sha surname: Ha fullname: Ha, Sha organization: Vaccines Process Development and Commercialization, Merck & Co., Inc – sequence: 9 givenname: Darrell surname: Sehlin fullname: Sehlin, Darrell organization: Vaccines Process Development and Commercialization, Merck & Co., Inc – sequence: 10 givenname: Joseph surname: Califano fullname: Califano, Joseph organization: Vaccines Process Development and Commercialization, Merck & Co., Inc – sequence: 11 givenname: Kristin surname: Ploeger fullname: Ploeger, Kristin organization: Vaccines Process Development and Commercialization, Merck & Co., Inc – sequence: 12 givenname: Malini surname: Mukherjee fullname: Mukherjee, Malini email: malini.mukherjee@merck.com organization: Vaccines Process Development and Commercialization, Merck & Co., Inc |
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CitedBy_id | crossref_primary_10_1021_acs_oprd_3c00081 crossref_primary_10_1016_j_jbiotec_2024_01_016 crossref_primary_10_1002_bit_28703 crossref_primary_10_1016_j_biotechadv_2024_108391 |
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Title | Development of process analytical tools for rapid monitoring of live virus vaccines in manufacturing |
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