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G. W. Hiller

4.6 Single-Use Bioreactors (SUBs)

Advancements in multilayer polymer lms and clever designs for structural support of the inatable bioreactor bags over the past decade have culminated with single­use or disposable bioreactors with volumes approaching 6000L [62]. SUBs elimi­nate the need for cleaning solutions, and cleaning and sterilization protocols and associated testing, saving considerable resources and changeover time. As many can attest, however, with the many pools of cell culture uid on the oor of the bioreac­tor suite, leaks are still quite common and signicant strides are required to improve the quality control of the manufacturing of single-use bioreactor inserts. Compared with their stainless-steel counterparts, SUBs also typically suffer with respect to their capability to handle highly intensied cell culture processes due to longer mix­ing times and reduced oxygen transfer capabilities due to substandard agitation and aeration equipment.
However, even with the mentioned shortcomings, the time and short-term cost to set up a facility for clinical production is greatly reduced using SUBs. If additional scale up is required, in the short run the “number up” methodology of scale up can be used, meaning just acquire additional SUBs of the same size. Since such bioreac­tors typically require little in the way of utilities, they can usually be placed in (merely rolled into) a simple “ballroom” type facility. Since the same scale and presumably the identical bioreactor design can be used, efforts to prove equivalent product quality with a change in scale are eliminated, and even concerns regarding process transfer to new manufacturing sites can also be reduced. While the efcien­cies of scale are certainly forfeited with such a strategy, the accelerated time to market and ease of regulatory concerns can make a single-use bioreactor facility very attractive, particularly for a small company with an independent mindset but little existing infrastructure.

4.7 Conclusions

Signicant advances in intensication of cell culture processes have occurred over the last decade. Higher productivity and a better understanding of the science of methods to manipulate product quality have been achieved. The versatility of bio­logical products to treat disease never before considered has led numerous biophar­maceutical companies recently to announce expansions of production bioreactor capacity in the hundreds of thousands of liters. If this much additional capacity is necessary, clearly there remains a need for signicant increases in efciency and productivity from upstream operations. Within this chapter, we’ve described multi­ple new technical innovations such as hybrid cell culture processes and a renewed interest in continuous perfusion processes, particularly with the potential to link directly to continuous or nearly continuous downstream recovery operations. New molecule modalities and elds such as cell and gene therapy, with minor modica­tions, can also benet from the innovations described in this chapter.
4 Advancements in the Manufacture of Monoclonal Antibodies and Other Large…
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Chapter 5
Process Development andManufacturing Considerations forMultispecic (Bispecic andTrispecic) Antibodies: Case Study
TimothyIskra, AshleySacramo, andJohnJ.Scarcelli
Abstract Antibodies as a therapeutic treatment have been the focus of numerous
companies for many years, resulting in over 100 currently on the market. This has led to the creation of a rich understanding of how to develop and manufacture these molecules. The result has been the creation of platforms consisting of high produc­tivity cell lines and optimized culture conditions that can generate titers as high as 10g/L.These platforms have also seen the introduction of streamlined downstream processes which typically consist of two to three chromatography steps.
In recent years, the bispecic and trispecic (or multispecic) antibodies have become a large area of development for most companies, as the ability to bind two different antigens at a time opens new and unique therapeutic areas. Although these are antibody-like, the complexity created due to the structurally diverse molecular formats and engineering adjustments presents a challenge to the current antibody development and manufacturing paradigm. New steps such as reactions to bring these molecules together as well as new impurities and stability issues have meant that these platforms have needed to be adjusted to enable production of suitable quantities of high-quality product.
Expression and production of multispecic antibodies have brought new challenges and considerations to cell line generation. Depending upon molecular
T. Iskra (*) Bioprocess Research and Development, Biotherapeutics Pharmaceutical Sciences, Pzer Inc., Andover, MA, USA e-mail: Timothy.iskra@pzer.com
A. Sacramo Pzer Inc., Andover, MA, USA
Solid Biosciences Inc., Charlestown, MA, USA e-mail: asacramo@solidbio.com
J. J. Scarcelli Pzer Inc., Andover, MA, USA
Sano, Framingham, MA, USA e-mail: Jack.Scarcelli@sano.com
K. Gadamasetti, S. A. Kolodziej (eds.), Bioprocessing, Bioengineering and Process Chemistry in the Biopharmaceutical Industry,
https://doi.org/10.1007/978-3-031-62007-2_5
105© The Author(s), under exclusive license to Springer Nature Switzerland AG 2024
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T. Iskra etal.
format, a strategy needs to be implemented encompassing choice of cell host organ­ism (microbial vs. mammalian), and in the case of mammalian expression, number of cell lines generated (single vs. dual cell lines), as well as random versus targeted integration of transgenes. These initial choices can have far reaching implications, often necessitating expanded cell line screening efforts when compared to tradi­tional monoclonals.
Once a suitable cell line is created, the production of multispecic molecules uses culture conditions similar to typical antibodies. Some adjustments are required however as the engineering of these molecules may result in a higher occurrence of clip species formation or presence of different molecule fragments or impurities. Attention has been paid to ways to reduce these impurities while increasing titers through culture growth conditions and setpoints.
After production there are several considerations that must be focused on to achieve a nal high-quality product. These complex molecules can be less stable than traditional antibodies and they tend to contain new and unique impurities that must be removed. Due to the engineering of the molecules, there can be issues with stability that may prevent traditional operations from being conducted such as low pH viral inactivation. This results in the need to design or nd additional means to achieve sufcient and robust viral safety. Also, most of the molecules have some level of homodimers present, and due to the similarity of these impurities to the heterodimer, the separation and removal can be difcult. This often results in either the addition of new steps or the use of less traditional steps being employed.
Keywords Multispecic antibodies · Bispecic antibodies · Trispecic antibodies
· Expression · Purication · Knob into hole · Charge-based multispecic

5.1 Introduction

Monoclonal antibodies (mAbs) have had a signicant impact over the last few decades in several therapeutic areas such as cancer, inammation, autoimmune, car­diovascular, and infectious diseases [1, 2]. There are now more than 100 approved mAb products marketed worldwide [3]. The focus on mAbs has created a rich understanding of how to develop and manufacture these molecules. The result has been the creation of mAb platform processes consisting of high productivity cell lines and optimized culture conditions that commonly generate titers as high as 10g/L.These mAb platforms have also seen the introduction of streamlined down­stream processes which typically consist of three or in some cases two chromatog­raphy steps [1] that have yields typically greater than 65% [4].
In recent years, improvements in molecular design have led to the creation of bispecic and trispecic (or multispecic) mAb-based modalities as new candidate therapeutics. The ability to simultaneously bind multiple antigens has opened up new and exciting therapeutic areas. Multispecic antibodies have the ability to tar­get specic cancer cells and coupled with the body’s own immune cells, can enable
5 Process Development and Manufacturing Considerations for Multispecic…
107
simultaneous mediators or pathways, or potentially increase binding specicity by interacting with two different antigens instead of only one [5]. As of 2021 there have been four bispecic molecules approved, with only three of them currently still on the market (amivantamab in the United States and European Union (EU); emici­zumab and blinatumomab in the USA, EU, and Japan, and catumaxomab approved originally in EU and USA and later withdrawn from the market), with many more in either clinical studies or early phase development.
Dozens of structurally diverse, multispecic molecular formats are currently available, which can lead to differences in properties such as valency, pharmacoki­netics, and mechanism of action [6, 7]. The decision to select a particular format can impact development and manufacturing. One example of this is the choice of host cell organism. If a particular molecular format does not require glycosylation or other complex post-translational processing, then a microbial host, such as Escherichia coli, having simple, scalable fermentations and shorter development timelines, may be the optimal choice. On the other hand, if glycosylation is central to the molecule’s mechanism of action (e.g., Fc-mediated effector function), then a mammalian cell host is required. This chapter will focus exclusively on immuno­globulin G (IgG)-like multispecics, which are most suitably expressed using mam­malian cell culture.
Multispecic antibody expression has brought new challenges and consider­ations to cell line generation. Molecular format can dictate the number of cell lines that require generation (single vs. dual cell lines), as well as transgene integration strategy, and clone screening approach. These initial choices can have far reaching implications, and often necessitate expanded cell line screening efforts when com­pared to traditional mAbs.
Once a suitable cell line is created, the production of multispecic molecules typically uses culture conditions traditionally employed for mAbs. Some adjust­ments are required as the engineering of these molecules may result in a higher occurrence of clipped species or the presence of different molecule fragments or product-related impurities. Development focus must be on ways to reduce these impurities, while at the same time increasing process yields through cell culture growth and downstream process optimization.
Beyond production of these molecules, there are several considerations to achieve a high-quality nal product. These complex molecules can be less stable than traditional mAbs and they tend to have an increased level of product-related impurities such as high molecular mass species (HMMS), residual homodimer, half antibodies, heavy chain-light chain mispairing, and/or fragments depending upon the molecular architecture [8, 9]. Some engineered multispecics may be less stable than traditional mAbs thus limiting the use of certain production technologies. One example is an increased sensitivity to low pH resulting in the need to nd alternative means to achieve an acceptable level of viral clearance. In addition, many of the techniques used to create these molecules result in low levels of product-related impurities, such as homodimers. Since homodimers are similar to the desired het­erodimer, separation of these impurities is often difcult. This may result in the addition of new and sometime less traditional downstream process steps.
108
HC pAiring problem

 
T. Iskra etal.
5.2 Strategies forMolecule andCell Engineering toProduce
IgG-Like Multispecics
5.2.1 Molecular Format Considerations
The multivalent nature of IgG-like multispecic molecules is facilitated by sequence differences in the fragment variable (Fv) domain between at least one of either the heavy chain (HC) or light chain (LC). Depending on the heterodimerization strat­egy, differences in the constant domains may exist as well. Once a decision is made to develop an IgG-like multispecic molecule, the challenges and constraints asso­ciated with development of a robust expression cell line and process must also be considered. As these molecules are often comprised of at least four distinct peptide chains (two LCs and two HCs), a strategy to ensure proper pairing of each chain within a given molecule becomes paramount. Without such a strategy, there exists the possibility of producing several different product-related impurities such as monovalent structures and other nonfunctional IgG-like structures, all resulting from mispairing between either a LC and HC (the LC pairing problem), or the two HCs (the HC pairing problem, see Fig.5.1) [10].
Catumaxomab is one of the rst examples of a multispecic molecule approved as a therapeutic, having afnity for both human CD3 and human EpCAM, and tar­gets T-cells to EpCAM-expressing tumor cells. Catumaxomab production
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ApproAch:
Knob into
hole /
common LC
ApproAch:
Knob into
Hole /
DomAin
swAp
ApproAch:
(Homodimers)
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LC pAiring problem
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


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Other product-relAted impuries
Desired heterodimer


Fig. 5.1 Possible product-related impurities encountered during generation of IgG-like multispe­cic molecules, and strategies to reduce/eliminate formation of product-related impurities. HC— heavy chain; LC—light chain; Redox—reduction/oxidation reaction; SCL—single cell line; LC-Fc—light chain fused to HC Fc domain; VH-CH1—peptide containing only the variable domain and rst constant region of HC
5 Process Development and Manufacturing Considerations for Multispecic…
109
overcomes chain pairing challenges by using isotype combinations from ortholo­gous species. The molecule is comprised of four total chains and two different LC/ HC pairs: one LC/HC pair of a mouse IgG2b isotype and the other being a rat IgG2a isotype [11]. The molecule is expressed in a single cell line, generated using quad­roma technology [11]. These cell lines are created via somatic hybridization of two hybridoma cell lines (a hybrid hybridoma), each expressing either the mouse IgG2b or the rat IgG2a. This strategy can accomplish high levels of correctly paired het­erodimer via (a) favorable LC-HC binding between homologous species chains, and (b) specic purication of properly heterodimerized Fab molecules [7]. Although this strategy results in properly paired chains, this format is highly immunogenic in humans and results in the development of antidrug antibodies in patients, which in theory limits its dosing [12].
Advances in both protein and cellular engineering have made alternative expres­sion and production strategies possible. First, the more commonly used Chinese Hamster Ovary (CHO) cell expression systems are suitable for the production of these molecules and provide distinct advantages over hybridoma lines [13]. CHO cells are well-known for the expression of large molecule biotherapeutics due to their ability to correctly assemble, fold, and properly modify recombinant proteins. CHO cells are also capable of rapid growth and reaching high cell densities to facili­tate high recombinant protein yield and have been adapted to suspension growth in serum-free, chemically dened media. Despite this, methods used to produce IgG­like multispecics must still overcome pairing problems with both the HCs and LCs. Here, we examine two common approaches employed to overcome both chal­lenges—the charge-based electrostatic approach, and the steric-based knob into hole (KiH) approach (Fig. 5.1), and cell line generation considerations for each strategy.
5.2.1.1 The Charge-Based Electrostatic Approach
Under certain conditions, HC disulde bonds of IgG4 molecules reduce and subse­quently reform new interchain disulde bonds both invivo and invitro, resulting in multispecic molecules [14]. This observation is unique to the IgG4 isotype and is facilitated by specic residues within the hinge and CH3 regions. Mutation of cor­responding residues in IgG1 and IgG2 molecules renders them competent for exchange as well. Further mutation of these residues to have opposing charges on each HC (glutamic acid for the negatively charged HC, arginine for the positively charged HC) favors formation of a stable heterodimeric molecule when the differ­ently charged HCs are mixed and mildly reduced [15].
Production of these molecules is facilitated by a two-cell line approach, in which each cell line produces a different parental homodimer possessing unique variable domains and opposing charges engineered into the HCs (either glutamic acid or arginine residues). After separate upstream manufacturing processes, puri­ed homodimers are mixed together under appropriate reduction and oxidation (redox) conditions to create the heterodimeric molecule. An example of such a