Advancing membrane chromatography processes for the purification of therapeutic viruses

Abstract

Viruses have emerged as a new class of biotherapeutics used as vectors in gene and cell therapies, vaccines, and as oncolytic agents in novel cancer immunotherapies. While these new and potentially curative new therapies bring great promise for patients, the large-scale purification of viruses is hampered by complicated unit operations, poor overall yields, and high costs. Membrane chromatography (MC) is one of the most ideal options for the removal of host-cell impurities in virus manufacturing. Centred on developing and improving MC processes for virus purification, this thesis focuses on different aspects of downstream processes that are directly related to MC. It describes the development of the first hydrophobic interaction MC process for the purification of vesicular stomatitis virus as a scalable method for the removal of host-cell protein and DNA. It also describes the development of MC for adenovirus purification, and how device design and membrane type impact the resolution; here, the novel laterally-fed membrane chromatography (LFMC) was proven to provide higher resolution than conventional MC devices, and allowed for the first direct comparison between the most popularly used membranes in virus manufacturing – Sartobind Q and Mustang Q. Beyond MC, this thesis also addresses how other downstream unit operations contribute to the final purity. Through an integrated study optimizing clarification, DNA digestion, and MC simultaneously, significant improvement in adenovirus purity was obtained. Finally, the collection of experimental results was used to model complete adenovirus production processes using BioSolve Process and determine the cost-of-goods (COG) of manufacturing for clinical applications. Through simulations of multiple scenarios, critical process parameters were identified and can serve as a guide for future process development decisions. It is anticipated that the contributions herein described will help address critically outstanding questions related to virus purification and thus enable the development of the economical processes for various manufacturing scales.