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VACCINE MANUFACTURE

VACCINE MANUFACTURE. PROCESS OUTLOOK. The vast majority of the over one billion doses of vaccines manufactured today are given to healthy individuals The ability to manufacture these vaccines safely and consistently is built on 4 competencies

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VACCINE MANUFACTURE

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  1. VACCINE MANUFACTURE

  2. PROCESS OUTLOOK • The vast majority of the over one billion doses of vaccines manufactured today are given to healthy individuals • The ability to manufacture these vaccines safely and consistently is built on 4 competencies • The manufacturing process that defines how the product is made • The compliance of the organization to successfully complete that process • The testing of that product and supporting operations • The regulatory authorization to release and distribute that product

  3. REGULATORY PROCESS • New vaccines are subjected to a well defined regulatory process for approval • The approval process consists of 4 principal elements • Preparation of pre clinical materials for proof of concept testing in animal models, manufacture of clinical materials according to current good manufacturing practices (cGMP) and toxicology analysis in an appropriate animal system • Submission of investigational new drug application (IND) for submission to FDA for review • Testing for safety and effectiveness through clinical and further non clinical studies • Submission of all data to FDA in the form of a biologics license application (BLA) for final review and licensure

  4. VACCINE PREPARATION BASICS • Conventionally two classes of microbes are targeted for vaccine production: Bacteria and Viruses. • Bacterial vaccines are comparatively easy to prepare, extract and formulate in comparison to viral vaccines.

  5. BACTERIAL VACCINE PRODUCTION

  6. VIRAL VACCINE PRODUCTION • The manufacture of vaccines is composed of several basic steps that result in the finished product • The first step is the generation of the antigen used to induce an immune response. This may be in the form of a pathogenitself ( for subsequent inactivation or isolation of a subunit) or generation of a recombinant protein derived from that pathogen. • Viruses are grown on cells, either primary cells as chicken fibroblasts (influenza) or on continuous cell lines such as MRC 5 (Hep A). • Recombinant proteins can be manufactured in bacteria, yeast or cell culture • The viral and bacterial seed culture as well as the cell lines for viral production are carefully controlled, stored, characterized and often protected • The final vaccine is a direct function of its starting materials and a change in this seed can be as complicated as initiating a new product development altogether

  7. The next step is to release the antigen from its substrate and isolate it from the bulk of environment used in its growth • This can be isolation of virus from cells, secreted protein from cells or cells containing the antigen from the spent medium • Next step is the purification of the antigen • for vaccines that are composed of recombinant proteins this may involve many unit operations of column chromatography and ultrafiltration • For an inactivated viral vaccine there may simply be inactivation of isolated virus with no further purification. Theformulation of the vaccine is designed to maximize the stability of the vaccine while delivering it in a format that allows efficient distribution and clinical delivery of the product. • Adjuvant, stabilizer, buffer, preservative, lyophlization etc.

  8. PRODUCTION PROCESS

  9. BIOREACTORS

  10. INFLUENZA VACCINE Inactivated Virus (influenza) • Influenza virus vaccine for intramuscular use is a sterile suspension prepared from influenza viruses propagated in chicken embryos • This vaccine is the primary method for preventing influenza and its more severe complications • The vaccine contains 2 strains of influenza A viruses (H1N1 and H3N2) and a single influenza B virus • This trivalent vaccine is the predominant influenza vaccine used today • Vaccine is produced from viral strains that are identified early each year by WHO, CDC and CBER

  11. The substrate used by manufacturers is usually 11 day old embryonated chicken egg • A monovalent virus suspension is passed in eggs • Eggs are incubated at specific temperature for a specific time period under controlled relative humidity and then harvested • The harvested allantoic fluid that contains the live virus are tested for virus infectivity, titer, specificity and sterility • These fluids are then stored wet frozen at extremely low temperatures to maintain stability of the monovalent seed virus (MSV) The allantoic fluid is then harvested and purified by high speed centrifugation on a sucrose gradient or by chromatography • Purified virus is the split using a detergent prior to final filtration • The virus is inactivated using formaldehyde • This process is repeated for the 3 strains of viruses and the individually tested and released inactivated viral components are combined and diluted to final vaccine strength

  12. RECOMBINANT PROTEIN (HEPATITIS B) • July 1986, a recombinant HB vaccine was licensed in the US • It was built on the knowledge that heat inactivated serum containing HBV or HBsAg was not infectious but rather immunogenic and partially protective against subsequent exposure to the virus • To produce this vaccine the HBsAg or the S gene was inserted into an expression vector that was directly capable of synthesizing large quantities of HBsAg in yeast e.g Saccharomyces • The recombinant saccharomyces cells expressing HBsAg are grown in stirred tank fermentors

  13. The medium used in this process is a complex fermentation medium that consists of yeast extract, soy peptone, dextrose, amino acids and mineral salts • In-process testing is conducted on the fermentation product to determine the percentage of host cells with the expression construct • The HBsAg is then harvested by lysing the yeast cells • Separated by hydrophobic interactions and size exclusion chromatography • The resulting HBsAg is assembled into 22nm diameter lipoproteins • Purified to 99% by physical and chemical methods • Purified product is treated in phosphate buffer with formaldehyde, sterile filtered and then co precipitated with ALUM to form bulk vaccine

  14. The vaccine contains no detectable yeast DNA but may contain not more than 1% yeast protein • Vaccines against Hep B prepared from recombinant yeast cultures are noninfectious and are free of association with human blood or blood products • Each lot of the vaccine is tested for safety in mice and guinea pigs and for sterility • This vaccine is supplied in 4 formulations • Pediatric • Adolescent/high risk infant • Adult and • Dialysis

  15. LIVE ATTENUATED VACCINE (MEASLES) • The measles virus isolated in 1954 is characterized as Morbillivirusparamyxoviridae • Current vaccines use Edmonston, Moraten and Schwartz strains • Are on market since 1970s • The final vaccine is a live attenuated viral vaccine inducing immunity in more than 90% of the recipients • Manufacture starts with specific pathogen free (SPF) embryonated chicken eggs that are incubated for several days

  16. The embryos are collected and treated with trypsin to prepare the chicken embryo fibroblasts (CEF) for cell culture • All operations are performed under highly aseptic conditions • Cell culture is grown in roller bottles using fetal calf sera and M199 Hanks media for optimal cell growth • The CEF cells are further infected by viral working seed and incubated several days for viral cultures • At the end the cells are disrupted by mechanical lysis to release the virus • It is purified by centrifugation and filtration and stored frozen • After QC tests the vaccine is formulated alone or with mumps and rubella vaccines and lypholized to obtain stable product

  17. Product Development and cGMP Considerations • Vaccine development involves the process of taking a new antigen or immunogen identified in the research process and developing this substance into a final vaccine that can be evaluated through pre clinical and clinical studies to determine the safety and efficacy of the resultant vaccine • During this process the product’s components, in process materials, final product specifications and manufacturing process are defined

  18. Clinical trials are usually performed in 3 phases • Phase I • Phase II • Phase III Phase I • Clinical materials produced for phase I clinical trials are used to demonstrate candidate product safety in a relatively small number of healthy human patients (tens of volunteers) and to verify the ability to manufacture the product duplicating the theoretical process employed to manufacture pre clinical materials used in animal toxicology studies

  19. The application of appropriate written controls, accurate and consistent data recording, and controlled equipment in the preparation and testing of even early stage candidate vaccine material is critical to ensuring the desired outcome and to set the foundation for subsequent development of the potential candidate vaccine Phase II • Phase II clinical trials are intended to demonstrate safety and dose response in a larger target population than would be expected to receive the vaccine (hundreds of volunteers)

  20. Manufacture of phase II clinical trial materials are used to develop initial consistency of product manufacture incorporating modifications and improvements based on the phase I production and testing experience • Control points for monitoring and evaluation of equipment and materials to ensure applicability of GMP is considered at this stage Phase III • These are intended to demonstrate safety and efficacy in a statistically significant target population (tens of thousands of volunteers) and to demonstrate the ability to consistently manufacture materials meeting pre described quality attributes

  21. Modifications and improvements based on the phase I and phase II production and testing experiences are incorporated into the manufacturing process and specifications for process and control points are defined • All processes and systems necessary for the manufacture and testing of late stage clinical materials should be validated according to cGMP, essentially mimicking those requirements applied to approved products

  22. Analytical Testing • The analytical testing of vaccines provides evidence that the vaccine and any of its intermediates meets the specifications defined in the BLA • In the mid 1990s the concept of a well characterized biologic was developed which was defined as a chemical entity whose identity, purity, impurities, potency and quantity can be determined and controlled through both analytical testing and control of the manufacturing process • The advantage of a well characterized products is that the quantifiable analytical measurements can relate molecule structure to function

  23. Identity testing of biologicals include a wide variety of tests designed to be specific to the moiety based on unique characteristics of its molecular structure or other properties • Current methodologies are • Chromatography GC and HPLC • Electrophoresis PAGE, IEF • Immunological immunodifussion, dot blot, western blot, ELISA, RIA • Amino acid analysis • Peptide mapping • Enzyme activity • N or C terminal sequencing (bioidentity)

  24. Purity tests are developed to identify the potential process or product related impurities that may be traced to the process, equipment or inherent product impurities These tests may include • Chromatography • Electrophoresis • Mass spectrometry • NMR • Loss on drying • Water determination

  25. Antigenicityprovides a quantitative measure of antigen present by measuring antigen : antibody interaction • Antigen assays fall into 4 groups • RIA • EIA • Non labeled immuno assay • Biosensor analysis Potency tests are used to ensure that the vaccine produces the desired immunologic effect per specification • Most potency tests fall into one of the 4 categories

  26. Traditional animal based assays that measure biological response in an animal model • Cell culture based assays that measure the biochemical and physiological response at the cellular level • Biological activity or response induced by immunologic interactions • Ligand or receptor binding assays Physical and chemical tests are performed on final formulations and dosage forms to characterize the material • These tests include pH, quantitation of preservatives, adjuvants, uniformity, particulate matter, loss on drying, residual moisture and dissolution for lypholized final dosage forms

  27. Industry’s Response to New Challenges Currently licensed vaccines are manufactured as • live attenuated • Inactivated • Purified subunits • Conjugate or recombinant vaccines • For conjugate vaccines, many components must be manufactured separately, conjugated, purified and then formulated into a single vaccine

  28. Cell Culture Derived Flu Vaccine • Current vaccine in embryonated chicken eggs • A variety of cell lines are currently under development for flu vaccine development • MRC-5 • Vero • PER.C6 • Elimination of risk of an avian influenza virus infecting the flocks used for egg production • To date, cell culture based influenza vaccines have not been licensed • There is no reduction in production cycle time for both types of vaccines

  29. Plasmid DNA Vaccines • Also known as GENETIC VACCINATION • Protein antigen is delivered as DNA sequence which is taken up by the host and expressed in vivo • Done in E.coli • Involves chromatographic and precipitation techniques • In order to remove host DNA, RNA, proteins and endotoxins

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