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Please cite this article in press as: M.. Matasci, et al., Recombinant therapeutic protein production in cultivated mammalian cells: current status and future prospects, Drug
Discov Today: Technol (2009), doi:10.1016/j.ddtec.2008.12.003
ECHNOLOGIES
DRUG DISCOVERY
TODAY
Recombinant therapeutic proteinproduction in cultivated mammaliancells: current status and future
prospectsMattia Matasci, David L. Hacker, Lucia Baldi, Florian M. Wurm*Institute of Bioengineering, Laboratory of Cellular Biotechnology, E cole Polytechnique Federale de Lausanne (EPFL), CH-1015 Lausanne, Switzerland
Recombinant therapeutic proteins produced in mam-
malian cells represent a major class of biopharmaceu-
ticals. In recent years, their demand has increased
dramatically and is now driving the development of a
variety of improvements to maximize their expression
in mammalian cells. Advances in media- and process
optimization have already resulted in more than 100-
fold improvement in yield, but further insights and
subsequent targeted modifications with respect to
the general biology of cells (genomics, physiology,
selection and adaptation) in bioreactors are hoped to
further improve protein yields and quality in the near
future.
Section Editors:Marco van de Weert, Eva Horn Moller
Introduction
Over the past two decades recombinant proteins have gained
increasing importance for therapeutic applications, and the
number of proteins either approved or launched into clinical
trials has continually increased over this period. Together
their annual global market is now valued to be more than $50
billion with an annual sales increase of about 20%. Currently
about 60% of all recombinant therapeutic proteins are pro-
duced in mammalian cells, mainly because of the ability of
mammalian hosts to generate high-quality proteins that are
similar in their biochemical properties to the naturally occur-
ring human forms. This growing demand for high-quality
recombinant therapeutics is driving the research and devel-opment of mammalian-cell-based manufacturing systems for
enhanced production yields. In this review we will present
relevant strategies developed to enhance the generation of
high producer cell lines and discuss how newtechnology may
contribute to the further development of cellular processes
for the production of therapeutic proteins.
Current strategy for recombinant cell line
development
The generation of recombinant cell lines follows a well-
defined multistep scheme that begins with the molecularcloning of the gene of interest (GOI) in a mammalian expres-
sion vector (Fig. 1). The GOI is then delivered into cells along
with a selection gene which may be cloned in the same or
different expression vector. Following DNA transfer, cells are
subjected to selective conditions to recover those that have
stably integrated the exogenous genes into a chromosome.
Well-established selection strategies rely upon complementa-
tion of a host auxotrophy. In Chinese hamster ovary (CHO)
cells, the major mammalian host for protein production, the
two most commonly used selection systems are based on the
Drug Discovery Today: Technologies Vol. xxx, No. xx 2009
Editors-in-Chief
Kelvin Lam Pfizer, Inc., USA
Henk Timmerman Vrije Universiteit, The Netherlands
Protein Therapeutics
*Corresponding author: F.M. Wurm ([email protected])
1740-6749/$ 2009 Elsevier Ltd. All rights reserved. DOI: 10.1016/j.ddtec.2008.12.003 e1
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dihydrofolate reductase (dhfr) and the glutamine synthetase
(gs) genes. Selection is achieved by the introduction into cells
of the GOI along with a copy of the gene that complements
the auxotrophy. Cells are then cultivated in medium lacking
the appropriate metabolite(s) (hypoxanthine and thymidine
in the case of DHFR selection and glutamine in the case of GS
selection) so that only transformed clones survive. A com-
mon alternative to the auxotrophic selection method is the
use of genes conferring resistance to antibiotics such as
geneticin (G418), hygromycin B, zeocin, blasticidin or pur-
omycin. With this strategy, transfected cells are selected
using medium containing the appropriate antibiotic. How-
ever, a major advantage of both the DHFR and GS selection
systems is that they allow for amplification of the integrated
recombinant genes. DNA amplification, which normally
results in enhanced productivity, is achieved by exposing
selected cells to increasing concentrations of an inhibitor of
the selection protein. Methotrexate (MTX) and methionine
sulphoximide (MSX) are inhibitors of DHFR and GS, respec-
tively. To survive, cells must produce a high level of the
selection protein. This may be achieved by gene amplifica-
tions of the integrated selection gene. This also results in an
increased copy number of the GOI because it is located at the
same integration site as the selection gene.
Thepool of cells recovered after selectionis highly hetero-
geneous in terms of specific protein productivity and cell
growth. This necessitates the isolation and evaluation of
several hundreds of individual cells to recover a few candi-
date production cell lines that possess the desired character-
istics. This is usually accomplished by one or more rounds of
limitingdilution in which the selected cells aretransferredtomultiwell plates so that on average only one cell is present
per well. Each clonal cell population derived from this pro-
cedure is evaluated for the level of recombinant protein
expression and the highest producers are further studied
for the stability of recombinant protein production because
a decrease in transgene expression over time is commonly
observed in the majority of clonal cell lines. Thus candidate
production lines must be cultivated and monitored for sev-
eral months to ensure a constant level of protein expression
over time [1].
Whereas the described procedure for the generation of
recombinant cell lines is a well-established process, it remainsquite tedious and time-consuming. In an industrial setting,
the whole process usually takes more than six months. This is
particularly inconvenient especially when multiple candi-
date therapeutics need to be produced in high amounts to
be evaluated for efficacy and safety in preclinical studies or
clinical trials.
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Figure 1. Schematic representation of the development of stablecell lines for the production of therapeutic recombinant proteins. Steps
that can be improved by the use of new technologies are shown on the
right. -Omic technologies can contribute to several aspects of the
process including engineering of the parental cell line, identification of
markers for screening, development of the manufacturing process and
media design. Vials represent banks of cells stored in liquid nitrogen.
Spinner flasks indicate scale-down systems for cell line evaluation and
process optimization, and bioreactors represent large-scale production
processes. Abbreviations: methotrexate (MTX), methionine
sulphoximide (MSX).
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Optimization of mammalian expression vectors
The choice of the appropriate expression vector is a crucial
factor to achieve very high and stable expression of recom-
binant proteins in mammalian cells, and nonviral expression
vectors are usually used for the generation of recombinant
cell lines. Strong promoter/enhancer sequences of viral or
cellular origin are typically used to drive expression of the
GOI, which is typically cloned as a cDNA-lacking intron
sequences. However, because the splicing process is known
to promote mRNA nuclear export and stability [2], most
expression plasmids include an intron between the promoter
and the 50-end of the cloned cDNA. Strong transcription
termination sequences added near the 30-end of the cDNA
ensure proper transcript termination. Additional optimiza-
tion of the transgene coding sequence by changing under-
represented codons, removing cryptic splice sites and increas-
ing the overall G + C content may help to improve levels of
recombinant protein expression [3].
The integration site in the host genome has a major effect
on both the level of transgene expression and the progressive
decrease in transcription over time. These two phenomena,
knownas position effect andgene silencing, arethought to be
associated with epigenetic factors resulting in the condensa-
tion and transcriptional inactivation of the chromatin at the
site of integration. Flanking of transgenes with DNA bound-
ary sequences able to block the formation of condensed
chromatin (heterochromatin) may help to obtain stable
transgene expression irrespective of the chromosomal inte-
gration site. These barrier elements include scaffold or matrix
attachment regions (S/MARs), insulators, antirepressor ele-
ments and ubiquitous chromatin opening elements (UCOEs)[4,5].
Cell culture format and media
The pharmaceutical manufacture of recombinant proteins
most frequently employs single-cell suspension cultures in
stirred-tank bioreactors of variable sizes up to 20,000 l [1,6,7].
The cells are typically maintained in media that areoptimized
for suspension growth at high cell density preferentially in
the absence of serum and other animal-derived components.
Cells may be cultivated during the entire protein production
phase without the addition of nutrient additives (batch cul-
ture). Alternatively, nutriments may be periodically added tothe culture to prolong cell viability and protein production
(extended- or fed-batch culture). In some cases, reduction of
the temperature to 30338C, increased osmolarity, or addi-
tion of histone deacetylase inhibitors such as sodium buty-
rate or valproic acid enhance protein productivity in both
batch and fed-batch processes.
Continuous perfusion is another type of process with
suspension cultures, useful for certain products that have a
high sensitivity toward degradative impacts from cell released
proteases or other physico-chemical influences. Perfused cells
are retained in a stirred-tank bioreactor while the culture
medium is exchanged several times each day by the addition
of many bioreactor volumes of fresh medium with the simul-
taneous removal of the same volume of spent medium from
the vessel. The possibility to maintain the perfused cultures
for several weeks or months at high cell densities is a major
advantage of this technology. Additionally the continuous
medium exchange allows the simultaneous recombinant
product harvest and the removal of toxic by-products.
Processes for the production of recombinant proteins from
cells attached to a surface rather than in suspension are also
used in industry [1,7,8]. However, adherent cell culture pro-
cesses are more demanding at large scales owing to the high
surface to volume ratio needed to maximize cell densities.
With roller bottles cells are grown attached to the inner wall
of the vessels filled with medium to 1030% of their nominal
volume while a slow rotation assures the regular wetting and
proper oxygenation of the cells. To increase the cell growth
surface area, adherent cells can also be grown attached to
polymer spheres (microcarriers). Microcarriers seeded with
cells are then maintained in suspension in conventional
stirred-tank bioreactors.
Future prospects for mammalian cell processes
Genomics and proteomics
Genome-scale technologies including genomics, transcrip-
tomics and proteomics are expected to contribute to the
development of mammalian cell-based production systems
[9,10]. Although high-throughput genomic and proteomic
tools are readily available for human- and mouse-derived
production hosts (such as NSO or HEK-293), the lack ofgenome sequence information for the major host (CHO cells)
has hindered the application of these technologies in the
recombinant protein production field. Early transcriptome
studies of CHO cells using DNA microarrays containing
mouse sequences have provided limited results because of
a relevant divergence between the genetic sequences of these
two rodent species. In 2006 the Consortium on CHO cell
genomics was founded with the aim of accelerating the
development of genomic resources for this host (http://
hugroup.cems.umn.edu/CHO/cho_index.html). To date this
cooperation between partners from industry and academia
has made possible the sequencing of more than 80,000expressed sequence tags (ESTs)of CHOorigin. This EST library
that includes more than 27,000 unique sequences have been
used to create tools for the transcriptome analysis of CHO
cells [11].
With further development these tools may aid in under-
standing the overall cellular physiology of this host and its
derived recombinant cell lines, eventually allowing the iden-
tification of features predictive of the level and stability of
transgene expression at production scale [12]. Such predictive
markers will be very useful in the early identification of high
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producing clonal cell lines. For example, several genes related
to cell growth, chromatin modification and protein proces-
sing and secretion have been shown to be differentially
expressed in cell lines producing high levels of recombinant
proteins [13,14]. Other -omic studies have compared host cell
responses associated with changes in culture conditions that
enhance productivity such as hypothermia, hyperosmosis
and exposure to butyric acid. Results from these and similar
studies may help in predicting how a cell line will respond to
changes in environmental conditions relevant to the bior-
eactor and thus be valuable for the optimization of process
conditions and media design [10,15]. In general it is expected
that -omic approaches will provide new insights into the
general physiology of cells that are crucial for protein pro-
duction in mammalian cells thus enhancing cell engineering
efforts to genetically redirect the cells metabolism toward
superior productivity and growth.
Host cell engineering
Many efforts have been made to genetically modify mamma-
lian cells for the purpose of improving recombinant protein
yield and quality. Host cell engineering strategies have
mainly focused on (i) control of cell proliferation; (ii)
enhancement of cellular viability; (iii) reduction of inhibitory
metabolic by-products (i.e. lactate and ammonia); (iv)
increase of protein secretion capacity; and (v) modulation
of post-translational protein modifications (i.e. glycosyla-
tion) [16,17]. Strategies to genetically modify mammalian
cells mainly rely on the overexpression of exogenous effector
genes and the downregulation or elimination of endogenous
genes. Downregulation of host gene expression is usuallyachieved by RNA interference (RNAi) or antisense RNA tech-
nology.
One of the main targets of host engineering has been the
apoptotic pathway. Overexpression of antiapoptotic proteins
such as Bcl-2 or Bcl-xL or the targeted inhibition of caspases, a
family of apoptosis-promoting proteins, has proved to be
effective in maintaining cell viability at high density [18].
Enhancement of the cellular capacity for protein secretion
through engineering of the protein folding machinery in the
endoplasmic reticulum has also been explored. However, the
overexpression of single chaperones or chaperon-like pro-
teins such as binding immunoglobulin protein (BiP) or pro-tein disulfide isomerase (PDI) has yielded mixed results [19].
Recently the overexpression of the X-box binding protein-1
(Xbp-1), a transcription factor which regulates the expression
of multiple genes involved in the unfolded protein response
(UPR), has been shown to enhance recombinant protein
production in CHO cells [20]. Strategies to reduce the amount
of lactate production during cultivation of CHO cells include
the knockdown of lactate dehydrogenase subunit A (LDH-A)
mRNA by antisense and RNAi approaches or the overexpres-
sion of the pyruvate carboxylase enzyme [21,22]. Similarly,
reduced accumulation of ammonium ions has been achieved
by the overexpression of the urea cycle enzymes carbamoyl
phosphate synthase I and ornithine transcarboxylase [23].
Variations in the glycan content of glycoproteins can signif-
icantly affect the stability, activity, immunogenicity and
pharmacokinetics of recombinant therapeutic proteins. In
this regard, engineering of the glycosylation pathways in
mammalian cells with the final aim to generate proteins with
a more humanized glycosylation profile and/or to enhance
the biological activity of therapeutic proteins has met with
some success [24].
High-throughput recombinant cell line selection methods
The traditional gene transfer, selection and amplification
methods used for the generation of stable cell lines are not
readily scalable to allow screening of more than a few
hundred cell lines. Therefore, current research focuses on
the development of high-throughput technologies with
increased screening capacities [25,26]. Particularly promising
are methods based on flow cytometry and cell sorting tech-
nologies. One elegant screening strategy employs the
cotransfection of cells with the GOI and a gene coding for
the green fluorescent protein (GFP). If the two genes are
genetically linked, a linear correlation between fluorescence
intensity and expression of the GOI is usually seen. Single
clones with high level of GFP expression are then recovered
by fluorescence-activated cell sorting (FACS) [27]. Coexpres-
sion of a nonfluorescent cell surface protein that can be
labeled with a fluorescent antibody before screening by FACS
is an alternative strategy [28]. Strategies to directly measure
the level of the recombinant protein rather than a reporterprotein are expected to be even more effective in the screen-
ing of high producing cell lines. However, because most of
the recombinant proteins produced in mammalian cells are
secreted, techniques to keep the recombinant protein in the
vicinity of the producing cell are required. This can be
accomplished by embedding individual recombinant cells
in a gel or semisolid matrix to limit the diffusion of the
secreted product and allow its detection using standard
immunohistochemical methods [29]. Automation of these
new screening methods will definitely reduce the time
needed to generate recombinant cell lines and increase the
probability of recovering high producing clones.
Transient gene expression
Transient gene expression (TGE) is a relatively new technol-
ogy that is being considered for the production of recombi-
nant proteins at large scale [30]. A key advantage of this
technology is thespeed by which significant amounts (grams)
of recombinant protein can be produced. Thus large-scale
TGE has attracted interest for the rapid production of recom-
binant proteins for basic research and preclinical studies.
Usually, the protein production phase for TGE lasts up to
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14 days following transfection, avoiding the time-consuming
process of generating stable clonal cell lines. The recombi-
nant gene is usually cloned in a nonviral expression vector
and transfected into single-cell suspension cultures by means
of a chemical delivery agent such as polyethylenimine (PEI).
To date, the largest volumetric scale for TGE has been about
100 l [31]. TGE has been performed in stirred-tank bioreac-
tors, orbitally shaken containers and wave-type bioreactors.
Whereas several host cell lines have been used for TGE, CHO
and HEK-293 cells are preferred owing to their high transfect-
ability and the ability of these cells to support high-density
growth in suspension [32,33]. Recently, volumetric yields of
recombinant protein comparable to those obtained for opti-
mized processes with stable lines have been achieved, under-
lining the potential of TGE as an economic alternative for the
manufacture of low-dose therapeutic proteins at moderate
volumetric scales [34].
Conclusions
Despite recent progress, recombinant protein expression
technology using mammalian cells is still in its infancy.
Much remains to be done to enhance the productivity of
production processes. In highly optimized fed-batch manu-
facturing processes yields of several grams of per liter of
secreted protein are frequently attained today for antibody
products and some other well-behaved proteins, a 10100-
fold increase compared to the yields that were obtained two
decades ago. This increase in volumetric productivity has
been primarily achieved through optimization of the manu-
facturing process by improvements in media composition,nutrient feeding strategies, cell line development and cell
screening strategies. However, even with these impressive
improvements in yield, opportunities still exist to further
enhance production levels. Yields of 1020 g/l in fed-batch
processes are expected to be reached in the near future. This
may be primarily achieved by an increase in viable cell
densities and duration of the culture process through opti-
mization of the culture conditions. The cell concentrations
for batch and extended-batch processes typically peak at
about 10 million cells/ml, meaning the cell biomass only
occupies about 34% of the volume of the culture. By contrast
microbial cultures may reach a biomass of 2030% of theculture volume.
The current strategies for the development of cell lines for
the recombinant expression of therapeutic proteins remain
empirical to a large extent. This is mainly due the lack of
consistent methods to predict production capacity and
growth characteristics of clonal cell lines at production scale.
In this regard the knowledge gained from -omic studies is
expected to provide a much better understanding of the
biochemistry and physiology of mammalian cells so that
higher product yields and quality may be achieved through
genetic engineering of the host or by a more rationale opti-
mization of the culture conditions.
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