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  • 7/27/2019 1. Recombinanttherapeuticprotein

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    DDTEC-212; No of Pages 6

    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

    http://dx.doi.org/10.1016/j.ddtec.2008.12.003mailto:[email protected]://dx.doi.org/10.1016/j.ddtec.2008.12.003http://dx.doi.org/10.1016/j.ddtec.2008.12.003mailto:[email protected]://dx.doi.org/10.1016/j.ddtec.2008.12.003
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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.

    Drug Discovery Today: Technologies | Protein Therapeutics Vol. xxx, No. xx 2009

    DDTEC-212; No of Pages 6

    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

    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).

    e2 www.drugdiscoverytoday.com

    http://dx.doi.org/10.1016/j.ddtec.2008.12.003http://dx.doi.org/10.1016/j.ddtec.2008.12.003
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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

    Vol. xxx, No. xx 2009 Drug Discovery Today: Technologies | Protein Therapeutics

    DDTEC-212; No of Pages 6

    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

    www.drugdiscoverytoday.com e3

    http://hugroup.cems.umn.edu/CHO/cho_index.htmlhttp://hugroup.cems.umn.edu/CHO/cho_index.htmlhttp://dx.doi.org/10.1016/j.ddtec.2008.12.003http://dx.doi.org/10.1016/j.ddtec.2008.12.003http://hugroup.cems.umn.edu/CHO/cho_index.htmlhttp://hugroup.cems.umn.edu/CHO/cho_index.html
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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

    Drug Discovery Today: Technologies | Protein Therapeutics Vol. xxx, No. xx 2009

    DDTEC-212; No of Pages 6

    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

    e4 www.drugdiscoverytoday.com

    http://dx.doi.org/10.1016/j.ddtec.2008.12.003http://dx.doi.org/10.1016/j.ddtec.2008.12.003
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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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    Drug Discovery Today: Technologies | Protein Therapeutics Vol. xxx, No. xx 2009

    DDTEC-212; No of Pages 6

    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

    e6 www.drugdiscoverytoday.com