METHOD FOR PRODUCING AN IMMUNOCONJUGATE

Abstract

Herein is reported a method for producing an immunoconjugate with reduced product- and process-related impurities by culturing mammalian cells that contain one or more nucleic acids encoding the immunoconjugate of interest in a cell culture medium, wherein the one or more nucleic acids are expressed under the conditions of cell culture comprising the steps of: culturing the mammalian cells in a cell culture medium at a first temperature and at a first pH; reducing the first temperature of the cell culture medium to a second temperature; and increasing the first pH of the cell culture medium to a second pH; recovering the immunoconjugate from the cells or the cell culture medium,
and thereby producing the immunoconjugate.

Claims

1. A method for producing an immunoconjugate with reduced product- and process-related impurities by culturing mammalian cells that contain one or more nucleic acids encoding the immunoconjugate of interest in a cell culture medium, wherein the one or more nucleic acids are expressed under the conditions of cell culture comprising the steps of: culturing the mammalian cells in a cell culture medium at a first temperature and at a first pH; reducing the first temperature of the cell culture medium to a second temperature; and increasing the first pH of the cell culture medium to a second pH; recovering the immunoconjugate from the cells or the cell culture medium, and thereby producing the immunoconjugate.

2. The method according to claim 1, wherein the method further comprises purifying the immunoconjugate with one or more purification steps.

3. The method according to claim 1, wherein the reduction to the second temperature and the increase to a second pH is after 2 to 9 days of a total cultivation time of 13 to 14 days.

4. The method according to claim 1, wherein both the reduction to the second temperature and the increase to the second pH is at about the same time.

5. The method according to claim 1, wherein the first temperature is 37 C.+/0.5 C. and the second temperature is in the range of 28 C. to 34 C.

6. The method according to claim 1, wherein the first temperature is 37 C.+/0.5 C. and is reduced to the second temperature of 29 C.+/0.5 C.

7. The method according to claim 1, wherein the second pH is 7.25 or higher.

8. The method according to claim 1, wherein the first pH is pH 7+/0.05 pH units and the first pH is increased by 0.25 to 0.4 pH units to the second pH.

9. The method according to claim 1, wherein the inoculation cell density is from about 600000 (610.sup.5) to about 1000000 (110.sup.6) cells/ml.

10. The method according to claim 1, wherein the osmolality of the cell culture medium is from 350 mOsmol/kg+/15 mOsmol/kg to 800 mOsmol/kg+/15 mOsmol/kg.

11. The method according to claim 1, wherein the immunoconjugate is a CEA-targeted IL-2 immunoconjugate, a FAP-targeted IL-2 immunoconjugate or an IgG-IL-2 immunoconjugate or a FAP-targeted 4-1-BBL immunoconjugate.

12. The method according to claim 1, wherein the cell culture is a fed-batch cell culture.

13. The method according to claim 1, wherein the mammalian cell is a CHO cell.

14. A composition comprising an immunoconjugate and a reduced level of fragments, aggregates and host cell proteins obtainable by the method according to claim 1.

15. The composition of claim 14, wherein the immunoconjugate is a CEA-targeted IL-2 immunoconjugate, a FAP-targeted IL-2 immunoconjugate or an IgG-IL-2 immunoconjugate or a FAP-targeted 4-1-BBL immunoconjugate.

Description

DESCRIPTION OF THE FIGURES

[0190] FIG. 1 Different process variants tested. The different key parameters for inoculation cell density, pH shift, temperature shift, and process length are shown for process 1 (reference/standard process), process 2 and process 3.

[0191] FIG. 2 Process variants 2 and 3 reduce supernatant Clusterin concentration at harvest for a clone expressing cM1. Cell-free samples of three fed-batch processes lasting 13 (Process 2) and 14 days (Process 3) in 2 L glass bioreactors using a recombinant CHO cell line expressing a complex cytokine-IgG fusion protein (cM1=CEA-IL-2 immunoconjugate) were analyzed for (A) Clusterin, (B) net titer, and (C) the ratio of Clusterin per net titer. Whiskers represent respective standard deviation (n=3)

[0192] FIG. 3a Process variants 2 and 3 reduce supernatant Clusterin concentration at harvest for two clones expressing cM2. Cell-free samples of a fed-batch processes lasting 13 (Process 2) and 14 days (Process 3) in 2 L glass bioreactors using two recombinant CHO cell lines (Clone 1 and Clone 2) expressing a complex cytokine-IgG fusion protein (cM2=IgG-IL-2 immunoconjugate) were analyzed for (A) Clusterin, (B) titer, and (C) the ratio of Clusterin per titer.

[0193] FIG. 3b Process variants 2 and 3 reduce supernatant CHO host cell protein (HCP) concentration at harvest for two clones expressing cM2. Cell-free samples of a fed-batch processes lasting 13 (Process 2) and 14 days (Process 3) in 2 L glass bioreactors using two recombinant CHO cell lines (Clone 1 and Clone 2) expressing a complex cytokine-IgG fusion protein (cM2=IgG-IL2 immunoconjugate) were analyzed for (A) CHO host cell protein and (B) the ratio of CHO HCP per titer.

[0194] FIG. 3c Process variants 2 and 3 reduce supernatant PLBL2 concentration at harvest for two clones expressing cM2. Cell-free samples of a fed-batch processes lasting 13 (Process 2) and 14 days (Process 3) in 2 L glass bioreactors using two recombinant CHO cell lines (Clone 1 and Clone 2) expressing a complex cytokine-IgG fusion protein (cM2=IgG-IL2 immunoconjugate) were analyzed for (A) PLBL2 and (B) the ratio of PLBL2 per titer.

[0195] FIG. 4 Process variant 3 reduces supernatant Clusterin concentration at harvest in production scale/large scale. Cell-free samples of a 13 day (Process 2) and 14 day (Process 3) fed-batch processes in 250 L single use bioreactors using a recombinant CHO cell line expressing a complex cytokine-IgG fusion protein (cM2=IgG-IL-2 immunoconjugate) were analyzed for Clusterin.

[0196] FIG. 5 Reduction of cM2 fragments and aggregates by process 3. (A) Fragments: heavy chain fragments+non-glycosylated heavy chain, measured by CE-SDS, and (B) Aggregates (HMW species), measured by SEC are shown for clone 1 and clone 2 expressing cM2. All experiments were performed in 2 L glass bioreactors.

[0197] FIG. 6 Modulation of supernatant Clusterin levels by process pH. Cell-free samples of a 14 day fed-batch process (Process 1) with pH shifts to 6.8, 7.0, 7.2, or 7.4 at day 8 in 2 L glass bioreactors using two recombinant CHO cell lines, clone 6 and clone 7, expressing a complex IgG fusion protein (cM3=FAP-4-1-BBL immunoconjugate) were analyzed for Clusterin.

[0198] FIG. 7 Modulation of supernatant Clusterin levels by process temperature. Cell-free samples of a 14 day fed-batch process (Process 1) with temperature shift to 33 C. or no temperature shift (37 C.) at day 8 in shake flasks using two recombinant CHO cell lines, clone 6 and clone 7, expressing a complex IgG fusion protein (cM3=FAP-4-1-BBL immunoconjugate) were analyzed for (A) Clusterin and (B) product titer. Whiskers represent respective standard deviation.

[0199] FIG. 8 Modulation of supernatant Clusterin levels by process osmolality. Cell-free samples of a 14 day fed-batch process (Process 1) with different base media osmolalities (300 and 400 mOsmol/kg) in shake flasks using the recombinant CHO cell lines clone 6 expressing a complex IgG fusion protein (cM3=FAP-4-1-BBL immunoconjugate) were analyzed for (A) Clusterin, (B) product titer, and (C) the ratio Clusterin per titer. Whiskers represent respective standard deviation.

[0200] FIG. 9 Reduction of cM1 (=CEA-IL-2 immunoconjugate) fragments and aggregates. (A) Fragments: heavy chain fragments+non-glycosylated heavy chain, measured by CE-SDS, and (B) Aggregates (HMW species), measured by SEC are shown for a clone expressing cM1. All experiments were performed in in 2 L glass bioreactors.

[0201] FIG. 10 Net titers for Processes 1, 2 and 3. Net titers for the different processes were determined by subtracting the amount of fragmented products from the total product titer. All processes show comparable levels of net titer.

[0202] FIG. 11 Viable cell density (A) and cell viability (B) is shown. Fed-batch processes lasting 13 (Process 2, grey markers and lines) and 14 days (Process 3, black markers and lines) in 2 L glass bioreactors using two recombinant CHO cell lines (Clone 1, circle markers, and Clone 2, square markers) expressing a complex cytokine-IgG fusion protein (cM2=IgG-IL2 immunoconjugate) were analyzed for (A) viable cell density and (B) cell viability.

[0203] FIG. 12 Viable cell density (A) and cell viability (B) is shown. Fed-batch processes (n=3) lasting 14 days (process variant 1, black; process variant 2, light grey; process variant 3, dark grey) in 2 L glass bioreactors using one recombinant CHO cell line expressing a complex cytokine-IgG fusion protein (cM1=CEA-IL-2 immunoconjugate) were analyzed for (A) viable cell density and (B) cell viability. All processes show comparable cell viability and viable cell densities.

DESCRIPTION OF THE SEQUENCE LISTING

[0204]

TABLE-US-00002 SEQ ID NO: 01 variable heavy chain domain VH of anti-CEA IgG comprised in CEA-targeted IL-2 immunoconjugate SEQ ID NO: 02 variable light chain domain VL of anti-CEA IgG comprised in CEA-targeted IL-2 immunoconjugate SEQ ID NO: 03 Interleukin 2 variant (IL-2) comprised in CEA- targeted IL-2 immunoconjugate and FAP-targeted IL-2 immunoconjugate SEQ ID NO: 04 Full heavy chain (knob) with IL-2 comprised in CEA-targeted IL-2 immunoconjugate SEQ ID NO: 05 Full heavy chain (hole) comprised in CEA-targeted IL-2 immunoconjugate SEQ ID NO: 06 Full light chain comprised in CEA-targeted IL-2 immunoconjugate SEQ ID NO: 07 variable heavy chain domain VH of anti-FAP IgG comprised in FAP-targeted IL-2 immunoconjugate SEQ ID NO: 08 variable light chain domain VL of anti-FAP IgG comprised in FAP-targeted IL-2 immunoconjugate SEQ ID NO: 09 Full heavy chain (knob) with IL-2 comprised in FAP-targeted IL-2 immunoconjugate SEQ ID NO: 10 Full heavy chain (hole) comprised in FAP-targeted IL-2 immunoconjugate SEQ ID NO: 11 Full light chain comprised in FAP-targeted IL-2 immunoconjugate SEQ ID NO: 12 variable heavy chain domain VH of untargeted IgG comprised in IgG-IL-2 immunoconjugate SEQ ID NO: 13 variable light chain domain VL of untargeted IgG comprised in IgG-IL-2 immunoconjugate SEQ ID NO: 14 Interleukin 2 variant (IL-2) comprised in IgG-IL-2 immunoconjugate SEQ ID NO: 15 Full heavy chain with IL-2 comprised in IgG-IL-2 immunoconjugate SEQ ID NO: 16 Full light chain comprised in IgG-IL-2 immunoconjugate

Example 1

General Methods and Material

Cell Lines

[0205] In the context of this work, transfected CHO (Chinese hamster ovary) K1 cell lines were used.

Immunoconjugates

[0206] The current invention is exemplified using a number of exemplary immunoconjugates such as a CEA-targeted-IL-2 immunoconjugate (anti-CEA antibody conjugated to IL-2) as described in WO 2012/146628 or SEQ ID NO: 01 to SEQ ID NO: 06; or a FAP-targeted-IL-2 immunoconjugate as described in WO 2012/107417 or SEQ ID NO: 07 to SEQ ID NO: 11 and SEQ ID NO: 03; or an untargeted IgG-IL-2 immunoconjugate as reported in WO 2015/118016 or SEQ ID NO: 12 to SEQ ID NO: 16; or a FAP-targeted-4-1-BBL immunoconjugate as described in WO 2016/075278.

Cell Culture Methods

[0207] Media and feeds required for cell culture were prepared and the parameters pH value, glucose concentration and osmolality adjusted according to the operating instructions of the supplier (Gibco/Life Technologies Inc.). Media and feeds were stored at 4 C. in the dark and consumed within four weeks (preculture medium, fermentation medium), three weeks (feed 1) and two weeks (feed 2), respectively. Correction agents were stored at room temperature and expended within 3 months (glucose solution; 50%), 6 months (sodium carbonate solution; IM) and 12 months (defoamer solution; Dow Corning Antifoam C emulsion, food grade, 10%).

[0208] The methods described in the following part are adapted from standard protocols (Lindl, T. Zell-und Gewebekultur: Einfiihrung in die Grundlagen sowie ausgewihlte Methoden und Anwendungen. Heidelberg/Berlin, Spektrum Akademischer Verlage GmbH 2002) and operating instructions of the respective supplier.

Preculture

[0209] Cells were thawed and precultured in shake flasks for two to three weeks in preculture medium. The incubation parameters were: Temperature 37 C., Humidity 80%, CO.sub.2 7%, Shaking frequency 210 rpm, Amplitude 5 cm. Cells were passaged every three to four days and expanded in preculture medium under selection pressure (Methotrexate) to the volume required for inoculation.

Standard Cell Culture Process (Process 1)

[0210] Cells were cultured in a or 14-day fed-batch process with Feed 1, Feed 2, and glucose with a start cell density of 3.5.Math.10E5 cells/ml. The feeds were started on day three and six of fermentation and were added continuously during the remaining days of fermentation in a rate of 2% (v/v) based on the start volume. If not stated otherwise, the pH value was adjusted with CO.sub.2 and IM Na.sub.2CO.sub.3 within a dead band of 0.05 pH units. Antifoam solution and antibiotics were added if necessary. During the process, the parameters temperature, pH value, and pO.sub.2 were monitored and controlled. The fermentation process was stopped after 14 days. The culture broth was harvested and sterile filtered. The bioreactors were dismantled and cleaned.

[0211] For adopted processes (process 2 and 3) see below.

Fermentation Setup in the Quad System

[0212] The 2 L double wall glass bioreactors are closed with a steel lid, where built-in components such as stirrer, probes, feed ports etc. are integrated. Four vessels are controlled by one BIOSTAT DCU3/4 (Sartorius Stedim Biotech AG) control system and, hence, termed Quad system.

[0213] The bioreactors were assembled and filled with KH.sub.2PO.sub.4 solution (1.4 g/l). The pH probes were calibrated and together with the pO.sub.2 probes integrated into the bioreactor. Subsequently the system was tested for pressure tightness. The bioreactors were autoclaved (wet program: 121 C. and 1.2 bar above atmospheric pressure for 30 min) and were connected to the supply towers (DCU3 and 4, respectively). KH.sub.2PO.sub.4 was replaced by 900 ml fermentation medium on the day before inoculation. In addition, pH probes were calibrated, base and glucose flasks were connected to the bioreactor, and controlling (stirrer, gassing for pO.sub.2 calibration, temperature, and pressure) was started. Before inoculation, pH probes were recalibrated, pO.sub.2 probes were calibrated and parameters were set to fermentation conditions (Temperature 37 C., pO.sub.2 35%, pH 7, Pressure 100 mbar). The feedback control system for pO.sub.2 was regulated over the following cascade: N2/air, air/O.sub.2, and stirrer.

Cell Growth Measurements

[0214] Viable Cell Density and Viability were assessed during the culture processes with trypan blue staining by a Cedex HiRes (Roche Diagnostics GmbH) device.

Protein a Purification

[0215] Purification and CE were carried out according to the protocols of the suppliers. In general, frozen samples containing protein were thawed cautiously at 4 C. and kept on ice when possible. Freeze and thaw cycles were avoided. Fermentation samples were centrifuged (4000g, 10-30 min, depending on the volume) and either purified and/or analyzed immediately or shock frozen in liquid nitrogen and stored at 80 C.

[0216] Affinity chromatography was used for purification of the antibodies. Protein A purification of small volumes (150 l-3 ml) was performed using PureSpeed tips (Mettler Toledo).

[0217] For larger volumes (2 L-3 L) Protein A MabSelectSure columns were equilibrated. Subsequently, the fermentation supernatant was loaded for the capture step. The column was washed before eluting the protein. Finally, the pH of the eluate was adjusted to 5.0 with neutralization buffer.

Capillary Electrophoresis (CE-SDS)

[0218] CE on a chip was performed with the Agilent Bioanalyzer 2100 or the PerkinElmer LabChip GX and the respective protein kits according to the instructions of the manufacturer.

[0219] Fragmentation was analyzed with CE in reduced state. The standard CE diagrams show different marker peaks and three product peaks: the light chain peak is visible at a size of approximately 28 kDa, the heavy chain hole (HChole, HC1) peak at about 58 kDa and the peak of the heavy chain knob (HCknob, HC2) with the attached IL-2 molecule at around 74 kDa. When fragmentation of the IL-2 moiety occurs, an additional peak is visible between the HC1 and HC2 peaks.

Net Product Titer

[0220] The product titer was measured with the Bioprofile 100 Plus. However, the device cannot differentiate between fragmented and not fragmented antibodies. For this reason, the net titer with less fragments was calculated as shown below.

T.sub.net=(1F).Math.T

With: Tnet=Net product titer (less fragments) [mg/l]
T=Total titer [mg/1]

F=Fragments [%]

Example 2

[0221] pH and Temperature Modulation Influence Clusterin Levels in CHO Fed-Batch Processes (Exemplified with cM1/cM2)

[0222] To elucidate the effect of pH and temperature on the supernatant Clusterin levels in CHO fed-batch processes three process variants, process 1, process 2, and process 3 were compared in triplicate.

TABLE-US-00003 TABLE Used process parameters tested. Inoculation cell density Process (E5cells/mL) pH value Temperature length Process 1 3.5 7.0 37 (day 1 to 14) 14 days (Standard) Process 2 6.5 7.0 37 (day 1-7) 13 days 34 (day 8-13) Process 3 9.0 7.0 (day 1-7) 37 (day 1-7) 14 days 7.3 (day 8-14) 34 (day 8-14)

[0223] Process 2 and process 3 differ from process 1 by an elevated inoculation cell density, an additional temperature shift at day 8, for both variants and harvest at day 13 for process 2 and an additional pH shift for process 3 (FIG. 1). In the given set up, a clone stably expressing a complex cytokine-IgG fusion protein (cM1=CEA-IL-2 immunoconjugate) were used for fed-batch processes in 2 L glass bioreactors. Both, process 2 and process 3 showed reduced levels of supernatant Clusterin at harvest when compared to baseline process variant 1 (FIG. 2A). Process 2 and process 3 reached the same productivity, calculated by net product titer, as the reference process 1 (FIG. 2B). By that, the ratio of supernatant Clusterin concentration per product concentration followed the same trend as the supernatant Clusterin levels alone: Process variants 2 and 3 induce a reduced Clusterin load in respect for the produced molecules (FIG. 2C).

[0224] Viable cell density and cell viability were assessed and found comparable for all three processes (FIGS. 11 and 12).

[0225] To analyze the general effect of modulating pH and temperature in CHO fed-batch processes on Clusterin levels two clones (clone 1 and clone 2) stably expressing another complex cytokine-IgG fusion protein (cM2=IgG-IL-2 immunoconjugate) and process variants 2 and 3 were used in 2 L bioreactor runs. As observed before the process variant 3 also showed for clone 1 and clone 2 a reduced level of supernatant Clusterin and Clusterin per product ratio, yet overall product titer remains the same (FIG. 3a,(A)). Same reduction trends for CHO host cell protein (FIG. 3b, (A)-(C)) and PLPL2 (FIG. 3c, (A)-(C)) could be observed for clone 1 and clone 2 using process variant 3.

[0226] The scalability of the process variant was proven by comparing process variant 2 and 3 in fed-batch processes using 250 L single use bioreactors (SUBs) as representative production scale. Again, process variant 3 showed decreased levels of supernatant Clusterin compared to process 2 (FIG. 4).

[0227] The final levels of cM2 product-related impurities (fragmentation and aggregation) at harvest, were measured by CE-SDS and SEC, respectively. Both clones tested, clone 1 and clone 2, showed a reduced level for cM2 fragmentation and aggregation when process variant 3 was used (FIG. 5).

Example 3

[0228] Clusterin Levels can be Modulated by pH, Temperature and Medium Osmolality (Exemplified with cM3)

[0229] In fed-batch experiments using either 2 L glass bioreactors or shake flasks the process and media parameters pH, temperature and osmolality were tested to effect supernatant Clusterin levels of CHO fed-batch cultivations. For that, two clones, clone 6 and clone 7, both expressing the same complex IgG fusion protein (cM3=FAP-4-1-BBL immunoconjugate), and process variant 1 were used. Temperature and pH shifts were started at day 8 and kept until harvest at day 14. The different medium osmolalities were used from the start of the cultivation on.

[0230] For both clones the supernatant Clusterin levels raised from pH 6.8 to pH 7.2 (FIG. 6). At pH 7.4 the Clusterin levels showed the lowest or comparable levels to 6.8 for clone 6 and clone 7, respectively.

[0231] Decreasing the temperature at day 8 to 33 C. reduced the Clusterin levels by approximately 50%, yet the productivity of the cultivation remained on a comparable level (FIG. 7).

[0232] Modulation of the process osmolality for CHO cells can be used to change the cell specific productivity. In a subsequent experiment the effect of medium osmolality on supernatant Clusterin were analyzed. By using higher medium osmolality the process yielded a slight reduced final titer compared to low medium osmolality levels (FIG. 8B). However, supernatant Clusterin levels and the ratio of Clusterin per product titer were reduced by approximately 50% (FIG. 8A,C).

Example 4

[0233] Modulation of Fragmentation and Aggregation Levels (Exemplified with cM1)

[0234] As described in Example 2 different parameters like pH and temperature on fragmentation and aggregation levels of recombinantly produced molecules in CHO cells were analyzed. Again, the three different fed-batch process variants, process 1, process 2, and process 3 (see Example 2) were compared. Here, a clone stably expressing a complex cytokine-IgG fusion protein (cM1=CEA-IL-2 immunoconjugate) were used for fed-batch processes.

[0235] The final levels of cM1 product-related impurities (fragmentation and aggregation) at harvest, were measured by CE-SDS and SEC, respectively.

[0236] Process 2 and especially process 3 show significantly reduced levels of fragmentation (11% for process 1 vs 4% for process 3 on day 14; FIG. 9 A). Aggregate levels were significantly reduced with process 3 (FIG. 9 B).

[0237] Importantly, the net titer was about the same for all three processes on day 14 (FIG. 10). Thus, productivity can be kept on a high level while fragmentation and aggregation can be reduced. Also, viable cell density and cell viability were assessed and found comparable for all three processes (FIG. 12).

Example 5

Purification of Immunoconjugates

[0238] Following the harvest of the produced immunoconjugates, further purification may be performed. Briefly, immunoconjugates were purified by one affinity step with protein A (HiTrap ProtA, GE Healthcare) equilibrated in 20 mM sodium phosphate, 20 mM sodium citrate pH 7.5. After loading of the supernatant, the column was first washed with 20 mM sodium phosphate, 20 mM sodium citrate, pH 7.5 and subsequently washed with 13.3 mM sodium phosphate, 20 mM sodium citrate, 500 mM sodium chloride, pH 5.45. The immunoconjugates were eluted with 20 mM sodium citrate, 100 mM sodium chloride, 100 mM glycine, pH 3. Fractions were neutralized and pooled and purified by size exclusion chromatography (HiLoad 16/60 Superdex 200, GE Healthcare) in final formulation buffer: 25 mM potassium phosphate, 125 mM sodium chloride, 100 mM glycine pH 6.7. The protein concentration of purified protein samples was determined by measuring the optical density (OD) at 280 nm, using the molar extinction coefficient calculated on the basis of the amino acid sequence. Purity and molecular weight of immunoconjugates were analyzed by SDS-PAGE in the presence and absence of a reducing agent (5 mM 1,4-dithiotreitol) and stained with Coomassie blue (SimpleBlue SafeStain, Invitrogen).