PROCESS FOR PRODUCTION AND PURIFICATION OF RECOMBINANT LYSOSOMAL ALPHA-MANNOSIDASE
20180036387 · 2018-02-08
Inventors
- Jens Fogh (Lynge, DK)
- Claes Andersson (Taby, SE)
- Cecilia Weigelt (Stockholm, SE)
- Pia Hydén (Stocksund, SE)
- Helena Reuterwall (Solna, SE)
- Stefan Nilsson (Uppsala, SE)
Cpc classification
A61K38/47
HUMAN NECESSITIES
International classification
Abstract
The present invention relates to a process for purification of recombinant alpha-mannosidase, a process for production of alpha-mannosidase, a composition comprising alpha-mannosidase, use of the composition as a medicament, use as a medicament for the treatment of alpha-mannosidosis and a method of treating alpha-mannosidosis and/or alleviating the symptoms of alpha-mannosidosis.
Claims
1. (canceled)
2. A composition comprising purified recombinant alpha-mannosidase, wherein at least 80% of the alpha-mannosidase is present as a 130 kDa glycoprotein.
3. The composition of claim 2, wherein the alpha-mannosidase is not equal to all or a portion of the wild-type alpha-mannosidase found in nature.
4. The composition of claim 2, wherein the alpha-mannosidase is recombinant human lysosomal alpha-mannosidase (rhLAMAN).
5. The composition of claim 2, wherein the alpha-mannosidase is a single polypeptide or a mixture of a single polypeptide and fractions thereof.
6. The composition of claim 2, wherein the recombinant alpha-mannosidase comprises a sequence selected from: a) a sequence set forth in SEQ ID NO: 2; b) an analogue of the sequence in a); or c) a subsequence of the sequence in a) or b).
7. The composition of claim 2, wherein the recombinant alpha-mannosidase is obtained from a cell culture.
8. The composition of claim 7, wherein the cell culture is a fed-batch or a continuous cell culture.
9. The composition of claim 8, wherein the cell culture is prepared by: a) inoculating a production reactor comprising a base medium with cells capable of producing recombinant alpha-mannosidase on day 0, to provide a cell culture; b) adding a feed medium to said cell culture at least once from day 1; and c) adjusting the temperature of said cell culture to 35 C., 34 C., 33 C., 32 C., or 31 C., either after day 3 or when the viable cell density is higher than 2.110.sup.6 viable cells/mL, whichever comes first.
10. The composition of claim 7, wherein said recombinant alpha-mannosidase is obtained by subjecting a fraction of said cell culture to chromatography on a resin comprising a multimodal ligand.
11. The composition of claim 10, wherein said fraction of said cell culture comprising the recombinant alpha-mannosidase is free of non-dissolved material or solids.
12. The composition of claim 2, wherein the composition is formulated in a formulation buffer comprising Na.sub.2HPO.sub.4, NaH.sub.2PO.sub.4, glycine, and mannitol.
13. The composition of claim 2, wherein the composition is formulated as an isotonic solution in a formulation buffer comprising 3.50 mM Na.sub.2HPO.sub.4, 0.17 mM NaH.sub.2PO.sub.4, 27 mM glycine, and 250 mM mannitol at a pH of 7.70.
14. A method of treating alpha-mannosidosis or reducing or alleviating the symptoms associated with alpha-mannosidosis, said method comprising administering to a subject in need thereof the composition of claim 6.
15. The method of claim 14, wherein the composition is formulated in a formulation buffer comprising Na.sub.2HPO.sub.4, NaH.sub.2PO.sub.4, glycine, and mannitol.
16. The method of claim 14, wherein the composition is formulated as an isotonic solution in a formulation buffer comprising 3.50 mM Na.sub.2HPO.sub.4, 0.17 mM NaH.sub.2PO.sub.4, 27 mM glycine, and 250 mM mannitol at a pH of 7.70.
17. A method of treating alpha-mannosidosis and/or reducing or alleviating the symptoms associated with alpha-mannosidosis, said method comprising: administering a composition that comprises: A) a composition comprising alpha-mannosidase obtainable by a process for purification of a recombinant human lysosomal alpha-mannosidase from a cell culture, wherein a fraction of said cell culture comprising said recombinant human lysosomal alpha-mannosidase is subjected to chromatography on a resin comprising a multi-modal ligand, wherein said resin bound multi-modal ligand is a substance having a carboxylic acid or sulphonic acid group; B) a composition comprising alpha-mannosidase obtained by a process for fed batch or continuous production of recombinant alpha-mannosidase, comprising: i. inoculating a production reactor comprising a base medium with cells capable of producing recombinant alpha-mannosidase on day 0, to provide a cell culture; ii. adding a feed medium to said cell culture at least once from day 1; iii. adjusting the temperature of said cell culture to at the most 35 C., either after day 3 or when the viable cell density is higher than 2.1 MVC/mL, whichever comes first; and iv. applying a process for purification of the recombinant human lysosomal alpha-mannosidase from the cell culture, wherein a fraction of said cell culture comprising said recombinant human lysosomal alpha-mannosidase is subjected to chromatography on a resin comprising a multi-modal ligand, wherein said resin bound multi-modal ligand is a substance having a carboxylic acid or sulphonic acid group; or C) a composition comprising purified recombinant alpha-mannosidase, wherein at least 80% of the alpha-mannosidase is present as a 130 kDa glycoprotein.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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[0034]
[0035] The present invention will now be described in more detail in the following.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Definitions
[0036] Prior to discussing the present invention in further details, the following terms and conventions will first be defined:
Recombinant Alpha-Mannosidase
[0037] In the context of the present invention recombinant alpha-mannosidase is defined as alpha-mannosidase which by virtue of its origin or manipulation is not equal to all or a portion of the wild-type alpha-mannosidases found in nature. Thus, it is constructed using recombinant techniques which involves recombinant DNA molecules, that is hybrid DNA sequences comprising at least two fused DNA sequences, the first sequence not normally being fused with the second sequence in nature. The recombinant alpha-mannosidase protein may be of human or non-human origin. In particular, it may be a recombinant human lysosomal alpha-mannosidase (rhLAMAN). The alpha-mannosidase product may be a single polypeptide or a mixture of a single polypeptide and fractions thereof. Also the alpha-mannosidase may be subject to posttranslational modifications and may therefore be in the form of a glycoprotein.
Cell Culture
[0038] A cell culture is the process by which cells are grown under controlled conditions. In the present context the cells of the cell culture are specifically designed to express a protein of interest, such as recombinant alpha-mannosidase. The cell culture may reside in a bioreactor, which is specially designed so as to allow control of the chemical and physical conditions.
Fraction
[0039] In the present context a fraction refers to a fraction of a cell culture. The fraction may constitute the whole cell culture, but is often a treated fraction of the culture, such as a clarified, filtered, concentrated, diluted or partly purified fraction.
Resin
[0040] In the context of the present invention a resin constitutes the basis of a stationary phase in a chromatography system, on which various chemical groups or substances are attached to provide a certain amount of affinity for a given molecule or protein of interest. Resins are often polymeric beads with ligands covalently attached, said resins being insoluble in the liquid mobile phases used.
Multi-Modal Ligand
[0041] By multi-modal ligand is meant any ligand which is designed to interact with a molecule or protein of interest in at least 2 ways. The individual interactions may independently be hydrophobic, hydrophilic, ionic, Van der Waals interactions, hydrogen bonding or any other intermolecular chemical or physical interaction. In the present context a ligand is an organic chemical substance attached to a resin as defined above. A multi-modal ligand will have different affinities for different substances that are passed through the chromatography column dissolved in a mobile phase. The differences in affinity leads to variations in retention time of the different substances on the chromatography column, enabling separation of the substances. The retention times are also dependent on other factors such as for example the constituents of the mobile phase, pH and temperature. Resins comprising multimodal ligands are sometimes referred to as mixed mode resins as well, but in the present context resins comprising a multi-modal ligand are not to be confused with so-called mixed-mode ion exchange resins which comprise several different ligands on the same resin which may have opposite charges, such as e.g. OH, Ca.sup.+ and PO.sub.4.sup.2 in the case of ceramic hydroxyapatite resin (CHT). In these resins the individual ligands are not multi-modal.
Loading
[0042] In the present context loading refers to the transfer of a harvest, eluate or other solution onto a chromatographic system, such as a chromatography column comprising a resin as a stationary phase.
Buffer
[0043] The term buffer is well known as a general description of a solution containing either a weak acid and/or its corresponding salt or a weak base and/or its corresponding salt, which is resistant to changes in pH. In the context of the present invention the buffers used are suitable for use in chromatographic systems, such buffers include but are not limited to: Phosphate buffers, e.g. disodium phosphate (Na.sub.2HPO.sub.4), sodium phosphate or potassium phosphate, acetate buffers, e.g. sodium acetate or potassium acetate, sulphate buffers, e.g. sodium sulphate or potassium sulphate, ammonium sulphate or Hepes, or other buffers, e.g. sodium borate or tris-HCl buffer.
Ultrafiltration
[0044] Ultrafiltration is a separation method in which hydraulic pressure is used to force molecules and solvent across a membrane comprising pores of a particular size, also known as the cut-off size or value. Only molecules which have a molecular weight smaller than the cut-off value of the membrane are able to cross the membrane while those with a larger molecular weight do not cross the membrane and form the so called retentate. The molecules present in the retentate may thereby be concentrated as the solvent flows across the membrane.
[0045] In a particular embodiment the concentration of a solution or composition comprising a polypeptide such alpha-mannosidase may be performed by Tangential flow filtration (TFF). This method is in particular useful for large-scale concentration, i.e. for concentration of solutions with a volume from one litre to several hundreds of litres. Thus this method is in particular useful for production of concentrated solutions of a polypeptide of interests on an industrial scale. The TFF technique is based on the use of a particular apparatus which causes the solution which is to be filtrated to flow across a semi-permeable membrane; only molecules which are smaller than the membrane pores will pass through the membrane, forming the filtrate, leaving larger matter to be collected (retentate). With the TFF method two different pressures are applied; one to pump the solution into the system and to circulate it in the system (inlet pressure), and another pressure is applied over the membrane (membrane pressure) to force the small molecules and the solvent across the membrane. The inlet pressure may typically be in the range of 1-3 bar, such as between 1.5-2 bar. The transmembrane pressure (TMP) may typically be larger than 1 bar. The concentrated composition of a polypeptide of interest may be collected as the retentate when TFF is used to concentrate the composition. Membranes useful for TFF may typically be made of regenerated cellulose or polyethersulphone (PES).
Diafiltration
[0046] In the present context diafiltration is a filtration process where a species of interest is in the retentate, i.e. it is not allowed to pass through the filter, whereas other components such as for example buffers and salts do pass through the filter. Thus diafiltration may for example be used to exchange one buffer by another or to concentrate solutions containing a species of interest such as recombinant alpha-mannosidase. A first aspect of the present invention is to provide a process for purification of recombinant alpha-mannosidase from a cell culture, wherein a fraction of said cell culture comprising recombinant alpha-mannosidase is subjected to chromatography on a resin comprising a multi-modal ligand. The advantage of using resins comprising a multimodal ligand in the present context is that these resins enable binding of the alpha-mannosidase species in solutions having high conductivity levels. This has the advantage that undiluted harvest with high conductivity levels can be used, and no exchange of the harvest buffer is necessary. The chromatography step comprising a multi-modal ligand may therefore preferably be the first chromatography step after isolating the fraction from the cell culture. Said chromatography step comprising a multi-modal ligand may often be referred to as a capture step, since the protein of interest is initially withheld on the column (i.e. captured), while many impurities pass through the column during washing steps. The protein is subsequently eluted using a specific elution buffer.
[0047] Thus, in one embodiment of the invention a process is provided wherein the fraction of the cell culture comprising the recombinant alpha-mannosidase is a clarified undiluted harvest. In the context of the present invention the term clarified undiluted harvest means a harvest of a cell culture, that is free of non-dissolved material or solids, i.e. it is a clear solution. The harvest may have been submitted to a treatment in order to convert it to a clear solution. Such treatments may include but are not limited to: Filtration and centrifugation. Furthermore, the harvest is not significantly diluted prior to subjection to chromatography steps. Hence the harvest is diluted by less than 10%, such as less than 7%, less than 5%, less than 2%, less than 1%, less than 0.5%, such as less than 0.1%. In the most preferred embodiment the harvest is not diluted.
[0048] In another embodiment a process is provided wherein the clarified undiluted harvest has a conductivity of 10-20 mS/cm, such as 12-17 mS/cm, preferably 15 mS/cm. The conductivity is measured prior to loading the harvest onto a chromatography system. In one embodiment said chromatography is performed on a resin comprising a multimodal ligand having a carboxylic acid or sulphonic acid group. The carboxylic and/or sulphonic acids comprised in these ligands may be in the protonated form or in a deprotonated (salt) form depending on the conditions in the chromatographic system, particularly the pH of the mobile phase.
[0049] In yet another embodiment a process is provided wherein the resin bound multi-modal ligand is a substance of formula (I), (II) or (III):
##STR00001##
[0050] wherein R of the substances of formula (II) and (III) is a functional group of formula (IV):
##STR00002##
[0051] The multimodal ligand represented by the functional group of formula (IV) is generally referred to as Cibracon Blue 3G and examples of commercial products represented by the substances of formula (I), (II) and (III) are Capto MMC, Capto Blue and Blue Sepharose fast flow respectively. Other useful resins of the multimodal type include: Capto Adhere, MEP HyperCel, HEA HyperCel and PPA HyperCel. In the context of the present invention such resins have been proven especially effective in the initial purification of an undiluted harvest comprising recombinant alpha-mannosidase.
[0052] An additional embodiment of the invention provides a process wherein the fraction of said cell culture loaded onto the resin comprising a multimodal ligand, is subjected to at least one washing step with a solution comprising isopropanol, preferably at least 1% (V:V) isopropanol, such as at least 2%, 3%, 4%, 4.5% (V:V) isopropanol, preferably at least 5% (V:V) isopropanol. The advantage of using a solution comprising isopropanol is that it provides for a better removal of unwanted host cell proteins (HCP's), specifically it helps to remove a protease responsible for the proteolytic degradation of the desired 130 kDa rhLAMAN species. HCP's are to understood as proteins endogenous to the host cell used in the cell culture during production. Although isopropanol is preferred other useful alcohols for this process includes ethanol, n-propanol and n-butanol.
[0053] In yet another embodiment a process is provided wherein the pH of the solution used for the washing step is in the range of pH 3.5-6.5, such as pH 4.0-6.0, pH 4.5-5.5, preferably pH 4.7-5.0. Another embodiment provides a process wherein the solution used for the washing step comprises an acetate buffer, preferably in a concentration in the range of 0.05-1.6M, such as 0.1-1.5M, 0.5-1.4M, 0.7-1.3M, 0.8-1.2M, 0.9-1.1M, preferably 0.95M. The acetate buffer may preferably be selected from the group consisting of sodium acetate, potassium acetate, lithium acetate, ammonium acetate.
[0054] Yet another embodiment provides a process wherein a first eluate comprising recombinant alpha-mannosidase is eluted from the resin comprising a multi-modal ligand using an aqueous solution comprising ethylene glycol or propylene glycol. The addition of ethylene glycol to the elution buffer was found to significantly enhance the yield of eluted recombinant alpha-mannosidase. Propylene glycol was also enhanced yield but ethylene glycol is preferred.
[0055] One embodiment provides a process wherein the concentration of ethylene glycol or propylene glycol in the aqueous solution is 20-60%, 20-50%, 25-50%, 30-50%, 35-45%, such as 40%.
[0056] In a preferred embodiment a process is provided wherein the aqueous solution comprising ethylene glycol or propylene glycol comprises sodium chloride. The addition of sodium chloride to this solution was found to significantly enhance yields by promoting the elution of the rhLAMAN enzyme.
[0057] In another embodiment the concentration of sodium chloride in the aqueous solution comprising ethylene glycol or propylene glycol is in the range of 0.2 to 2.4M, such as in the range of 0.4 to 2.2M, 0.6 to 2.0M, 0.8 to 1.9M, 1.0 to 1.8M, 1.2 to 1.7M, 1.4 to 1.6M, preferably 1.5M. Alternatively the concentration of sodium chloride maybe in the range of 0.2 to 1.6M or in the range of 1.4 to 2.4M.
[0058] In a preferred embodiment the aqueous solution comprising ethylene glycol or propylene glycol comprises a buffer. Said buffer may preferably be a phosphate buffer, such as sodium phosphate or potassium phosphate. Although phosphate buffers are preferred, additional useful buffers for the aqueous solution include citrate and borate buffers, Tris, MES, MOPS and Hepes buffers.
[0059] In another preferred embodiment the concentration of the buffering salts in the aqueous solution comprising ethylene glycol or propylene glycol is 50-350 mM, 55-300 mM, 65-280 mM, 70-250 mM, 75-200, 80-200 mM, 85-150 mM, preferably 90 mM.
[0060] In yet another preferred embodiment the pH of the aqueous solution comprising ethylene glycol or propylene glycol is pH 7.0-9.0, such as pH 7.1-8.5, pH 7.2-8.3, pH 7.5-8.0, preferably pH 7.7.
[0061] In one embodiment a process is provided wherein a first eluate comprising alpha mannosidase obtained from the resin comprising a multi-modal ligand is further subjected to a process comprising the steps of
[0062] i) applying a fraction comprising alpha-mannosidase to a hydrophobic interaction chromatography resin to provide an eluate comprising the recombinant alpha-mannosidase,
[0063] ii) passing a fraction comprising alpha-mannosidase through a mixed-mode ion exchange resin to allow retention of contaminates to provide a flow through comprising the recombinant alpha-mannosidase, and
[0064] iii) subjecting a fraction comprising alpha-mannosidase to chromatography on a anion exchange resin to provide a eluate comprising the recombinant alpha-mannosidase.
[0065] In one embodiment a process is provided involving steps i)-iii) as described above, wherein the fraction in step i) has been subject to a purification on said resin comprising a multimodal ligand, the fraction of step ii) is derived from the eluate from step i) and the fraction of step iii) is derived from the flow through from step ii). In other words steps i) to iii) are performed in the order they are listed, however without precluding intermediate steps in between steps i) to iii). These may be intermediate purification steps and/or virus reduction or virus removal steps. In a preferred embodiment the hydrophobic interaction chromatography resin of step i) is an alkyl substituted resin, preferably butyl sepharose resin. Alkyl substituted resins may include ethyl-, butyl- and octyl sepharose resins. Furthermore, phenyl sepharose resins are also applicable. Examples of such resins are Butyl-S Sepharose 6 Fast Flow, Butyl Sepharose 4 Fast Flow, Octyl Sepharose 4 Fast Flow, Phenyl Sepharose 6 Fast Flow (high sub) and Phenyl Sepharose 6 Fast Flow (low sub), Butyl Sepharose High Performance, Phenyl Sepharose High Performance. The advantage of a purification step involving hydrophobically interacting resins and particularly butyl sepharose resin is effective removal of host cell proteins and DNA residues, while retaining good yield of the rhLAMAN enzyme.
[0066] In yet another embodiment step i) comprises at least one washing step, wherein the solution used for washing comprises a phosphate buffer and an acetate buffer, preferably sodium phosphate and sodium acetate. This dual buffer washing step has proved especially effective in removing impurities such as host cell proteins and DNA residues.
[0067] In yet another embodiment the concentration of phosphate buffer in the dual buffer washing of step i) is in the range of 5-40 mM, such as 10-30 mM, 15-25 mM, preferably 20 mM, and the concentration of acetate buffer is in the range of 0.9-1.5M, such as 1.0-1.4M, 1.1-1.3M, preferably 1.2M.
[0068] In another embodiment step i) comprises at least one washing step, wherein the solution used for washing comprises no more than one buffer, preferably a phosphate buffer, preferably sodium phosphate.
[0069] In another embodiment the one buffer of the at least one washing step comprising no more than one buffer is present in a concentration in the range of 0.4-0.8M, such as 0.5-0-7M, preferably 0.6M.
[0070] In one embodiment a process is provided wherein the mixed-mode ion exchange resin of step ii) is a ceramic hydroxyapatite or fluoroapatite resin, preferably ceramic hydroxyapatite type I (CHT I) resin. Applying this chromatography step has been shown to efficiently separate a significant amount of DNA impurities from the recombinant alpha-mannosidase composition and bind host cell proteins while the rhLAMAN enzyme product passes the column without binding.
[0071] In another embodiment the anion exchange resin of step iii) is a strong anion exchange resin, such as a quaternary ammonium strong anion exchange resin. Such resins are included but not restricted to the following examples: Q-Sepharose HP Q-Sepharose FF, DEAE-Sepharose, Capto Q, Uno Q, ANX Sepharose.
[0072] In yet another embodiment a process is provided wherein a virus inactivation step is performed, preferably in between step ii) and step iii). In a preferred embodiment the virus inactivation step comprises mixing the flow through of step ii) with an aqueous solution of isopropanol (1:1 V/V of flow through/aqueous isopropanol) for at least 2 hours, preferably followed by concentration by ultrafiltration and removal of isopropanol using diafiltration. The aqueous isopropanol during inactivation may be in the range of 10-50% isopropanol, such as 20-40%, 25-35%, 28-32%, preferably 30% isopropanol. The 1:1 V/V solution of flow through and aqueous isopropanol thus has a final concentration of isopropanol of 15%.
[0073] Another preferred embodiment is a process wherein a virus reduction step is performed, preferably after chromatography step iii).
[0074] In one embodiment the virus reduction step comprises filtration of a solution comprising recombinant alpha-mannosidase, preferably the eluate of step iii), through a filter, preferably a virus removal filter, such as a Ultipor VF grade DV20 filter, or a Planova 15N or 20N filter, Preferably a Planova 15N filter is used.
[0075] The purification process of the present invention may advantageously be performed on a large scale, thus in preferred embodiments the process is performed on chromatography columns having a column volume of at least 0.5 L, such as at least 1.0 L, 2.0 L, 5.0 L, 10 L, preferably at least 13.0 L.
[0076] In another embodiment of the present invention a purification process as described above is provided, wherein the alpha-mannosidase has a sequence selected from:
[0077] A) the sequence set forth in SEQ ID NO 2
[0078] B) an analogue of the sequence in A
[0079] C) a subsequence of the sequence in A) or B)
[0080] Where the sequence described by SEQ ID NO 2 represents the amino acid sequence for the recombinant human lysosomal alpha-mannosidase (rhLAMAN) as provided in WO 02/099092.
[0081] By subsequence is meant a fragment of the parent sequence having a size of no less than 50% of the parent sequence, such as no less than 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90% or no less 95% of the parent sequence. Accordingly, the subsequences in question may have a length of from 505-1009 consecutive amino acid residues, such as from 525-1009, from 550-1009, 575-1009, 600-1009, 625-1009, 650-1009, 675-1009, 700-1009, 725-1009, 750-1009, 775-1009, 800-1009, 825-1009, 850-1009, 875-1009, 900-1009, 925-1009, 950-1009, 975-1009, 980-1009, 990-1009 or such as from 1000-1009 consecutive amino acid residues. Furthermore, the relevant subsequences of SEQ ID NO: 2 or analogues thereof must retain the catalytic site. Although the 3D structure of human LAMAN is unknown, the 3D structure of the bovine LAMAN has been reported and based on that data it has been concluded that the following amino acids participate in the active site and/or are responsible for coordinating the Zn.sup.2+ atom required for activity also in human LAMAN: AA 72=H, AA 74=D, AA 196=D, AA 446=H (UniProtKB/Swiss-Prot database: 000754, MA2B1_HUMAN_, Heikinheimo et al. J. Mol. Biol. 327, 631-644, 2003). It has been shown that mutations of AA 72 and 196 in human LAMAN results in almost complete loss of enzyme activity (Hansen et al., Biochem. J. (2004), 381, pp. 537-567). In order to display activity, a subsequence of the rhLAMAN should retain at least the regions containing the above four amino acids. Preferably, the subsequences of rhLAMAN also comprise one or more additional conformational parts, including for example binding sites, beta-turns, disulfide bridges, stop codons and others. In the human form of LAMAN there are several disease causing mutations indicating importance for that particular amino acid, e.g. AA 53, 72, 77, 188, 200, 355, 356, 359, 402, 453, 461, 518, 563, 639, 714, 750, 760, 801, 809, 916 (The human gene mutation database, HMDG professional, Cardiff University, 2009) and there are also amino acids which are of importance for glycosylations, including AA 133, 310, 367, 497, 645, 651, 692, 766, 832, 930 and 989 and amino acids involved in disulfide bridges such as AA 55+358, 268+273, 412+472 and 493+501.
[0082] By analogue is meant a sequence with a certain percentage of sequence identity with the parent sequence, this may be at least 60% sequence identity, such as at least 70%, 80%, 85%, 90%, 95%, 98% or preferably 99% sequence identity It will be understood that the analogues and sub-sequences set forth above are preferably functionally equivalent to the alpha-mannosidase having the amino acid sequence set forth in SEQ ID NO: 2 in the sense that they are capable of exerting substantially the same enzymatic activity.
[0083] The term substantially the same enzymatic activity refers to an equivalent part or analogue having at least 50%, preferably at least 60%, more preferably at least 70%, more preferably at least 75%, more preferably at least 80%, more preferably at least 85%, more preferably at least 90%, more preferably at least 95% and most preferably at least 97%, at least 98% or at least 99% of the activity of the natural enzyme. An example of a functionally equivalent analogue of the enzyme could be a fusion protein which includes the catalytic site of the enzyme in a functional form, but it can also be a homologous variant of the enzyme derived from another species. Also, completely synthetic molecules that mimic the specific enzymatic activity of the relevant enzyme would constitute functionally equivalent analogues. Non-human analogues of LAMAN are generally not applicable for therapy as they can potentially induce the formation of antibodies in the patient and cause disease. Human analogues however may be useful in enzyme replacement therapy, when the mutations are not disease causing and do not diminish the desired enzyme activity significantly. Examples of such mutations are: His70Leu, Gln240Arg, Ser250Ala, Leu278Val, Ser282Pro, Thr312Ile, Ala337Arg, Ser413Asn, Ser481Ala, Gln582Glu, Arg741Gly, Thr873Pro (Source: www.ensembl.org.; transcript ID ENST00000456935). Also Pro669Leu and Asp402Lys are known by the inventors not to cause disease. Generally, the skilled person will be able to readily devise appropriate assays for the determination of enzymatic activity. For LAMAN, an appropriate enzyme activity assay is disclosed in WO 02/099092 page 26, lines 8-28. Briefly, the following procedure may be performed for screening purposes using flat-bottomed 96-well plates: 75 l of 4 assay buffer (8 mM p-Nitrophenyl-alpha-D-mannopyranoside, 2 mg/mL BSA, 0.4M Na Acetate (pH 4.5) is added to 75 l of sample or an appropriate dilution of it (in 10 mM Tris pH 7.4 containing 150 mM NaCl+10% superblock). The plates are incubated at 37 deg C. for 30 min and stopped with 75 l of 1.8M Na.sub.2CO.sub.3 and the absorbance recorded at 405 nm on a plate reader. The 96-well plates are read on a spectrophotometer. Specific activity is defined as moles of p-Nitrophenyl-alpha-D-mannopyranoside hydrolysed per minute per mg protein.
[0084] As commonly defined identity is here defined as sequence identity between genes or proteins at the nucleotide or amino acid level, respectively. Thus, in the present context sequence identity is a measure of identity between proteins at the amino acid level and a measure of identity between nucleic acids at nucleotide level. The protein sequence identity may be determined by comparing the amino acid sequence in a given position in each sequence when the sequences are aligned. Similarly, the nucleic acid sequence identity may be determined by comparing the nucleotide sequence in a given position in each sequence when the sequences are aligned.
[0085] To determine the percent identity of two amino acid sequences or of two nucleic acids, the sequences are aligned for optimal comparison purposes (e.g., gaps may be introduced in the sequence of a first amino acid or nucleic acid sequence for optimal alignment with a second amino or nucleic acid sequence). The amino acid residues or nucleotides at corresponding amino acid positions or nucleotide positions are then compared. When a position in the first sequence is occupied by the same amino acid residue or nucleotide as the corresponding position in the second sequence, then the molecules are identical at that position. The percent identity between the two sequences is a function of the number of identical positions shared by the sequences (i.e., % identity=# of identical positions/total # of positions (e.g., overlapping positions)100). In one embodiment the two sequences are the same length. One may manually align the sequences and count the number of identical amino acids. Alternatively, alignment of two sequences for the determination of percent identity may be accomplished using a mathematical algorithm. Such an algorithm is incorporated into the NBLAST and XBLAST programs. BLAST nucleotide searches may be performed with the NBLAST program, score=100, wordlength=12, to obtain nucleotide sequences homologous to a nucleic acid molecules of the invention. BLAST protein searches may be performed with the XBLAST program, score=50, wordlength=3 to obtain amino acid sequences homologous to a protein molecule of the invention. To obtain gapped alignments for comparison purposes, Gapped BLAST may be utilised. Alternatively, PSI-Blast may be used to perform an iterated search, which detects distant relationships between molecules. When utilising the NBLAST, XBLAST, and Gapped BLAST programs, the default parameters of the respective programs may be used. See www.ncbi.nlm.nih.gov. Alternatively, sequence identity may be calculated after the sequences have been aligned e.g. by the BLAST program in the EMBL database (www.ncbi.nlm.gov/cgi-bin/BLAST). Generally, the default settings with respect to e.g. scoring matrix and gap penalty may be used for alignment. In the context of the present invention, the BLASTN and PSI BLAST default settings may be advantageous.
[0086] The percent identity between two sequences may be determined using techniques similar to those described above, with or without allowing gaps. In calculating percent identity, only exact matches are counted.
[0087] Another embodiment of the present invention is a composition comprising alpha-mannosidase obtainable by the purification process described above. In a second aspect of the present invention a process is provided for fed batch or continuous production of recombinant alpha-mannosidase, comprising the following steps: a. inoculating a production reactor comprising a base medium with cells capable of producing recombinant alpha-mannosidase on day 0, to provide a cell culture; b. adding a feed medium to said cell culture at least once from day 1; c. adjusting the temperature of said cell culture to at the most 35 C., such as 34 C., 33 C., 32 C., preferably at the most 31 C., either after day 3 or when the viable cell density is higher than 2.1 MVC/mL, whichever comes first.
[0088] In the above process inoculation day is defined as day 0, and the following day is day 1 and so on. The starting temperature used from day 0 until the adjustment described in point c. is in the range 36-37 C., preferably 36.5 C. It is to be understood that the abovementioned temperatures are actual measured temperatures, not set points, i.e. in the bioreactor setup used for the present invention the temperature of 31 C. mentioned above required a temperature set point of 32 C. Likewise a temperature of 36.5 C. requires a set point temperature of 37 C.
[0089] Suitable host cells for the expression and production of recombinant alpha-mannosidase are derived from multicellular organisms, preferably from mammals.
[0090] In particular, the cells used to produce recombinant alpha-mannosidase may be selected from the group consisting of monkey kidney CVI line transformed by SV40 (COS-7); human embryonic kidney line (293 or 293 cells subcloned for growth in suspension culture); baby hamster kidney cells (BHK); Chinese hamster ovary cells/-DHFR (CHO); mouse Sertoli cells (TM4); monkey kidney cells (CV I); African green monkey kidney cells (VERO-76); human cervical carcinoma cells (HELA); canine kidney cells (MDCK); buffalo rat liver cells (BRL 3A); human lung cells (W138); human liver cells (Hep G2, HB 8065); mouse mammary tumor (MMT 060562); TM cells; MRC 5 cells; FS4 cells; and a human hepatoma line (Hep G2). Insect cell lines or human fibroblast cells are also available as suitable host cells. Production of recombinant alpha-mannosidase is obtained using cells transfected with an appropriate nucleic acid construct using techniques known to the skilled person. In particular, the nucleic acid construct may comprise a nucleic acid sequence selected from the group consisting of: i) the nucleic acid sequence set forth in SEQ ID NO: 1; and ii) a nucleic acid sequence coding for a sub-sequence or analogue of the sequence set forth in SEQ ID NO 2 as provided above.
[0091] The cells may preferably be a rLAMAN Chinese Hamster Ovary (CHO) cell line developed specifically for the purpose of producing recombinant enzyme as described in WO 02/099092. A culture of this cell line DSM ACC2549 which was deposited at the DSMZ GmbH, Maschroderweg 1b, D-38124 Braunschweig, Germany for the purpose of patent deposit according to the Budapest treaty on 6 Jun. 2002. This cell may be obtained using the expression plasmid pLamanExpi having the sequence shown in SEQ ID NO 1.
[0092] The process of steps a-c may further comprise the following step: d. A process for purification of recombinant alpha-mannosidase from said cell culture, wherein a fraction of said cell culture comprising recombinant alpha-mannosidase is subjected to chromatography on a resin comprising a multi-modal ligand having a carboxylic acid or sulphonic acid group, as described above.
[0093] In yet another embodiment the cell culture used in the production process is essentially free of any supplements derived from animals, such as cod liver oil supplements. Avoiding the use of such supplements reduces the risk of viral contamination in the final enzyme product.
[0094] In one preferred embodiment of the production process the undiluted harvest of the fed batch or continuous production has a concentration of alpha-mannosidase of at least 0.1 g/L, such as at least 0.2 g/L, 0.3 g/L, 0.4 g/L, preferably at least 0.5 g/L.
[0095] In another embodiment the undiluted harvest of the fed batch or continuous production has an enzyme activity in the range of 3-35 U/mL, such as 5-35 U/mL, 7-35 U/mL, preferably in the range of 10-35 U/mL. It is to be understood that upon further process optimization the enzyme activity of the harvest may become even higher than 35 U/mL.
[0096] The production process may advantageously be performed at a large scale. Thus in one embodiment the process for fed batch or continuous production is performed at a volume of at least 30 L, such as at least 50 L, 75 L, 100 L, 150 L, 200 L, preferably at least 250 L.
[0097] In another embodiment of the present invention a production process as described above is provided, wherein the alpha-mannosidase has a sequence selected from:
[0098] A) the sequence set forth in SEQ ID NO 2
[0099] B) an analogue of the sequence in A
[0100] C) a subsequence of the sequence in A) or B)
[0101] Another embodiment of the present invention is a composition comprising alpha-mannosidase obtainable by the production process described above. Such compositions may in preferred embodiments comprise additional active product ingredients (API), adjuvants, and/or excipients.
[0102] In a third aspect of the present invention a composition is provided comprising purified recombinant alpha-mannosidase, wherein at least 80% of the alpha-mannosidase is present as a 130 kDa glycoprotein.
[0103] In a preferred embodiment the composition comprising purified recombinant alpha-mannosidase is provided wherein the recombinant alpha-mannosidase remains stable in liquid solution for at least 4 days when stored at +5 C. or for at least 24 months when stored at 20 C.
[0104] The currently preferred composition for the formulation buffer solution for the rhLAMAN enzyme product is described below and the achieved stabilities are also listed:
[0105] Na.sub.2HPO.sub.4 3.50 mM (Dibasic sodium phosphate)
[0106] NaH.sub.2PO.sub.4 0.17 mM (Monobasic sodium phosphate)
[0107] Glycine 27 mM
[0108] Mannitol 250 mM
[0109] pH 7.70, 290 mOsm/kg (isotonic solution)
TABLE-US-00001 In-use stability: Stable solution +5 C.-4 days +20 C.-6 hours 20 C.-24 months Freeze Dried +5 C.-24 months
[0110] In another embodiment of the present invention a composition as described above is provided, wherein the alpha-mannosidase has a sequence selected from:
[0111] A) the sequence set forth in SEQ ID NO 2
[0112] B) an analogue of the sequence in A
[0113] C) a subsequence of the sequence in A) or B)
[0114] Another preferred embodiment is the above composition comprising purified recombinant alpha-mannosidase for use as a medicament.
[0115] In a further embodiment the above composition comprising purified recombinant alpha-mannosidase is for use in the treatment of alpha-mannosidosis.
[0116] Yet another embodiment is the use of the above composition comprising purified recombinant alpha-mannosidase for the preparation of medicament for the treatment of alpha-mannosidosis. Another embodiment is a method of treating alpha-mannosidosis and/or reducing or alleviating the symptoms associated with alpha-mannosidosis, said method comprising a step of administering a composition comprising a purified recombinant alpha-mannosidase as provided above to a subject in need thereof.
[0117] It should be noted that embodiments and features described in the context of one of the aspects of the present invention also apply to the other aspects of the invention.
[0118] All patent and non-patent references cited in the present application, are hereby incorporated by reference in their entirety.
[0119] The invention will now be described in further details in the following non-limiting examples.
EXAMPLES
Abbreviations Used
[0120] CIP: Clean In Place
[0121] CV: Column Volume
[0122] Cv: viable cell density
[0123] DF: Diafiltration
[0124] DO: Dissolved Oxygen
[0125] IPA: Isopropanol
[0126] MVC/mL: 10.sup.6 viable cells/mL
[0127] NaPi: Sodium Phosphate
[0128] NaAc: Sodium Acetate
[0129] OD: Optical Density
[0130] EG: ethylene Glycol
[0131] TFF: Tangential Flow Filtration
[0132] TMP: Transmembrane pressure
[0133] UF: Ultrafiltration
Example 1Currently Preferred Overall Purification Procedure
[0134] The purification procedure for obtaining the optimum yields and purities for alpha-mannosidase in the context of the present invention is as described below. Standard conditions for regeneration and cleaning of resins are used, as prescribed for the individual resin (see also examples 2-5). The resins used are available at GE healthcare life sciences and BioRad. [0135] Providing fraction of a harvest from a production of alpha-mannosidase, and clarifying the fraction without significant dilution. Preferably no dilution at all is made. [0136] Performing a capture step involving column chromatography of the above fraction on a resin comprising a multimodal ligand. These resins are selected from the group consisting of: Capto MMC, Capto Adhere, PlasmidSelect Xtra, Capto Blue, Blue Sepharose Fast Flow resin, MEP HyperCel, HEA HyperCel and PPA HyperCel.
[0137] Several washes are performed at pH 4.5-8.5, and the wash buffers are selected from the group consisting of: sodium acetate, potassium acetate, ammonium acetate, sodium phosphate, potassium phosphate, sodium sulphate, potassium sulphate, ammonium sulphate, MES, MOPS, Hepes, sodium borate, tris-HCl, citrate buffer or combinations thereof (buffer group A, hereinafter). In at least one wash however, the washing solution comprises isopropanol and the pH is between pH 4-6. The elution buffer is selected from buffer group A, and the elution solution comprises ethylene glycol. Elution pH is kept at pH 7.0-8.5. [0138] Performing an active intermediate step involving column chromatography of a composition comprising alpha-mannosidase on a hydrophobic interaction resin. These resins are selected from the group consisting of: Butyl-S Sepharose 6 Fast Flow, Butyl Sepharose 4 Fast Flow, Octyl Sepharose 4 Fast Flow, Phenyl Sepharose 6 Fast Flow (high sub) and Phenyl Sepharose 6 Fast Flow (low sub), Butyl Sepharose High Performance, Phenyl Sepharose High Performance.
[0139] Several washes are performed at pH 7-8. The wash buffers are selected from buffer group A. The elution buffer is also selected from buffer group A and elution pH is between pH 7-8. [0140] Performing a passive intermediate step involving column chromatography of a composition comprising alpha-mannosidase on a mixed-mode ion exchange resin to provide a flow-through. These resins are selected from the group consisting of: ceramic hydroxyapatite type I or II (preferably type I) resin, or fluoroapatite. One wash is performed to provide a flow-through at pH 7-8. The wash buffer is selected from buffer group A. [0141] Performing a polishing step involving column chromatography of a composition comprising alpha-mannosidase on an anion exchange resin. These resins are selected from the group consisting of: Q-Sepharose HP, Q-Sepharose FF, DEAE-Sepharose, Capto Q, Uno Q, ANX Sepharose.
[0142] Several washes are performed at pH 7-8. The wash buffers are selected from buffer group A and TRIS-HCl buffer. The elution buffer is also selected from buffer group A and elution pH is kept between pH 7-8. [0143] Performing a virus inactivation step by bringing a solution of the alpha-mannosidase in contact with isopropanol. [0144] Performing a virus removal step using nano-filtration.
[0145] The yields and product components ratios for the purified composition comprising alpha-mannosidase according to the present invention are shown in the below table 1, with comparison to previous methods, wherein:
[0146] Method 1 is: The currently preferred method according to the present invention.
[0147] Method 2 is: Similar to method 1 without a polishing step. It is also without washing steps comprising isopropanol for the capture step and with fewer washes in the active intermediate step, and finally it is without virus inactivation/removal steps.
[0148] Method 3 is: As described in WO 02/099092 (multimodal ligands not used).
TABLE-US-00002 TABLE 1 yields and purities resulting from past and current purification procedures Scale Overall Overall %130 %55 %75 (Culture Method yield purity kDa kDa kDa volume) 1 .sup.70% 99.6% 95.2% 1.5% 2.9% 250 L 2 60-70% 98.2% 92.1% 2.6% 3.5% 30 L 3 70-80% 80% <80% >5% >5% 1 L
[0149] See also example 10 and
Example 2Chromatographic Capture Step Using a Multi Modal Ligand
[0150] Clarified undiluted harvest comprising alpha-mannosidase binds by mixed mode interaction to a multimodal ligand type resin such as Capto MMC as used in this example. Increasing salt and addition of ethylene glycol elutes the product. The capacity of Capto MMC was 260 U/ml resin. The capture stage was performed using the following steps: [0151] Regenerate the column with 1-2 column volumes (CV) of 3M NaCl, pH 10-12 at 300 cm/hr. [0152] Equilibrate with 5 CV of 50 mM sodium phosphate buffer (NaPi), 0.15M NaCl pH 7.5 at 300 cm/hr. [0153] Load clarified, undiluted harvest (conductivity 15 mS/cm) at 300 cm/hr. [0154] Wash 1: 4 CV of equilibration buffer. [0155] Wash 2: 3 CV of 0.95M NaAc, 5% (v:v) isopropanol, pH 4.9 at 300 cm/hr. [0156] Wash 3: 4 CV of equilibration buffer (until stable baseline, 0.06 Au with 5 mm flowcell) of equilibration buffer at 300 cm/hr. [0157] Elute the product with 6 CV of 1.5M NaCl, 40% ethylene glycol in 90 mM NaPi, pH 7.7 at maximum 120 cm/hr. Start collecting when the absorbance increases (around 10 mAu from the new baseline). Collect 4 CV. [0158] Regenerate the column, as above with 3 CV, downward flow direction, maximum 120 cm/hr. [0159] Clean in place (CIP) and sanitize, preferably with upward flow direction, with 3 CV H.sub.2O, 3 CV 1M NaOH (60 minutes contact time), 2-3 CV of phosphate buffer, pH 7, 3 CV 20 mM sodium phosphate+20% ethanol. Store in 20 mM sodium phosphate+20% ethanol.
[0160] Table 2 shows an example of a purification scheme. Table 3 summarizes the step.
TABLE-US-00003 TABLE 2 Capture stage purification scheme: Capto MMC packed in a 13.5 2 ml (27 ml) XK 16 column Total OD 280 Vol. Activity activity divided Yield HCP Step (ml) (U/ml) (U) by 1.8 (%) g/ml Load 439 15 6585 (=244 U/ml resin) Flow through + 1.sup.st 560 ~37 0.6 equilibration (eq) buffer wash 0.95M NaAc + 90 0 5% IPA, pH 4.9 Eq. buffer 101 0.3 30 0.5 Eluate 118 50 5900 2.2 89 28
TABLE-US-00004 TABLE 3 Summary of conditions for Capto MMC capture stage Flow rate Volume Flow Step Buffer (cm/hr) (CV) Direction Regeneration 3M NaCl, pH ~11 300 2 down Equilibration 50 mM NaPi, 150 mM 300 5 down NaCl, pH 7.5 Load Harvest 300 down Wash 1 50 mM NaPi, 150 mM 300 4 down NaCl, pH 7.5 Wash 2 0.95M NaAc, 5% IPA, 300 3 down pH 4.8 Wash 3 50 mM NaPi, 150 mM 300 4 down NaCl, pH 7.5 Elution 90 mM NaPi, 1.5M NaCl, 120 6 down 40% EG, pH 7.7 Regeneration 2M NaCl, pH ~11 120 3 down Flush Water 300 3 up CIP 1M NaOH 300 3 up Conditioning Phosphate buffer (RB to 300 1-3 up decide) Storage 20 mM NaPi + 20% 100 3 up Ethanol
Example 3Chromatographic Intermediate Active Step Using Hydrophobic Interaction
[0161] The product from the capture stage comprising alpha-mannosidase binds by hydrophobic interactions after addition of sodium sulfate to hydrophobic interaction type resins, such as Butyl Sepharose 4 FF as used in this example. Reducing the salt concentration elutes the product. The capacity was 195 U/ml resin. The following steps were used in the intermediate active stage: [0162] Regenerate the column with 1 CV 20 mM sodium phosphate (NaPi) buffer, pH 7.5 at 100 cm/hr. [0163] Equilibrate the column with 5 CV 0.5M Na.sub.2SO.sub.4, 20 mM NaPi, pH 7.5 at 150 cm/hr. [0164] Mix the product pool from step 1 with the same volume 20 mM NaPi, 0.8M Na.sub.2SO.sub.4, pH 7.5 and load it onto the column at 70 cm/hr. The mixing can be performed in-line or maximum 3 hours before loading starts. The 1:1 volume:volume (v:v) mix corresponds to approximately 1.11:1, weight:weight (w:w) (eluate: sodium sulfate buffer). If needed the conditioned load should be filtered through 0.45 m filter (hydrophilic PES or PVDF) before loading. [0165] Wash the column with 3 CV of equilibration buffer at 70 cm/hr to remove ethylene glycol, in addition to host cell proteins, from the previous step. [0166] Wash with 3.5 CV of 20 mM NaPi, 1.2M NaAc, pH 7.5 at 100 cm/hr. [0167] Wash with 3.5 CV of 0.6M NaPi, pH 7.0 at 150 cm/hr. [0168] Elute the product with 4 CV of 60 mM NaPi, pH 7.5 at 150 cm/hr. Collect the peak from the initial increase of absorbance until baseline is reached, 2 CV. [0169] Regenerate the column with 2 CV 20 mM NaPi, pH 7.5 followed by 3 CV H.sub.2O at 150 cm/hr. [0170] Clean and sanitize with 3 CV 1M NaOH (60 min contact time), 1 CV H.sub.2O, 1-3 CV of phosphate buffer and 2 CV 20 mM sodium phosphate+20% ethanol. Store in 20 mM sodium phosphate+20% ethanol.
[0171] Table 4 shows an example of a purification scheme. Table 5 summarizes the step.
TABLE-US-00005 TABLE 4 Intermediate active purification scheme using Butyl Sepharose 4FF packed in a 13.5 cm H 2 cm.sup.2 (27 ml) XK 16 column Total OD 280 Volume Activity activity divided Yield HCP Step (ml) (U/ml) (U) by 1.8 (%) ng/mg Load 236 23 5413 (=200 U/ml resin) Flow through + ~390 0.3 ~100 1.8 eq buffer wash 1.2M NaAc, 95 0.5 48 0.8 pH 7.5 0.6M NaPi, 97 0.2 19 0.3 pH 7.0 Eluate 66 81 5346 3 98 940
TABLE-US-00006 TABLE 5 Summary of conditions for Butyl Sepharose 4FF step Flow rate Volume Flow Step Buffer (cm/hr) (CV) Direction Regeneration 20 mM NaPi, pH 7.5 150 1 down Equilibration 20 mM NaPi, 0.5M sodium 150 5 down sulfate, pH 7.5 Load Conditioned Capto MMC 70 ~6 down eluate Wash 1 20 mM NaPi, 0.5M sodium 70 3 down sulfate, pH 7.5 Wash 2 20 mM NaPi, 1.2M NaAc, 100 3.5 down pH 7.5 Wash 3 0.6M NaPi, pH 7.0 150 3.5 down Elution 60 mM NaPi pH 7.5 150 4 down Regeneration 20 mM NaPi, pH 7.5 150 2 down Flush water 150 3 up CIP 1M NaOH 150 3 up Flush water 150 1 up Conditioning Phosphate buffer (RB to 150 1-3 up decide) Storage 20 mM Na-Pi + 20% 150 3 up Ethanol
Example 4Chromatographic Intermediate Passive Step Using Mixed-Mode Ion Exchange
[0172] Two eluates comprising alpha-mannosidase from the intermediate active step were pooled and mixed 1:1 (weight:weight) with water to reduce the conductivity and loaded onto a mixed-mode ion exchange resin, such as in this example a Ceramic Hydroxyapatite I (CHT I) resin. The product passes without binding, while host cell proteins bind to the column. The flow through, containing the product was collected. The capacity was 550 U/ml resin. The following steps were used in this example of an intermediate passive stage: [0173] Regenerate the column with 2 CV of 0.6M NaPi pH 7.0 at 300 cm/hr. [0174] Equilibrate the column with 5 CV of 60 mM NaPi, pH 7.5 at 300 cm/hr. [0175] Load the conditioned eluate from step 2 at 300 cm/hr and collect the flow through, containing the product. The conductivity and pH of the load will be 10 mS/cm and 7.3, respectively. Collect the flow through, containing the product from an OD increase of 20 mAu until OD is back to 20 mAU, approximately the loading volume and 2 CVs wash. End-of step filter the product pool through 0.45 m hydrophilic PES or PVDF filter. [0176] Wash the column with 4 CV equilibration buffer at 300 cm/hr. [0177] Regenerate the column with 3 CV of 0.6M NaPi, pH 7.0 at 300 cm/hr. [0178] Clean and sanitize with 3 CV 1M NaOH (60 min contact time), 1 CV of 60 mM NaPi, pH 7.5 and 2 CV 20 mM sodium phosphate+20% ethanol. Store in 20 mM sodium phosphate+20% ethanol.
[0179] Table 6 shows an example of a purification scheme. Table 7 summarizes the step.
TABLE-US-00007 TABLE 6 Purification scheme for intermediate passive stage using CHT I packed in a 10 cm 2 cm2 (20 ml) XK 16 column Total OD 280 Volume Activity activity divided Yield HCP Step (ml) (U/ml) (U) by 1.8 (%) ng/mg Load 360 31.6 11390 (=570 U/ml resin) Flow through = 392 27.5 10780 95 ~500 product end-of step filtered 0.5M NaPi 40 0.45 18
TABLE-US-00008 TABLE 7 Summary of conditions for CHT I step Flow rate Volume Flow Step Buffer (cm/hr) (CV) Direction Regeneration 600 mM NaPi, pH 7.0 300 2 down Equilibration 60 mM NaPi, pH 7.5 300 5 down Load Butyl eluate + H.sub.2O 300 down Wash 1 60 mM NaPi, pH 7.5 300 4 down Regeneration 600 mM NaPi, pH 7.0 300 3 down CIP 1M NaOH 300 3 up Conditioning NaPi buffer (RB to 300 1 up decide) Storage 20 mM NaPi + 20% 300 3 up Ethanol
Example 5Virus Inactivation Step
[0180] Virus inactivation may be performed at different stages of the process. In this example the virus inactivation was performed after the intermediate passive step and prior to the polishing step. Virus inactivation of the intermediate passive pool comprising alpha-mannosidase is obtained by 13515 min incubation at 215 C. with 15% isopropanol (1:1 mixture with 30% aqueous isopropanol). The tank can be cooled by a cooling jacket at +4 C. to keep the process at 215 C. Tangential flow filtration (TFF), with 100 kDa polyethersulfone membrane, Screen A (from Millipore or Sartorius) was used to remove the isopropanol and change to sodium phosphate buffer. The following steps were used to inactivate viruses in this example: [0181] Mix the product (flow through) from the intermediate passive step with 30% isopropanol in 60 mM sodium phosphate, 1:1 (v:v), which corresponds to 1:0:94 (w/w). Mix, e.g. by recirculation pumping. The product protein concentration will be 0.3-1 mg/ml. [0182] Incubate the solvent/product pool at room temperature for 13515 min. [0183] Equilibrate the TFF membrane with 60 mM sodium phosphate buffer. [0184] Concentrate the pool to target concentration 2 mg/ml (0.5-3 mg/ml) by ultrafiltration at transmembrane pressure (TMP) 1.1 bar, at 215 C. pressure in =1.4-1.5 bar and pressure out=0.7-0.8 bar. [0185] Exchange 6 volumes by diafiltration against 60 mM sodium phosphate buffer. Start at TMP 1 bar (1.4 bar in/0.6 bar out). After the first volume is exchanged the TMP can be increased to 1.1. [0186] Collect the retentate. Rinse the membrane with 2-3 system volumes of dilution buffer to remove loosely bound product. Collect the rinse together with the retentate. The final target protein concentration is 2 mg/ml (0.5-3 mg/ml). [0187] Clean the membrane with H.sub.2O, followed by 0.5M NaOH (60 min contact time). Store in 0.1M NaOH.
[0188] Table 10 shows the conditions for the virus inactivation/TFF step
TABLE-US-00009 TABLE 10 Summary of conditions for virus inactivation/TFF step Dil. TMP Step Buffer w:w UF DF bar Comment Start 30% IPA/ 1.94 x 135 15 min, RT 70% NaPi Equili- NaPi bration UF ~5x 1.1 Concentrate to (1.5in/ 2 mg/ml 0.7 (0.5-3 mg/ml), out) flux ~100-65 LMH DF NaPi 6x 1.0-1.1 First volume at (1.5in/ lower TMP (1.4in/ 0.7 0.6out), then out) increase to TMP 1.1, flux ~65-100 LMN System NaPi 2 system volumes, wash pool with retentate to target concen- tration 2 mg/ml (0.5-3 mg/ml) Rinse water CIP 0.5-1M NaOH store 0.1M NaOH NaPi = 60 mM sodium phosphate, pH 7.5
Example 6Chromatographic Polishing Step Using Anion Exchange
[0189] The conductivity of the retentate comprising alpha-mannosidase from the intermediate passive stage, was reduced by dilution 6 times with conditioning buffer (20 mM Tris-HCl, 10 mM NaCl, 75 mM mannitol, 0.005% Tween 80, pH 7.5) in order to bind by ionic interaction onto a anion exchange resin, such as in this example a quarternary ammonium high performance strong anion exchange resin (Q Sepahrose HP resin). The retentate was either diluted directly before loading or by in-line dilution. The product was eluted, into a container prefilled with 1CV of elution buffer, by addition of sodium chloride. The capacity is 400 U/ml resin. The following steps were used for the polishing stage in this example: [0190] Regenerate the column with 1 CV 50 mM NaPi, 1M sodium chloride, pH 7.5 at 120 cm/hr. [0191] Equilibrate the column with 5 CV 20 mM Tris-HCl, 10 mM sodium chloride, pH 7.5 at 120 cm/hr. [0192] Load the diluted retentate from step 4 at 120 cm/hr. [0193] Wash the column with 5 CV of equilibration buffer and 1 CV of 20 mM sodium phosphate, pH 7.5 at 120 cm/hr. [0194] Elute the product with 4 CV of 50 mM sodium phosphate, 0.2M sodium chloride, pH 7.5 at 120 cm/hr into the prefilled (1 CV of elution buffer) container. Collect the peak from the initial increase (start collect at 10-20 mAu) of absorbance until 30-50 mAu (2 mm flowcell), 0.5-1.5 CV. [0195] Regenerate the column with 3 CV 50 mM NaPi, 1M sodium chloride, pH 7.5 at 120 cm/hr. [0196] Clean and sanitize with 3 CV 1M NaOH (60 min contact time) and 3 CV 10 mM NaOH. Store in 10 mM NaOH.
[0197] Table 8 shows an example of a purification scheme. Table 9 summarizes the step.
TABLE-US-00010 TABLE 8 Example of purification scheme for polishing step using Q Sepharose HP resin 19 cm 2 cm.sup.2 (38 ml) Total OD 280 Volume Activity activity divided Yield HCP Step (ml) (U/ml) (U) by 1.8 (%) ng/mg Load 1095 9.6 10500 (=276 U/ml resin) Flow ~1300 0.07 ~90 ~1 through 20 mM 75 1.7 127 ~1 sodium phosphate Wash Eluate 69 145 10024 5.3 95.5 (=49 ml eluate + 20 ml prefill
TABLE-US-00011 TABLE 9 Summary of conditions for Q Sepharose HP step Flow rate Volume Flow Step Buffer (cm/hr) (CV) Direction Regeneration 50 mM NaPi, 1M NaCl pH 120 1 down 7.5 Equilibration 20 mM Tris-HCl, 10 mM 120 5 down NaCl pH 7.5 Load Conditioned retentate step 4 120 down Wash 20 mM Tris-HCl, 10 mM 120 5 down NaCl pH 7.5 Wash 20 mM NaPi, pH 7.5 120 1 down Elution into 50 mM NaPi, 0.2M NaCl, 120 4 down prefilled bag pH 7.5 Regeneration 50 mM NaPi, 1M NaCl pH 120 3 down 7.5 CIP 1M NaOH 120 3 up Storage 10 mM NaOH 300 3 up
Example 7Virus Reduction Step
[0198] Virus reduction may be performed at different stages of the process. In this example the virus reduction was performed after the polishing step. The eluate from the polishing step is nanofiltered, after 0.1 m pre-filtration, through a Planova 15N filter. The following steps were used: [0199] The eluate from the polishing step is pre-filtered through a 0.1 m filter. The filter is rinsed with a small volume of 50 mM sodium phosphate, 0.2M sodium chloride, pH 7.5 to remove loosely bound product. [0200] The eluate is filtered at pressure 0.8 bar, at room temperature. The filtration is followed by a post wash of approximately three Planova 15 system volumes with 50 mM sodium phosphate, 0.2M sodium chloride, pH 7.5.
Example 8Formulation and Storage
[0201] Tangential flow filtration (TFF), with a 100 kDa, Screen A, polyethersulfone membrane (Sartorius or Millipore) changes the buffer to formulation buffer. The tank can be cooled by a cooling jacket at +4 C. to keep the process at 215 C. The estimated capacity is 100 l/m.sup.2. The following steps were used for formulation and storage: [0202] Equilibrate the membrane 3.5 mM Na.sub.2HPO.sub.4, 0.17 mM NaHPO.sub.4, 250 mM mannitol, 27 mM glycine, pH 7.7 (formulation buffer). [0203] Dilute the purified product comprising alpha-mannosidase with approximately 1 volume formulation buffer to target concentration 2-3 mg/ml. If the protein concentration is low in the product it is possible (but not necessary) to concentrate to 4-6 mg/ml to reduce the volume before dilution with formulation buffer. [0204] Concentrate twice to target concentration 6 mg/ml by ultrafiltration at TMP 0.8 and at 215 C. [0205] Exchange 6 volumes by diafiltration against formulation buffer at TMP 0.8, 215 C. [0206] Concentrate 1.5 times by ultrafiltration and collect retentate. Rinse the membrane with 1 system volume of formulation buffer to remove loosely bound product. Collect the rinse together with the retentate. An alternative is to measure OD 280 in the rinse and pool only if it contains product. The final target protein concentration is 72 mg/ml. [0207] Clean the membrane with H.sub.2O, followed by 0.5M NaOH (60 min contact time). Store in 0.1M NaOH.
TABLE-US-00012 TABLE 11 Summary of conditions for the formulation TFF step UF/DF dil. Target conc. TMP Step Buffer factor (mg/ml) (bar) Comment Dilution of Formulation 2 2-3 If protein conc. is step 6 buffer <4 mg/ml in step 6 product product a UF step can be introduced before dilution Equilibration Formulation buffer UF 2 6 2 0.8 1.1 bar in/0.5 bar out DF Formulation 6 2 6 2 0.8 buffer UF ~1.5 7 2 Collect retentate System wash Formulation 1 system 7 2 if pooled Collect and pool with buffer volume with retentate retentate if protein Rinse water CIP 0.5-1M NaOH store 0.1M NaOH
[0208] The product was diluted to 5 mg/ml and sterile filtered. The filtered drug substance is filled into bottles and frozen.
Example 9Fed Batch Cultivation Process for Alpha Mannosidase
[0209] After cell thaw, the cells were expanded in shake flasks, 10 L seed bioreactor and 50 L seed bioreactor before their transfer to a production bioreactor (250 L). At inoculation day of the production bioreactor, the cell density in the 50 L seed bioreactor was between 2 and 2.5 MVC/mL. The cells were inoculated in the production reactor from the seed bioreactor at a cell density of 0.5 MVC/mL so that the cell suspension volume was 100 L when the inoculation was completed. Inoculation day is called day 0, the day after is called day 1, and so on. From day 1 to the end of the run, feed medium was added daily in boost according to a predefined rate (see below). From day 1 to the end of the run, glutamine and glucose were added daily in boost according to predefined rates and rules (see below). When the viable cell density >2.2 MVC/mL or at day 3, whatever came first, the temperature was decreased to the production temperature
TABLE-US-00013 TABLE 12 Actual temperatures and experimental conditions. DO (%) 40 5 pH day 0 to day 2 (*) between 6.60 and 6.95 pH day 3 to end 6.9 0.05 Temperature ( C.) A) .fwdarw. shifted to B) when the A) 36.5 0.5 temperature shift condition is fulfilled .fwdarw. B) 31.0 0.5 Temperature shift condition Cv 2.2 MVC/mL or day 3 (whatever comes first) Agitation rate (rpm) to be adjusted according previous suggestion: 45 rpm, shear stress experience of the production bioreactor tolerance of the cells supposed to be normal for CHO cells at 31 C. (not tested) Inoculation viable cell density, (MVC/mL), at day 0 0.5 0.1 Max pCO.sub.2 in liquid phase level not known, tentatively 18 kPa Feed of feed medium, glutamine and glucose See text below Glucose target in culture (mM) 6 [5.5 9.0] Glutamine target in culture (mM) 2 mM D1-D3, 1 mM D4 and forward Harvest condition day 18-21 or viability <65%, whatever comes first Working volume (L): initial .fwdarw. final 100 .fwdarw. about 200 Alkali added for pH control 0.5M Na.sub.2CO.sub.3 Dilution of inoculate cell broth from seed bioreactor to 4 production bioreactor after completion of inoculation larger than Criteria of the expanded cells in the seed bioreactor at the inoculation of the production bioreactor Minimal cell density (MVC/mL) 2.0 Maximal cell density (MVC/mL) 2.5 Number of millions viable cells 44 to 56 Viability 93% Batch cultivation in seed bioreactor 50 L before 76 inoculation of production bioreactor not longer than (hours) (*) Between day 0 and day 2, only CO.sub.2 was automatically added by pH control. Alkali was not added unless pH would be <6.60. [0210] Base Medium
[0211] ACF medium (ExCell302, SAFC) supplemented with 2 mM glutamine and containing 11.1 mM (2 g/L) glucose. The base medium without glutamine can be transferred into the production bioreactor up to 3 days and stored at 36.5 C. i.e. during the sterility test of the bioreactor. Otherwise, the medium is stored at 4 C. [0212] Feed Media
[0213] The feed medium, E35, was 35% CHO CD Efficient Feed B (InVitrogen cat nr. SKU# A10240-01) feed concentrate diluted in ACF medium without glutamine and containing 11.1 mM glucose. Feed medium was stored dark at 4 C. The feed medium can stand dark during up to 96 hours, i.e. four days, at room temperature during the cultivation.
TABLE-US-00014 TABLE 13 Feed medium volume added per day Days 0 1 to 5 6 to 16 Volume added/day in (L) 0 12 4 [0214] Additives
[0215] a) Stock solution of 2500 mM glucose. b) Stock solution of 200 mM glutamine. c) Alkali 0.5M Na.sub.2CO.sub.3. [0216] Delivery of Feed Medium, Glucose and Glutamine
[0217] Feed medium was pumped daily in boost. Glucose and glutamine were added daily to maintain their concentrations within the given targets by adding, in boost, stock solutions of glucose and glutamine in amounts according to below.
Glutamine Addition Rules:
[0218] Day 1 to day 3: add a volume of glutamine stock solution so that the glutamine concentration in the bioreactor is 2 mM. [0219] From day 4: add a volume of glutamine stock solution so that the glutamine concentration in the bioreactor is 1 mM.
Glucose Addition Rules:
[0220] Day 0 to day 8: no addition of glucose stock solution [0221] From day 9, if glucose concentration in production bioreactor 8 mM, add a volume of glucose stock solution so that the glucose concentration in the bioreactor is 8 mM.
Process Overview:
[0222]
TABLE-US-00015 TABLE 15 Day by day overview of cultivation process: Day Action 3 or Sterilization of the bioreactor and filling with ACF medium without or glutamine 2 in volume 75 L or minimal volume to cover the probes (in case this is larger than 75 L) Calibration of DO probe 0 a) Cell count of expanded cells in exponential growth from 50 L seed bioreactor and fulfilment of criteria for inoculation b) Removal of ACF medium from production bioreactor if volume is >75 L. Stabilization of medium in production bioreactor at pH and temperature set points during at last 45 min and addition of glutamine to obtain a final glutamine concentration of 2 mM in 100 L medium. The glutamine present in the cell broth from the 50 L seed bioreactor is not taken into account. c) Transfer of cell broth from 50 L seed bioreactor to production bioreactor d) Adjustment of volume to 100 L cell suspension in production bioreactor e) Stabilization for 1 hr (between 45 and 2 hrs 30) and sample for cell count, pH and metabolism parameters 1 to 2 Cell count, sample, feed of feed medium, feed of glucose and glutamine pH controlled between 6.60 and 6.95 with automatic addition of CO2 (avoid alkali addition) 3 Cell count, sample, feed of feed medium, feed of glucose and glutamine pH controlled at set point 6.9 0.05 with automatic addition of alkali or CO.sub.2 Decrease of temperature to 31 C. when either: 1) The viable cell density has reached 2.2 MVC/mL or 2) On day 3 4 to 17 Cell count, sample, feed of respective feed media, feed of glucose and glutamine 18-21 or Harvest viability <65%
Example 10Characterization of the Purified Product Comprising Alpha-Mannosidase
[0223] Table 16 below shows how the purification scheme of the present invention provided alpha-mannosidase with a high proportion of the 130 kDa glycoprotein species, as compared to the breakdown products of 75 and 55 kDa respectively. It is also shown how a 250 L process using a 4-step purification process with improved wash steps for both the capture step comprising multimodal ligands and the intermediate active step as well as a Q sepharose HP polishing step performed better than the 30 L process using a 3 step process with respect to both yield, overall purity and yield of the 130 kDa species.
TABLE-US-00016 TABLE 16 Yields of alpha-mannosidase species in purified product Percentages of individual alpha- Purification Scale, method mannosidase species after purification and purity 130 kDa 55 kDa 75 kDa 250|4-step, 70% yield, purity = 95.2% 1.5% 2.9% 99.6% 30|3-step, 60-70% yield, purity = 92.1% 2.6% 3.52% 98.2%
[0224] The distribution of species is seen in HPLC diagram of
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