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Enhancing nanofiltration efficiency in mAb production process

Cancer is the second-leading cause of death worldwide, with nearly 10 million people dying yearly. In this blog, we look at two novel approaches that have emerged as effective in treating cancer—induced proximity-based drugs and precision medicines.

Induced proximity-based drugs

Targeted protein degradation
Induced proximity-based drugs pertain to a new wave of multi-specific medicines that promise to harness the principle of “induced proximity” using innate biological mechanisms (effectors) to drug “undruggable” targets. PROteolysis Targeting Chimeras (PROTACs) have garnered much attention recently for their ability to exploit the cell’s own degradation machinery (ubiquitin-proteasome system) to degrade target proteins irreversibly.

One important benefit of PROTAC compared to small molecules is its catalytic mechanism of action in inducing the degradation of the target protein. PROTACs have also shown success and remarkable biological responses across challenging and non-druggable targets. Not only is this novel strategy enabling the development of more potent and selective treatments for cancer and other intractable diseases, but it is also unlocking parts of the proteome that have traditionally been considered “undruggable”.

Syngene has acquired considerable expertise in induced proximity as a treatment mode for cancer. We offer Discovery expertise from target identification and validation to the identification of a development candidate. Our Formulation services include diverse approaches to ensure the bioavailability of your PROTAC using technologies such as nanoemulsion, nanosuspension,  spray-drying, etc.

Syngene’s end-to-end expertise in PROTAC

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Chemical Development Formulation Analytical Development Clinical Development

Targeted protein stabilization

Another upcoming area is targeted protein stabilization (TPS) — a targeted therapy approach to reverse intractable disease conditions. For example, tumor suppressors for cancer (e.g., TP53, CDKN1A, CDN1C, BAX) would benefit from a targeted protein stabilization (TPS) strategy rather than degradation. Unlike degradation, targeted protein stabilization is enabled through a small-molecule recruiter of a deubiquitinase (DUB) linked to a protein-targeting ligand to form a chimeric molecule. This action induces the deubiquitination and stabilization of the protein of interest.

Syngene has developed expertise in this novel approach by focusing on discovering covalent ligands for specific deubiquitinases. When linked to the appropriate protein-targeting ligand, the covalent ligand stabilizes a specific target protein – the so-called DUBTAC platform.

Precision medicine

Precision medicines promise to provide treatments that suit specific patient populations rather than a one-size-fits-all approach, where treatments are developed with little consideration for individual differences.

CAR T-cell therapy (a form of personalized medicine therapy) combines cellular, gene, and immune therapy. The most common procedure for CAR T-cell therapy starts with the extraction of T cells from the patient being treated, a process called leukapheresis. The T cells are then genetically modified to express a CAR molecule and expand. Finally, they are injected back into the patient, ready to fight the tumor.

Syngene has acquired significant expertise in precision medicines (especially for cancer), working with large pharma clients and helping new biotechs rapidly scale their programs. Our capability lies in two key areas –– molecularly targeted therapy and immunotherapy.

We have a comprehensive suite of services across NGS, cell Line engineering (CRISPR-Cas9), CAR-T proof of principle studies (autologous and allogeneic), and In-vivo oncology models (PDX/CDX/Syngeneic/Humanized). Syngene also offers extensive services across customized reagent generation, antibody development [monoclonal/bispecific/tri-specific/ antibody-drug conjugates (ADCs)], cell line development, and In-vivo PK studies. We have particular expertise in modeling head and neck cancer, with our unique PDX repository of 100+ patient tumour samples.

 Syngene’s rich suite of Precision Medicine capabilities

The context

Nanofiltration is a highly effective viral clearance method in mAb manufacturing, primarily based on size exclusion. An essential part of validating the efficacy of the nanofiltration step are virus spiking studies to ensure the nanofiltration process can reliably remove viruses and meet regulatory requirements for product safety.

The requirement

A major pharmaceutical company was facing challenges in the nanofiltration step of their mAb production process. During virus spiking at 1% – 0.5% of the load volume, they encountered reduced filtration efficiency and flux decay. These issues affected the overall performance of the nanofiltration step, including increasing operational costs due to the need for frequent filter changes.

The pharma company decided to partner with Syngene to address these problems. Their goal was to improve the efficiency of the nanofiltration process in order to achieve viral clearance and reduce operational costs

Challenges posed by the nanofiltration process

  • Low protein concentration: Low protein concentration passing through the membrane resulting in reduced filtration efficiency.
  • Filter flux decay: High flux decay during protein processing affecting filter performance.
  • Low virus clearance efficiency: Need to ensure effective virus clearance while maintaining high throughput.
  • Compatibility issues: Adapting the spike percentage so that it was compatible with the filter, protein matrix, and virus concentration.

The solution

Our team approached the problem by focusing on optimizing the nanofiltration process. The solution involved a multi-step methodology.

  1. Optimization of viral load: Our Viral Testing team adjusted the viral load used in the spiking studies to a level that ensured high throughput while maintaining effective virus clearance. This was crucial for overcoming the limitations of low protein concentrations and improving filter performance.
  2. Adjustment of spike percentage: By decreasing the spike percentage in the suspension, we enhanced compatibility with the filter and protein matrix. This adjustment was critical for minimizing flux decay and maintaining effective virus clearance.
  3. Enhanced filter compatibility: We carefully matched the filter, protein matrix, and virus concentration to improve overall filtration efficiency. This included selecting filters with optimal characteristics for handling the adjusted spike percentage.
  4. Implementation and monitoring: We implemented the process in a controlled manner with continuous monitoring to ensure the flux decay remained low and the virus aggregates also remained controlled. Real-time data was used to make necessary adjustments and optimize performance.

Impact and results

After implementing our solution, the client successfully achieved the desired target throughput with flux decay levels at under 40%. The virus aggregates were effectively controlled, resulting in a more efficient and cost-effective nanofiltration process. The optimized process enabled the client to operate at higher flow rates, while maintaining effective virus clearance throughout the process. The new process also required fewer filter changes, significantly reducing overall costs.

Impact and results

The client is considering further collaboration with Syngene to explore additional optimizations and innovations in their manufacturing processes. Our expertise continues to be a key driver in advancing the client’s production capabilities and ensuring continued success in drug manufacturing.

Our ongoing capability and capacity expansion in biologics have established Syngene as one of the largest CRDMOs in India. As a trusted biologics partner, we have delivered 100 commercial batches in the last two years. Our track record of over 250 GMP batches, 150+ projects, and support for over 25 INDs across biologics modalities is a testament to our expertise

To know more about our Viral Testing and Clearance services, contact our experts

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