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Cohen N, Simon I, Hazan O, Tal A, Tzadok H, Levin L, Girshengorn M, Mimran LC, Natan N, Baruhi T, David AB, Rosen O, Shmaya S, Borni S, Cohen N, Lupu E, Kedmi A, Zilberman O, Jayson A, Monash A, Dor E, Diamant E, Goldvaser M, Cohen-Gihon I, Israeli O, Lazar S, Shifman O, Beth-Din A, Zvi A, Oren Z, Makovitzki A, Lerer E, Mimran A, Toister E, Zichel R, Adar Y, Epstein E. Enhanced production yields of rVSV-SARS-CoV-2 vaccine using Fibra-Cel ® macrocarriers. Front Bioeng Biotechnol 2024; 12:1333548. [PMID: 38449674 PMCID: PMC10915211 DOI: 10.3389/fbioe.2024.1333548] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/05/2023] [Accepted: 02/02/2024] [Indexed: 03/08/2024] Open
Abstract
The COVID-19 pandemic has led to high global demand for vaccines to safeguard public health. To that end, our institute has developed a recombinant viral vector vaccine utilizing a modified vesicular stomatitis virus (VSV) construct, wherein the G protein of VSV is replaced with the spike protein of SARS-CoV-2 (rVSV-ΔG-spike). Previous studies have demonstrated the production of a VSV-based vaccine in Vero cells adsorbed on Cytodex 1 microcarriers or in suspension. However, the titers were limited by both the carrier surface area and shear forces. Here, we describe the development of a bioprocess for rVSV-ΔG-spike production in serum-free Vero cells using porous Fibra-Cel® macrocarriers in fixed-bed BioBLU®320 5p bioreactors, leading to high-end titers. We identified core factors that significantly improved virus production, such as the kinetics of virus production, the use of macrospargers for oxygen supply, and medium replenishment. Implementing these parameters, among others, in a series of GMP production processes improved the titer yields by at least two orders of magnitude (2e9 PFU/mL) over previously reported values. The developed process was highly effective, repeatable, and robust, creating potent and genetically stable vaccine viruses and introducing new opportunities for application in other viral vaccine platforms.
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Affiliation(s)
- Noam Cohen
- Department of Biotechnology, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Irit Simon
- Department of Biotechnology, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Ophir Hazan
- Department of Biotechnology, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Arnon Tal
- Department of Biotechnology, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Hanan Tzadok
- Department of Biotechnology, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Lilach Levin
- Department of Biotechnology, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Meni Girshengorn
- Department of Biotechnology, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Lilach Cherry Mimran
- Department of Biotechnology, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Niva Natan
- Department of Biotechnology, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Tzadok Baruhi
- Department of Biotechnology, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Alon Ben David
- Department of Biotechnology, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Osnat Rosen
- Department of Biotechnology, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Shlomo Shmaya
- Department of Biotechnology, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Sarah Borni
- Department of Biotechnology, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Noa Cohen
- Department of Biotechnology, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Edith Lupu
- Department of Biotechnology, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Adi Kedmi
- Department of Biotechnology, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Orian Zilberman
- Department of Biotechnology, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Avital Jayson
- Department of Biotechnology, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Arik Monash
- Department of Biotechnology, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Eyal Dor
- Department of Biotechnology, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Eran Diamant
- Department of Biotechnology, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Michael Goldvaser
- Department of Organic Chemistry, Israel Institute for Biological, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Inbar Cohen-Gihon
- Department of Biochemistry and Molecular Genetics, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Ofir Israeli
- Department of Biochemistry and Molecular Genetics, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Shirley Lazar
- Department of Biochemistry and Molecular Genetics, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Ohad Shifman
- Department of Biochemistry and Molecular Genetics, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Adi Beth-Din
- Department of Biochemistry and Molecular Genetics, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Anat Zvi
- Department of Biochemistry and Molecular Genetics, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Ziv Oren
- Department of Biochemistry and Molecular Genetics, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Arik Makovitzki
- Department of Biotechnology, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Elad Lerer
- Department of Biotechnology, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Avishai Mimran
- Department of Biotechnology, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Einat Toister
- Department of Biotechnology, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Ran Zichel
- Department of Biotechnology, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Yaakov Adar
- Department of Biotechnology, Israel Institute for Biological Research, Ness-Ziona, Israel
| | - Eyal Epstein
- Department of Biotechnology, Israel Institute for Biological Research, Ness-Ziona, Israel
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