1. Developing a manufacturing process to deliver a cost effective and stable liquid human rotavirus vaccine
- Author
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Prashant Kumar, Julie E Bines, Pim Velthof, Christopher Yallop, Ahd Hamidi, Sangeeta B. Joshi, Swathi R. Pullagurla, David B. Volkin, Alfred Luitjens, Menzo J. E. Havenga, Angelique A. C. Lemckert, Femke Hoeksema, Wilfried A.M. Bakker, and Gert Gillissen
- Subjects
Rotavirus ,Malawi ,HP-SEC, High Performance Size-Exclusion Chromatography ,Cost-Benefit Analysis ,ICH, International Council for Harmonisation of Technical Requirements for Pharmaceuticals for Human Use ,medicine.disease_cause ,CDAI, Cell Density at Infection ,USP, Up-Stream Processing ,0302 clinical medicine ,Chlorocebus aethiops ,GAVI, Global Alliance for Vaccines and Immunization ,030212 general & internal medicine ,Child ,Cost–benefit analysis ,Manufacturing process ,Vaccination ,FFA, Focus Forming assay ,UNICEF, United Nations Children's Fund ,Dose-ranging study ,COGs, Cost of Goods ,Rotavirus vaccine ,USD, United States Dollar ,LIC, Low Income Countries ,Infectious Diseases ,Molecular Medicine ,Stable liquid formulation ,DOE, Design of Experiments ,DS, Drug Substance ,medicine.medical_specialty ,qPCR, Quantitative Polymerase Chain Reaction ,030231 tropical medicine ,DP, Drug Product ,DSP, Down-Stream Processing ,Vaccines, Attenuated ,Article ,WHO, World Health Organization ,Rotavirus Infections ,03 medical and health sciences ,medicine ,Animals ,Humans ,HBGA, Histo-Blood Group Antigen ,LLOQ, Lower Level Of Quantification ,Dosing ,Intensive care medicine ,Vero Cells ,IU, International Unit ,General Veterinary ,General Immunology and Microbiology ,business.industry ,Cost-of-goods modelling ,Public Health, Environmental and Occupational Health ,Rotavirus Vaccines ,Infant ,ELISA, Enzyme-Linked Immuno-Sorbent Assay ,Oral rotavirus vaccine ,Vaccine efficacy ,FFU, Focus Forming Units in Focus Forming assay ,CCID50, Cell Culture Infectious Dose 50% ,Indonesia ,MOI, Multiplicity of Infection ,Fixed bed bioreactor ,BSA, Bovine Serum Albumin ,ORV, Oral Rotavirus Vaccine ,business ,MVS, Master Virus Seed - Abstract
Highlights • A low-cost manufacturing process for a neonatal rotavirus vaccine was developed. • The formulation process developed resulted in a stable liquid vaccine at 2–8 °C. • No pretreatment of vaccinees with antacid needed before oral administration. • Tech. transfer package includes manufacturing, formulation, assays and COGs model., Despite solid evidence of the success of rotavirus vaccines in saving children from fatal gastroenteritis, more than 82 million infants worldwide still lack access to a rotavirus vaccine. The main barriers to global rotavirus vaccine coverage include cost, manufacturing capacity and suboptimal efficacy in low- and lower-middle income countries. One vaccine candidate with the potential to address the latter is based on the novel, naturally attenuated RV3 strain of rotavirus, RV3-BB vaccine administered in a birth dose strategy had a vaccine efficacy against severe rotavirus gastroenteritis of 94% at 12 months of age in infants in Indonesia. To further develop this vaccine candidate, a well-documented and low-cost manufacturing process is required. A target fully loaded cost of goods (COGs) of ≤$3.50 per course of three doses was set based on predicted market requirements. COGs modelling was leveraged to develop a process using Vero cells in cell factories reaching high titers, reducing or replacing expensive reagents and shortening process time to maximise output. Stable candidate liquid formulations were developed allowing two-year storage at 2–8 °C. In addition, the formulation potentially renders needless the pretreatment of vaccinees with antacid to ensure adequate gastric acid neutralization for routine oral vaccination. As a result, the formulation allows small volume dosing and reduction of supply chain costs. A dose ranging study is currently underway in Malawi that will inform the final clinical dose required. At a clinical dose of ≤6.3 log10 FFU, the COGs target of ≤$3.50 per three dose course was met. At a clinical dose of 6.5 log10 FFU, the final manufacturing process resulted in a COGs that is substantially lower than the current average market price, 2.44 USD per dose. The manufacturing and formulation processes were transferred to BioFarma in Indonesia to enable future RV3-BB vaccine production.
- Published
- 2021