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1 Educational Web Seminar “Challenges and Problem-Solving in Cell Therapy Product Development” Thursday, September 25, 2014 12:00 PM 12:00 PM –– 1:30 PM ET 1:30 PM ET Ann Leen, PhD Associate Professor, Department of Pediatrics Center for Cell and Gene Therapy Baylor College of Medicine Claudio Brunstein, MD, PhD Associate Professor University of Minnesota University of Minnesota Derek Hei, PhD Director Waisman Biomanufacturing University of Wisconsin-Madison Today’s web seminar presentation slides are available publicly at www.pactgroup.net CE Credit and certificates of attendance provided upon request The Accreditation Council for Continuing Medical Education (ACCME) is the governing body that accredits AABB to provide continuing medical education credits for physicians. In accordance with the ACCME Standards for Commercial Support, AABB implemented mechanisms, prior to the planning and implementation of this CME/CEU activity, to identify and resolve conflicts of interest for all individuals in a position to control content of this CME/CEU activity. Faculty Disclosure Nature of Relationship Manufacturer/Provider Ann Leen, PhD None Speaker N/A Claudio Brunstein, MD, PhD None Speaker N/A Claudio Brunstein, MD, PhD None Derek Hei, PhD None Speaker N/A Debbie Wood None Planning Committee PACT Staff N/A David Styers None Planning Committee PACT Staff N/A Karin Quinnan None Planning Committee PACT Staff N/A Laarni Ibenana None Planning Committee PACT Staff N/A Holly Baughman None Planning Committee PACT Staff N/A Sharon Moffett None AABB Staff N/A Tola Cocker None AABB Staff N/A

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Page 1: Educational Web Seminar “Challenges and Problem-Solving in ...pactgroup.net/system/files/092514_webinar_handouts.pdf · Today’s web seminar presentation slides are available publicly

1

Educational Web Seminar

“Challenges and Problem-Solving in Cell Therapy Product Development”

Thursday, September 25, 201412:00 PM 12:00 PM –– 1:30 PM ET1:30 PM ET

Ann Leen, PhDAssociate Professor, Department of Pediatrics

Center for Cell and Gene TherapyBaylor College of Medicine

Claudio Brunstein, MD, PhDAssociate Professor

University of MinnesotaUniversity of Minnesota

Derek Hei, PhDDirector

Waisman BiomanufacturingUniversity of Wisconsin-Madison

Today’s web seminar presentation slides are available publicly at www.pactgroup.net

CE Credit and certificates of attendance provided upon request

The Accreditation Council for Continuing Medical Education (ACCME) is the governing body thataccredits AABB to provide continuing medical education credits for physicians. In accordance with theACCME Standards for Commercial Support, AABB implemented mechanisms, prior to the planning andimplementation of this CME/CEU activity, to identify and resolve conflicts of interest for all individualsin a position to control content of this CME/CEU activity.

Faculty Disclosure Nature of Relationship Manufacturer/ProviderAnn Leen, PhD None Speaker N/A

Claudio Brunstein, MD, PhD None Speaker N/AClaudio Brunstein, MD, PhD None p /

Derek Hei, PhD None Speaker N/A

Debbie Wood None Planning Committee PACT Staff N/A

David Styers None Planning Committee PACT Staff N/A

Karin Quinnan None Planning Committee PACT Staff N/A

Laarni Ibenana None Planning Committee PACT Staff N/A

Holly Baughman None Planning Committee PACT Staff N/A

Sharon Moffett None AABB Staff N/A

Tola Cocker None AABB Staff N/A

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In this web seminar, speakers will discuss manufacturing challenges faced in various points along the development pathway

of a cellular therapy clinical product. Challenges will be highlighted in both the pre-clinical aspects of processhighlighted in both the pre clinical aspects of process

development and in the evolution of preparing a product for use in clinical trials. Speakers will share challenges and successes

encountered with products they were involved with developing.

Inclusion of companies in this web seminar does not indicate endorsement by either the speakers or PACT nor is it meant to implyspeakers or PACT, nor is it meant to imply that their products or services are superior

to those of other companies.

Virus‐specific T cells post‐transplant

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Viral infections post‐transplant

• 40% deaths after alternative donor transplant due to viral infections

• Antiviral drugsAntiviral drugs –Costly–Significant side effects –Often ineffective

• Alternative - Adoptive T cell transfer

1

Blood draw

SCT

donor

Adoptive T cell transfer

1

Blood draw

T cells 

SCT

donor

Adoptive T cell transfer

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1

Blood draw

Antigen  Specificity

2

T cells 

SCT

donor

Adoptive T cell transfer

T‐cell product generation

3

1

Blood draw

Antigen  Specificity

2

T cells 

SCT

donor

Adoptive T cell transfer

T‐cell product generation

3

Infusion4

SCT

recipient

Immunotherapy for viral infections

• Virus-specific T cells as prophylaxis and treatment–EBV–Adv/EBV (bivirus)–Adv/EBV/CMV (trivirus)

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Trivirus VST generation

6 wkPBMC EBV LCL

B95-8 EBV virus

6 wk

Trivirus VST generation

6 wkPBMC EBV LCL

B95-8 EBV virus

6 wk

Ad5f35pp65 vector

PBMC

6 wkPBMC EBV LCL

B95-8 EBV virus

Ad5f35pp65 transduced EBV LCL

Ad5f35pp65 vector

Trivirus VST generation

6 wk

TrivirusCTL

Restimulation

+IL2

6 wk

Ad5f35pp65 vector

PBMC

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6 wkPBMC EBV LCL

B95-8 EBV virus

Ad5f35pp65 transduced EBV LCL

Ad5f35pp65 vector

PACT Project C001

Trivirus VST generation

6 wk

TrivirusCTL

Restimulation

+IL2

6 wk

Ad5f35pp65 vector

PBMC

• In vitro expanded donor-derived virus-specific T cells targeting Adv, EBV, CMV

–Safe

Clinical Outcome Summary –Donor‐specific setting

–Safe–Reconstituted antiviral immunity for

EBV, CMV and Adv–Effective in clearing disease–Considerable expansion in vivo

Leen et al, Nat Med. 2006Leen et al, Blood. 2009

1

Blood draw

Antigen  Specificity

2

T cells 

SCT

donor

Problems

#1

T‐cell product generation

3

Infusion4

SCT

recipient

#1

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7

1

Blood draw

Antigen  Specificity

2

T cells 

SCT

donor

Problems

#1

#2

T‐cell product generation

3

Infusion4

SCT

recipient

#1

Addressing Problem #1

Manufacturing limitations

Addressing Problem #1

Manufacturing limitations

Reduce cost‐ Reduce cost

‐ Reduce complexity

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Cost

6 wkPBMC EBV LCL

B95-8 EBV virus

Ad5f35pp65 transduced EBV LCL

Ad5f35pp65 vector

6 wk

TrivirusCTL

Restimulation

+IL2

6 wk

Ad5f35pp65 vector

PBMC

EBV LCL

Ad5f35pp65

Reduce cost:Replace virus/vector with peptides

EBV LCL

Ad5f35pp65

Overlapping peptide libraries

Reduce cost:Replace virus/vector with peptides

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9

EBV LCL

Ad5f35pp65

Overlapping peptide libraries

Reduce cost:Replace virus/vector with peptides

Target antigens‐ EBV‐ EBNA1, LMP2, BZLF1‐ CMV‐ IE1, pp65‐ Adv‐ Hexon, Penton‐ BK‐ Large T, VP1‐ HHV6‐U11, U14, U90

Addressing Problem #2

Manufacturing limitations

R d t tid √‐ Reduce cost – peptides √

‐ Reduce complexity

Complexity

day 12 – IL2 feed

day 0 – CTL initiation 2.4 x 107

day 9 - restim 2 x 107

day 16-harvest and reseed 6 x 107

day 20 – split + IL2 feed

day 23 – harvest and reseed 1.2 x 108

Day 30 - harvest/freeze

day 27 – split + IL2 feed

3.6 x 108

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Reduce complexity:Simplifying Production using G‐Rex devices

• Gas permeable membrane allows CO2/O2 exchange

• Supports cell growth with large volumes of media

• Reduces feeding frequency and manipulation

• No rocking or stirring

6160

80

CTLs 

Superior expansion of VSTs in G‐Rex vs 24w plate

24w Plate

G‐Rex 10

PACT Project 00029

1

21

41

20

40

Day 0 Day 9 Day 16

1E+06 

Production time halved

10

Bajgain et al, Mol Therapy Methods and Clinical Development, 2014

Solutions

Manufacturing limitations

‐ Reduce cost – peptides √p p

‐ Reduce complexity – G‐Rex √

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Solutions

Manufacturing limitations

‐ Reduce cost – peptides √p p

‐ Reduce complexity – G‐Rex √

Will they work?

AdV – Hexon, PentonEBV – EBNA1, LMP2, BZLF1CMV – IE1, pp65BKV – LT, VP1HHV6– U11, U14, U90

Rapidly generated T cell lines targeting 5 viruses (ARMS)

mVSTs

PACT Project 00053

+IL4/7

T cell stimulation/ expansion10 days

G‐Rex

• 11 pts infused on study: 4 pts: 5x106/m2 (DL1) 4 pts: 1x107/m2 (DL2) 3 pts: 2x107/m2 (DL3)

Patients infused

• No dose limiting toxicity• 1 Grade II skin GvHD (improved with topical steroids)

• 3 infused prophylactically• All remained infection-free for at least 3 months

• 8 pts had active infections

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Patient with AdV CMV EBV BKV HHV6

1 virusx

x

x x

8 pts treated for infections

2 viruses x x

x x

3 virusesx x x

x x x

4 viruses x x x x

Patient with AdV CMV EBV BKV HHV6

1 virusx

x

x x

8 pts treated for infections

2 viruses x x

x x

3 virusesx x x

x x x

4 viruses x x x x

Patient with AdV CMV EBV BKV HHV6

1 virusx

x

x x

8 pts treated for infections

2 viruses x x

x x

3 virusesx x x

x x x

4 viruses x x x x

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Patient with AdV CMV EBV BKV HHV6

1 virusx

x

x x

8 pts treated for infections

2 viruses x x

x x

3 virusesx x x

x x x

4 viruses x x x x

100000

1000000

A

Pre mVSTs

Clinical response - Pt with EBV-PTLD

1

10

100

1000

10000

wk-2 wk-1 Infusion wk1 wk2 wk3 wk4 wk6 wk8 wk12

EB

V c

op

ies/μ

g D

NA

Viral load

500

600

100000

1000000

A

Pre mVSTs

Clinical response - Pt with EBV-PTLD

mVSTs

0

100

200

300

400

1

10

100

1000

10000

wk-2 wk-1 Infusion wk1 wk2 wk3 wk4 wk6 wk8 wk12

SF

C/5

x105

EB

V c

op

ies/μ

g D

NA

Viral loadEBV

T cells

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500

600

100000

1000000

A

Post mVSTs

Pre mVSTs

Clinical response - Pt with EBV-PTLD

mVSTs

0

100

200

300

400

1

10

100

1000

10000

wk-2 wk-1 Infusion wk1 wk2 wk3 wk4 wk6 wk8 wk12

SF

C/5

x105

EB

V c

op

ies/μ

g D

NA

Viral loadEBV

T cells

10000

100000

1000000

ml

Clinical response - Pt with AdV

Viral load

1

10

100

1000

10000

wk-3 wk-2 wk-1 Infusion wk1 wk2 wk3 wk4 wk6 wk8 wk12

Ad

v co

pie

s/m

200

250

10000

100000

1000000

05

ml

Viral load Adv T cells

Clinical response - Pt with AdV

mVSTs

0

50

100

150

1

10

100

1000

10000

wk-3 wk-2 wk-1 Infusion wk1 wk2 wk3 wk4 wk6 wk8 wk12

SF

C/5

x10

Ad

v co

pie

s/m

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1

10

100

1000

10000

BK

V c

op

ies/

ml

Blood

Clinical response - Pt with BKV

Viral load

1wk-3 wk-2 wk-1 Infusion wk1 wk2 wk3 wk4 wk6 wk8 wk10 wk12

1.E+00

1.E+02

1.E+04

1.E+06

1.E+08

1.E+10

wk-3 wk-2 wk-1 Infusion wk1 wk2 wk3 wk4 wk6 wk8 wk10 wk12

BK

V c

op

ies/

ml

Urine

Viral load

0

20

40

60

80

1

10

100

1000

10000

SF

C/5

x105

BK

V c

op

ies/

ml

Blood

Viral load BKV T cells

Clinical response - Pt with BKVmVSTs

01wk-3 wk-2 wk-1 Infusion wk1 wk2 wk3 wk4 wk6 wk8 wk10 wk12

1.E+00

1.E+02

1.E+04

1.E+06

1.E+08

1.E+10

wk-3 wk-2 wk-1 Infusion wk1 wk2 wk3 wk4 wk6 wk8 wk10 wk12

BK

V c

op

ies/

ml

Urine

Viral load

mVSTs

Outcomes

• Complete response: (√)

viral load to the normal range

resolution of clinical signs/symptoms

• Partial response: (PR)

>50% reduction in viral load

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Patient with Adv CMV EBV BKV HHV6

1 virus

PR

94% Response Rate

2 viruses

3 viruses

x 4 viruses PR

Conventional Rapid

Specificity AdV, EBV, CMV AdV, EBV, CMV, BK, HHV6

Blood vol 60ml 20ml

Old vs New

Blood vol. 60ml 20ml

Cells LCL, CTL CTL

Time 56‐84 days 10 days

Cell # 200x106 390x106

Papadopoulou et al, Sci Trans Med, 2014

Conventional Rapid

Specificity AdV, EBV, CMV AdV, EBV, CMV, BK, HHV6

Blood vol 60ml 20ml

Old vs New

Blood vol. 60ml 20ml

Cells LCL, CTL CTL

Time 56‐84 days 10 days

Cell # 200x106 390x106

Papadopoulou et al, Sci Trans Med, 2014

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1

Blood draw

T cells 

SCT

donor

Adoptive T cell transfer

#1

Antigen  Specificity

2

T‐cell product generation

3

Infusion4

SCT

recipient

#1

1

Blood draw

Antigen  Specificity

2

T cells 

SCT

donor

Adoptive T cell transfer

T‐cell product generation

3

Infusion4

SCT

recipient

G‐Rex

Peptides

1

Blood draw

Antigen  Specificity

2

T cells 

SCT

donor

Adoptive T cell transfer

#2

T‐cell product generation

3

Infusion4

SCT

recipient

G‐Rex

Peptides

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Addressing Problem #2

- Investigate the therapeutic benefit of 3rd party T cellsbenefit of 3rd party T cells

Assess whether banked virus‐specific T cells (VSTs) produced clinical benefit in partially HLA‐matched 3rd party recipients

PACT Project 00014

3rd party T cells ‐ “Off the shelf” 

Blood

onor

B d

A1, A24; B8, 18; DR1, 15

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3rd party T cells ‐ “Off the shelf” 

Blood

onor

Trivirus VST

B d

A1, A24; B8, 18; DR1, 15

EBV activity – B8, DR1CMV activity – A24Adv activity – A1, A24, DR15

G‐Rex

Blood

onor

Trivirus VST

EBV – A1, 11; B8, 35; DR8

MDACC

3rd party T cells ‐ “Off the shelf” 

B d

A1, A24; B8, 18; DR1, 15

EBV activity – B8, DR1CMV activity – A24Adv activity – A1, A24, DR15

G‐Rex

Blood

onor

Trivirus VST

EBV – A1, 11; B8, 35; DR8

Boston

MDACC

3rd party T cells ‐ “Off the shelf” 

B d

A1, A24; B8, 18; DR1, 15

EBV activity – B8, DR1CMV activity – A24Adv activity – A1, A24, DR15

CMV – A2, 24; B7, 27; DR1, 15

Adv – A1, 11; B7, 8; DR3, 11

CHLA

G‐Rex

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Clinical protocol

• Treatment of refractory EBV, CMV, or AdV

• Patients receive 2 x 107 VSTs/m2/

• If partial response may receive additional doses at 2+ weekly intervals 

Patients Treated on Study

• 50 patients infused – 45 evaluable

– 19 received VSTs for CMV

– 17 received VSTs for Adv

– 9 received VSTs for EBV

ity 0 6

0.8

1.0

Cumulative Incidence of First CR/PR by Infection

74% Overall Response Rate

74% ‐ CMV 

67% ‐ EBV 

CR/PR based on infection

Pro

ba

bili

0.0

0.2

0.4

0.6

Days Post VST Infusion0 7 14 21 28 35 42

CMV (N=23) EBV (N=9)Adenovirus (N=18)

79% ‐ Adv

Durable

4 subsequent

progression/recurrence Days post‐VSTLeen et al Blood 2013

PACT Project 00014/64/88

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Donor‐derived VSTs

Where we started

SafeEffective

CostlyComplexTime consumingBiohazardsLimited breadth

Donor‐derived VSTs

Where we are now3rd partyVSTs

SafeEffective

CostlyComplexTime consumingBiohazardsLimited breadth

SafeEffective

RapidSimpleScalableBroad spectrum

Where we are now

Peptides

G‐Rex

“A” “A” “A”

“A” “A” “A”

“A” “A” “A”

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3rd party T cells

PACT 00014/64“Off the shelf” Trivirus‐

specific T cells

PACT supportSimplify/Abbreviate Manufacturing

PACT 00023Trivirus‐specific T cells (plasmids)PACT 00029

G‐Rex

PACT C001Trivirus‐specific 

T cells

PACT 00088“Off the shelf” 

Multivirus‐specific T cells

PACT 00053Pentavalent‐specific T cells (pepmixes)

G Rex

Thanks!TRL Lab PIsCliona RooneyHelen HeslopMalcolm BrennerJuan VeraBilal OmerCath Bollard

QA/QC LaboratoryCHALLAHJ. Antin

EMMESAdam Mendizabal

NMDPDennis Confer

NHLBIJohn Thomas

TRL LaboratoryAnastasia PapadopoulouIfigeneia TzannouUsha KatariNikita KootiyanyilKate RyanManik KuvalekarUlrike GerdemannJacqueline KeirnanQ /Q y

Adrian GeeSara RichmanDebbie LyonSuzanne PooleZhuyong MeiCrystal Silva‐Lentz

GMP LaboratoryHuimin ZhangOumar DioufJoyce KuBirju MehtaSpoorthi Fnu

B. DeyD. AviganP. SzabolcsE.J. ShpallP Kebriaei,N. KapoorS‐Y Pai, S.D. Rowley BR Dey 

Funding:  NCI Program Project Grant, NHLBI Somatic Cell Therapy Center, Lymphoma SPORE, Leukemia and Lymphoma Society Specialized Center of Research, Doris Duke Distinguished Clinical Scientist Award, PACT

Jacqueline KeirnanLisa Rollins

Clinical ResearchBambi GrilleyBridget MedinaYu‐Feng LinAmy ReynaHao Liu

Transplant ServiceBob KranceKathy LeungCaridad MartinezGhadir SasaGeorge Carrum

QuestionWhat are the major obstacle(s) limiting the commercialization of cell therapy products?

(a) Lack of IP/patents

(b) k f i f i d(b) Lack of interest from industry partners/investors

(c) Complexity of preparing personalized therapies

(d) Manufacturing limitations (eg scale up issues)

(e) Other

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Dr. Claudio Brunstein’s presentation will not be publicly available.p y

Considerations for cGMP Production of Patient‐Specific Cell Therapeutics –

A PACT Case Study

Derek J. Hei, Ph.D.Director, Waisman Biomanufacturing

University of Wisconsin

September 25, 2014

Challenges for Patient‐Specific Cell Therapeutics

Autologous or allogeneic cell therapeutics with patient-specific donor (not “off-the-shelf” therapy)

Manufacturing cost – cost of goods, Quality Control testing, cleanroom time

Scale-up vs scale-outScale up vs. scale out

Manufacturing logistics – timing, QC testing

Patient/donor variability and impact on manufacturing process

In some cases repeat dosing is highly desirable –increased cost

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PACT Project Overview 

Proposed clinical trial -• PI – Dr. Ken DeSantes, UW Carbone Cancer Center

• Neuroblastoma – relapsed/refractory in pediatric patients

• Haploidentical NK cells from KIR-mismatched parent

• hu14.18-IL2 immunocytokine - humanized anti-GD2 mAb linked to IL-2 (Osenga et al., Clin Cancer Res 2006; 12(6):1750)

• Goal – multiple doses, preferably from single manufacturing processp , p y g g p

Initial proposed target dose –• 1E6 NK cells/kg escalate to 1E8 NK cells/kg

• Potential for up to 4 doses per patient

• Requires up to 2.8E10 CD56+ cells for 70 kg patient

• T cell reduction is critical < 5E4 CD3+ cells/kg

Ex-vivo expansion of NK cells using K562-mbIL15-41BBL feeder cells (Campana et al., Cancer Res 2009; 69(9):4010-7)

Natural Killer CellsCytotoxic lymphocytes that are active against cells infected with viruses and intracellular pathogens

NK cell killing determined by inhibitory and stimulatory ligands expressed by malignant and infected cells including lack of MHC expression

Currently under evaluation as therapy against a wide range of cancers including AML, ALL, g g , ,NSCLC, multiple myeloma

CD56+ CD3- cells comprising 5-20% of circulating monocytes

Potential sources –

• PBMNCs from Apheresis with immunomagnetic selection (CD56+ / CD3-), IL-2/IL-15 activation

• Ex vivo expansion using stimulatory “feeder” cells (K562-mbIL16-41BBL)

/biotechhelpline16.blogspot.com

NK Cell Manufacturing ProcessK562-mbIL15-41BBL

Expansion(10-12 Days)

Donor Apheresis

K562 Irradiation PBMC Isolation CD3 Depletion(CliniMACS)

NK Formulation

NK Cell/K562-IRRBioreactor Expansion

(11 days)

K562-IRR QC Testing/Release

• 21-23 day manufacturing process• Quality Control testing logistics for K562-IRR intermediate• Goal to produce 3-4 doses/patient

NK Harvest(10X vol reduction)

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Potential Improvements to NK Cell Manufacturing Process

K562-mbIL15-41BBL production and testing• Ability to produce irradiated, cryopreserved cells that retain

function in NK cell expansion?

• Ability to scale-up K562-IRR production

NK cell expansionNK cell expansion -• Ability to produce multiple doses in a bioreactor?• Ability to cryopreserve NK cell product and maintain function

Potential Improvements to NK Cell Manufacturing Process

K562-mbIL15-41BBL production and testing• Ability to produce irradiated, cryopreserved cells that retain

function in NK cell expansion?

• Ability to scale-up K562-IRR production

NK cell expansionNK cell expansion -• Ability to produce multiple doses in a bioreactor?• Ability to cryopreserve NK cell product and maintain function

K562 Expansion and Irradiation

Processing logistics –• Require 10:1 K562:CD56+ cells for NK expansion – >2E9 K562s/run• Expansion time for K562 cell line is approximately 2 weeks• QC testing for release of K562-IRR cells – time and money

K562-mbIL15-41BBL cell banks• Master Cell Bank provided by Baylor PACT facility• Produced Working Cell Bank under cGMP• Adventitious agent testing

K562-IRR production process• Expand K562 WCB in suspension culture – spinner flasks, bioreactor• Harvest and irradiate (100 Gy)• Cryopreservation – demonstrated acceptable recovery and function of

cryopreserved K562-IRR for NK cell expansion• Final dose – 1E7 cells/mL, 200 mL RPMI-1640 + 20% FBS + 10% DMSO• Is the process scalable?

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K562‐mbIL15‐41BBL Suspension Culture

Maximum density for late-logarithmic growth = 1.5E6/mL

Expansion from spinner flasks to 50L Single-Use Bioreactor (SUB)

Projected yield = 15-20 bags at 2E9 K562 cells/bag

Cleanroom time savings = 25-35 weeks/year

K562‐mbIL15‐41BBL Harvest and Recovery

• Hollow fiber TFF system (0.65 m)

• Sterile, completely closed single-use system

• Three pump system – fed batch with permeate flow control

• 10X volume reduction, < 1 hour, > 95% recovery

K562 Expansion and Irradiation

Advantages of irradiated/cryopreserved K562 cells• Cells can be thawed for immediate expansion of NK cells• Decreased cleanroom time and overall process cost – 25-35 weeks/yr• Decreased QC testing requirements due to increased batch size• Improved consistency in K562 cells

Attribute  Method  Specificationp

Bacterial Endotoxin  Kinetic chromogenic LAL  < 5 EU/kg/dose 

Mycoplasma   

PTC method (direct and indirect culture)  No contamination detected 

Sterility Test    

21 CFR 610.12  bacteristasis and fungistasis 

No contamination detected 

Post‐thaw viable cell recovery  Trypan Blue  > 70% 

Residual uninactivated K562 cells   

Click‐it® Cell Proliferation assay  Perform post‐irradiation 

< 0.1%   

 

5 EU/mL

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NK Cell Manufacturing ProcessK562-mbIL15-41BBL

Expansion(10-12 Days)

Donor Apheresis

K562 Irradiation PBMC Isolation CD3 Depletion(CliniMACS)

NK Formulation

NK Cell/K562-IRRBioreactor Expansion

(11 days)

K562-IRR QC Testing/Release

• 21-23 day manufacturing process• Quality Control testing logistics for K562-IRR intermediate• Goal to produce 3-4 doses/patient

NK Harvest(10X vol reduction)

Overview of NK Cell Manufacturing Process

Donor Apheresis

PBMC Isolation CD3 Depletion(CliniMACS)

NK Formulation

Thaw CryopreservedK562-IRR

NK Cell/K562-IRRBioreactor Expansion

(11 days)

NK Harvest(10X vol reduction)

• 11 day manufacturing process• Cryopreserved K562-IRR intermediate with full QC testing • Goal to produce 3-4 doses/patient

Potential Improvements to NK Cell Manufacturing Process

K562-mbIL15-41BBL production and testing• Ability to produce irradiated, cryopreserved cells that retain

function in NK cell expansion?

• Ability to scale-up K562-IRR production

NK cell expansionNK cell expansion -• Ability to produce multiple doses in a bioreactor?• Ability to cryopreserve NK cell product and maintain function

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NK Cell Expansion Process

Apheresis unit – 4-8E8 PBMCs, 5-20% NK cells

NK expansion in Wave 20 Bioreactor• 10:1 K562:NK cells (irradiated, cryopreserved)

• XVivo 10/hAB serum, 100 U/mL hIL-2

• 60-150X expansion over 11 days

NK harvest Cobe TFFNK harvest – Cobe, TFF

CD3 depletion - CliniMACS

Release first dose as fresh NK cells

Cryopreserve additional 3 doses of NK cells• Goal: 1E6 NK/kg escalate to 1E8/kg, up to 4 doses per patient

• 2E7 cells/mL, 100-350 mL dose

• Can NK cells be cryopreserved and maintain viability and activity?

Cytotoxicity is Maintained in Expanded NK Cells

*Maximum Lysis based on 51Cr release using Cetrimide Detergent

Kimberly A. McDowell MD, PhDDepartment of PediatricsDivision of Hematology, Oncology and Bone Marrow Transplant

Cryopreservation of Expanded NK Cells

• NK cells cryopreserved following expansion in Wave bioreactor at 2.0x107cells/mL

• 1 fresh dose, 3 cryopreserved doses

• Two cryopreservation media evaluated in initial PD studies – Initial viable cell recovery >80%, delayed onset cell deathy , y

– Plasmalyte + 5% HSA + 5% DMSO 18-36% recovery

– BioLife Solutions Cryostor CS5 Medium 45-55% recovery

• Process Qualification trials (N=3)– 40% human AB serum, 50% Plasmalyte, 10% DMSO (Dean Lee, MDACC)

– Viable NK recovery > 90% post thaw and wash

– Cell washing process qualified

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Neuroblastoma cell lineCHLA21

Melanoma cell lineM21

Cytotoxicity Testing of Cryopreserved NK Cells

Cytotoxicity of NK cell resistant cell lines

Cytotoxicity of NK cell sensitive cell line

Ab = hu14.18K322A (100 ng/ml)IL2 = Interleukin 2 (100 units/ml)

4 hour 51Cr assay

CML cell lineK562

Process Qualification TrialsProcess Qualification trials – demonstrate process reproducibility and impact of donor variability

NK cell expansion in Wave bioreactor• 1.3 – 6.0 E10 NK cells

• 30-200 fold expansion

CliniMACS CD3 depletion• < 0 1% residual T cells< 0.1% residual T cells

• > 87% CD56+ CD3- cells

Thaw/wash qualification studies• Validate process – sterility, endotoxin, viable cell recovery

• Stability study performed out to 6 months on frozen NK cells

Donor variability – still a challenge• In-process testing to predict final process outcome

• Process adjustments based on in-process tests?

Conclusions

For autologous/patient-specific cell therapeutics its critical to address manufacturing logistics, scale-out, and manufacturing cost issues early in development

Donor/patient variability will continue to be a challenge –in process testing and process adjustments are key inin-process testing and process adjustments are key in addressing this issue

QC testing logistics on final fresh and thawed/washed product should be addressed along with shipping and post-thaw processing issues

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Special Thanks To…Special Thanks To…Waisman BiomanufacturingWaisman Biomanufacturing

Bryan Atkinson

Chris Bartley

Jaime Bellon

Alan Bettermann

Neehar Bhatia

Janice Boyer

Diana Drier

Heather Dunn

Rebecca Ertel

Michael Hainstock

Jen Jauquet

Bill Kreamer

Ross Meyers

Carl Ross

Natalie Russell

Josh Sotos

Tim Sparks

Megan Stone

UW PACT TeamUW PACT TeamPeiman Hematti,  Deb Bloom,  Jaehyup Kim

Amish Raval,  John Centanni,  Eric Schmuck

Tim Hacker,  Jill Koch

Marlowe Eldridge,  Ruedi Braun   

Janice Boyer

Paula Brisco

Lisa Burdette

Brian Dattilo

Bill Kreamer

Laurie Larson

Connor Lyons

Eric Mauer

Megan Stone

Kari Thostenson

John Welp

Kathy Yee

UW Carbone Cancer CenterUW Carbone Cancer CenterKen De Santes, MD

Paul Sondel, MD, PhD

Kim McDowell, MD, PhD

“Challenges and Problem“Challenges and Problem--Solving Solving in Cell Therapy Product in Cell Therapy Product

Development”Development”

Speaker Contact EmailSpeaker Contact Email

Ann [email protected]

Claudio BrunsteinClaudio [email protected]

Derek [email protected]

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This activity has been planned and implemented in accordance with the Essential Areas and Policies ofthe Accreditation Council for Continuing Medical Education (ACCME) through the joint sponsorship ofAABB and PACT. AABB is accredited by the ACCME to provide continuing medical education forphysicians (Provider number 0000381). AABB designates this educational activity for a maximum of1.5 hours of Category 1 credit toward the AMA Physicians Recognition AwardTM. Each physicianshould claim those credits that he/she actually spent in the activity.

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AABB is an approved accrediting agency for continuing education for California licensed clinicallaboratory personnel. This event has been approved for a maximum of 1.5 contact hours. AABB’saccrediting agency number is 0011. Credit earned through attendance at this event may be used tofulfill the state requirement for continuing education hours to maintain licensure status.

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Administrators, nurses (other than California-licensed nurses), clinical laboratory personnel (otherthan California- and Florida-licensed personnel), and other health-care professionals may receive acertificate of attendance for participation in this event. This certificate verifies the attendance at theevent.

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