Optimization of a MRC-5 cell culture process for the production of a smallpox vaccine

A cell culture process adaptable to produce smallpox vaccine at large scale has been developed. To achieve this, Design of Experiments (DOE) was applied to identify and optimize critical cell culture process parameters for MRC-5 cell growth and recovery during cell expansion. For cell growth, a 25−1 partial factorial (two level, five factor, 16 conditions) study was designed to evaluate the effects of basal media, seeding density, culture volume, feeding frequency and serum concentration on population doubling level (PDL) after 6–7 days in adherent T-flask cultures. Results indicated that lowering the cell density to 1×104 cells/cm2, increasing the culture volume to 0.5 ml/cm2 and increasing serum concentration to 20% significantly improved cell expansion. These findings correlated with PDLs above 2.0 and cell densities above 1×105 cells/cm2 at the end of the study period. For cell recovery at passaging, a similar DOE was used to evaluate the effect of trypsin concentration, solution temperature, duration of treatment, incubation temperature and duration of standing time between quenching and reseeding. By increasing the trypsin treatment duration to 60 min and lowering the standing time between quenching and reseeding to within 1 h, the recovery of the MRC-5 cells was greatly improved. By using these newly defined conditions, a two-fold improvement in cell expansion was consistently achieved in both roller bottles and 10 layer Nunc® Cell Factories (Cell Factories). Application of these new conditions for current Good Manufacturing Practices (cGMP) production of MRC-5 cell banks and clinical material demonstrated predictably high cell expansion as well as significantly higher production of vaccinia virus, thus providing the basis for manufacturing vaccinia virus at large scale. These findings demonstrate the need for cell culture optimization and the effectiveness of DOE to rapidly define processes suitable for cGMP manufacturing of a smallpox vaccine or other viral vaccine products.