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One-Bac 4.0 system is an insect/baculovirus system for AAV production. The production process consists of several key parts: baculovirus plasmid construction, seed virus production, seed virus amplification, seed virus infection of insect cells, and AAV harvest. This system achieves linear amplification of production by infecting insect cells with baculovirus containing the AAV genome, overcoming the bottleneck of large-scale AAV preparation. One-Bac 4.0 system has the potential to benefit more patients due to its high yield compared to other AAV production systems. 

One-Bac 4.0 System New Patent Group

One-Bac 4.0 system process flow chart


QC index for AAV

Genevoyager is equipped with a one-stop gene therapy CDMO platform, alongsidean experienced GMP quality control teamwithexpertise inmethodology development, validation/verification, and testing toensure the high quality of our products.The routine quality release tests and methods are outlined below.


Category

Test Item

Test Method

Identification and structural analysis

DNA identification

Sanger sequencing, Next-generation sequencing (NGS), Third-generation sequencing (TGS)

Capsid protein identification

Western blot, SDS-PAGE, CE, LC-MS

Biological activity

Potency

In vitro cell-based biological activity, Animal studies

Content

Virus capsid titer

ELISA

Genome titer

ddPCR, qPCR

Infectious titer

TCID50

VG:IU

Ratio of genome titer to infectioustiter

Purity

Total protein

microBCA

Capsid protein purity

SDS-PAGE, CE

Viral monomer purity

SEC-HPLC

Empty capsid ratio

AUC, TEM, AEX-HPLC, SEC-MALS

Particle size

DLS

Impurities

Residual Sf9 host cell DNA

qPCR

Residual Sf9 host cell protein

ELISA

Residualnuclease

ELISA

Residualinfectious baculovirus

Plaque assay, TCID50

Residualbaculovirus DNA

qPCR

Residualrhabdovirus

qPCR

Specific process-related residues (affinity ligand, Triton, Tween20, etc.)

ELISA, UV, HPLC

Safety

Replication-competent AAV (rcAAV)

Culturemethod+ qPCR

Mycoplasma

qPCR, Culture method

Spiroplasma

qPCR, Culture method

Endotoxin

Gel electrophoresis, Spectrophotometry

Sterility

Membrane filtration, Direct inoculation

Abnormal toxicity

Injectionin mouse and guinea pig 



✔ A comprehensive analytical method development & quality control platform covering the entireproduct lifecycle
✔ Development, transfer, validation, and verification of analytical methods
✔ Stringent release management to ensure high quality
✔ One-stop services for stability studies
✔ Robust quality management system, supporting IND/NDA/BLA for global partners



Regulatory Compliance
Aligned with ICH Q10 principles and global CMC regulations to meet GMP standards n China, the US,and the EU
Comprehensive Documentation
Structured to meet GMP requirements, covering six key areas: Quality, Materials, Manufactuing,Facilities &Equipment, Laboratories, and Packaging&Labeling
Tailored Quality Management Science-based, regulation-driven, and product-focused-tailored to CDMO operations and adapted to different project stages
Data Integrity

Strict compliance with data integrity standards,fully aligned with ALCOA principles across manufacturing and testing

On-site Monitoring Robust in-process control framework covering the 5Ms -Man,Machine,Material,Method,and Measurement-to ensure product quality
Validation & Control
Comprehensive qualification and validation processes to ensure product consistency and quality control


More Content of Interest

High Safety Profile:

The One-Bac 4.0-derived AAVs present low levels of impurities and are free of rcAAV. 



Data from second-generation sequencing (illumina) and third-generation sequencing (PacBio) confrm that Genevoyager's One-Bac 4.0-derived AAVs exhibit high purity. 



DNA was extracted from the culture supernatant after three rounds of cell culture,and rcAAV was detected by qPCR.The results demonstrated the following:


For the positive control samples(wtAAV2/9)at 100 IU and 10IU,Ct values progressively decreased over the three amplification rounds,indicating successful amplification of rcAAV during culture.


For rAAV2/9 produced using the One-Bac 4.0 system,with inoculation doses of 1E+11vg and 1E+10vg,no significant decrease in Ct values was observed after three rounds.The Ct values remained comparable to the negative control(NC),indicating no detectable rcAAV.


In contrast,for rAAV2/9 produced using the HEK293T system at a dose of 1E+10 vg,Ct values showed a marked decreasing trend over the three amplification rounds,confirming amplification of rcAAV during culture.

High Yields:

The One-Bac 4.0-derived AAVs maintain high yields both before and after purification at a production scale of 50L.


High Full Capsid Ratio:

The One-Bac 4.0 system achieves an impressive full capsid ratio of over 90% in its final product.


High Infectious Activity:

Results from cell and animal experiments demonstrate that One-Bac 4.0-derived AAV exhibits equivalent or higher infectivity compared to HEK293 AAV.





High Passage Stability of BEV:


The Baculovirus Expression Vector (BEV) employed in the One-Bac 4.0 system maintains high stability over multiple passages and during long-term storage at ≤-80℃ for over 24 months,ensuring consistent high yields and robust expression levels of AAV batches at commercial scales.



High Recovery Rate:

With a consistent recovery rate of ≥30% from 5L to 200L scale-up, One-Bac 4.0 system demonstrates good scalability and effciency for large-scale production.


Low Aggregation at High Concentration:

AAVs produced using the One-Bac 4.0 system exhibit low aggregation even at high concentrations. Stability assessments,including ddPCR-GOl and main peak SEC-HPLC,demonstrate that product quality remains stable under 4℃ and withstands multiple freeze-thaw cycles.



Moreover,the One-Bac 4.0-derived AAVs are free of residual rcAAVs,exhibit high purity and high expression levels,addressing critical safety and effcacy concerns for gene therapy.

Improved Accessibility:

The One-Bac 4.0 system offers a more cost-effective approach to AAV production by replacing costly GMP plasmids and transfection reagents with a streamlined process for baculovirus vector production, significantly reducing the cost of materials for AAV vector manufacturing.



Reduced timelines:

The establishment of a virus seed bank facilitates a rapid and simplified process for viral infection during production. This feature becomes more prominent as the scale of virus production increases, resulting in reduced timelines for production and delivery.


US: 3675 Market Street, Suite 200, Philadelphia, PA19104 Tel: +1 (215) 205-6963 | +086 027-65023363
E-mail: hui.wang@genevoyager.com

China: No128, Guanggu 7th Rd, East Lake High-tech Development Zone, Wuhan, China Tel: 17720522078
E-mail: marketing@genevoyager.com

ABOUT US TECHNOLOGY PLATFORM

US: 3675 Market Street, Suite 200, Philadelphia, PA19104 Tel: +1 (215) 205-6963 | +086 027-65023363
E-mail: hui.wang@genevoyager.com

China: No128, Guanggu 7th Rd, East Lake High-tech Development Zone, Wuhan, China Tel: 17720522078
E-mail: marketing@genevoyager.com

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