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.
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.
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.
The One-Bac 4.0-derived AAVs maintain high yields both before and after purification at a production scale of 50L.
The One-Bac 4.0 system achieves an impressive full capsid ratio of over 90% in its final product.
Results from cell and animal experiments demonstrate that One-Bac 4.0-derived AAV exhibits equivalent or higher infectivity compared to HEK293 AAV.
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.
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.
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.
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.
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