Building New Cell Therapy Workflow Solutions by Leveraging ...
1
Thermo Fisher Scientific • 5781 Van Allen Way • Carlsbad, CA 92008 • thermofisher.com Carl Dargitz 1 , Pushpalatha Chaluvappa 1 , Enoch Tsui 1 , Steffany Dunn 1 , Sarah Daoudi 1 , Sean Chang 1 , Namritha Ravinder 1 and Xavier de Mollerat du Jeu 1 1 Thermo Fisher Scientific, 5781 Van Allen Way, Carlsbad, CA 92008 INTRODUCTION Processing and manufacturing cell and gene therapy products is of vital importance to patients and has presented numerous challenges. The Gibco TM CTS TM Rotea TM Counterflow Centrifugation System’s closed technology enables gentle cell isolation, and wash and concentrate, and can be easily automated and programmed to serve many additional workflows. Together the single use kit and instrument are able to capture and sustain billions of cells in a stable, fluidized bed with flexible inputs up to 20 liters and output volumes as low as 5 mL. Two of the Rotea system’s core capabilities are PBMC isolation from fresh leukopaks, and wash and concentration of T cells, two common and vital processes in cell therapy workflows. Recently, we have utilized the flexible Rotea system to isolate PBMC from frozen leukopaks, and wash and concentrate frzoen PBMC and cultured NK cells. Figure 1. Current cell therapy workflow. (A) Current processes rely heavily on cell isolation, wash, and concentrate. Automated processing in each step indicated in (B) can increase the efficiency and lower the cost of cell therapy manufacturing. Cell therapy processing Cell isolation and activation Cell engineering Cell expansion Fill, finish, and cryopreservation Lot release and characterization Thaw cells A) B) 2D Barcode CFC Chamber Rotary Coupling Bubble Trap Pump tubing Valve ID (A, B, C, D, E, F & G) Kit Label LocaGon Hole LocaGon Hole Sealed Input and Output Tubes Concentrate Output Tube Tube Retainer Carrier Frame Bubble Sensors (B, C, D, E, F) Pressure Sensor (P2) Pinch Valve (H) Pressure Sensor (P1) Pinch Valves (A, B, C, D, E, F & G) PeristalAc Pump 2D Barcode Reader OpAcal Density Sensor “STOP” “START”/”PAUSE” “ADVANCE” “DOOR UNLOCK” Camera Pinch Valves (J & K) Centrifuge Chamber Carrier Img 24 Moisture Sensor Centrifuge Chamber sensor Figure 2. The Rotea system which includes the single use kit, instrument and accompanying software, provides closed and automated cell processing solutions by collecting cells of interest in a fluidized cell bed. Key Features: • Scalable throughput- continuous processing of up to 20L • Small minimum output volume- As low as 5 mL • Flexible- programmable, multiple processing modes including cell separation, concentration and washing. The system can easily be adapted by the user to new workflows. • Universal kit (consumable) for different cell types and applications • Small bench top footprint RESULTS PBMC RBC 0 20 40 60 80 100 % of Cells Recovered Figure 3. T cells processed using the Rotea system exhibit similar quality as compared to Ficoll control throughout expansion. (A, B) Rotea completes PBMC isolation in 30 minutes with thorough platelet and RBC depletion. Additionally, the composition of cells after processing with the Rotea system is comparable to manual density gradient processing. Figure 4. A) PBMC Isolations from fresh leukopak donors using ACK Buffer for RBC lysis. The average PBMC recovery across 7 donors was ~90%. After Isolation and RBC lysis, on average less than 5% of the starting population of RBCs remained. B) PBMC isolations from frozen leukopak donors. Average recovery across 2 donors was 88% and viability averaged 94% after processing. C) Frozen PBMC using the Rotea system to remove cryopreservation medium and wash into growth medium (buffer exchange). For n=3 Rotea system runs, both viability and recovery of frozen PBMC exceeded 90%. 0 10 20 30 40 50 60 70 80 90 100 CD4 CD8 % Before Rotea After Rotea Viability Recovery 0 10 20 30 40 50 60 70 80 90 100 Percentage of Cells Viability and Recovery of T Cell Wash & Concentrate. N=10 TRADEMARKS/LICENSING © 2021 Thermo Fisher Scientific Inc. All rights reserved. All trademarks are the property of Thermo Fisher Scientific and its subsidiaries unless otherwise specified. For Research Use Only. Not for use in diagnostic procedures. CONCLUSIONS • The Rotea system provides highly efficient PBMC isolation from both fresh and frozen leukopaks across many donors with high recovery and cell quality. It can isolate PBMCs much faster than manual methods while maintaining equivalent or improved quality and cell health • The Rotea system provides gentle and efficient cultured T cell, and frozen PBMC wash and concentrate with >90% recovery of T cells, and maintenance of viability with flexible input and output volume. The system is also capable of performing wash and concentrate of NK cells with high viability and recovery • Due to it’s high level of flexibility and programmability, the Rotea system is capable of facilitating many important aspects of cell therapy workflows, from PBMC isolation all the way to cryopreservation Figure 6. Rotea system T cell wash and concentrate with controllable input and output. A) T cell recovery and viability over 10 runs of T Cell wash and concentrate, both recovery and viability averaged over 90% with low variability. B) Phenotype of T Cells both before and after T cell wash and concentration with the Rotea system. The composition of CD4+ and CD8+ cells is not altered after Rotea system wash and concentrate. [email protected] A. Ficoll separation (2 hr) 46% 54% Cells Others (platelets) 96% 4% Leukocytes RBC 80% T cells 8% B cells 9% Monocytes 3% NK Leukocyte CD45-FITC CD3-eFluor450 CD3-eFluor450 CD3-eFluor450 B & T Monocyte & T NK & T CD14-APC CD19-PE CD56-PerCP- eFluor710 0 10 20 30 40 50 60 70 80 0 5 10 15 20 25 Fold Expansion Day of Expansion 97.1 97.2 84.3 0 20 40 60 80 100 Pre-Rotea Viability Post Rotea Viability Cell Recovery Percentage (%) 91% 91% Viability Recovery 0 20 40 60 80 100 120 Percentage (%) A) B) Leukocyte CD45-FITC CD3-eFluor450 CD3-eFluor450 CD3-eFluor450 B & T Monocyte & T NK & T CD14-APC CD19-PE CD56-PerCP- eFluor710 B. Rotea system separation, no Ficoll (<30 min) 66% 34% Cells Others (platelets) 97% 3% Leukocytes RBC 80% T cells 8% B cells 9% Monocytes 3% NK Figure 5. NK cell expansion and subsequent Wash and concentrate performed on Day 21 of expansion. NK cell viability was maintained and cell recovery was over 84% prior to Rotea system protocol optimization. C) 94% 88% Viability Recovery 0 20 40 60 80 100 120 Percentage (%) A) B) Building New Cell Therapy Workflow Solutions by Leveraging the Flexibility of the Rotea System’s Closed Automated Cell Processing Technology
Transcript of Building New Cell Therapy Workflow Solutions by Leveraging ...
Thermo Fisher Scientific • 5781 Van Allen Way • Carlsbad, CA 92008 • thermofisher.com
Carl Dargitz1, Pushpalatha Chaluvappa1, Enoch Tsui1, Steffany Dunn1, Sarah Daoudi1, Sean Chang1, Namritha Ravinder1 and Xavier de Mollerat du Jeu1
1Thermo Fisher Scientific, 5781 Van Allen Way, Carlsbad, CA 92008
INTRODUCTION Processing and manufacturing cell and gene therapy products is of vital importance to patients and has presented numerous challenges. The GibcoTM CTSTM RoteaTM Counterflow Centrifugation System’s closed technology enables gentle cell isolation, and wash and concentrate, and can be easily automated and programmed to serve many additional workflows. Together the single use kit and instrument are able to capture and sustain billions of cells in a stable, fluidized bed with flexible inputs up to 20 liters and output volumes as low as 5 mL. Two of the Rotea system’s core capabilities are PBMC isolation from fresh leukopaks, and wash and concentration of T cells, two common and vital processes in cell therapy workflows. Recently, we have utilized the flexible Rotea system to isolate PBMC from frozen leukopaks, and wash and concentrate frzoen PBMC and cultured NK cells.
Figure 1. Current cell therapy workflow. (A) Current processes rely heavily on cell isolation, wash, and concentrate. Automated processing in each step indicated in (B) can increase the efficiency and lower the cost of cell therapy manufacturing.
Cell therapy processing
Cell isolation and activation
Cell engineering
Cell expansion
Fill, finish, and cryopreservation
Lot release and characterization
Thaw cells
A)
B)
2DBarcode
CFCChamber RotaryCoupling
BubbleTrap
Pumptubing
ValveID(A,B,C,D,E,F&G)
KitLabel
LocaGonHole LocaGonHole
SealedInputandOutputTubes
ConcentrateOutputTube
TubeRetainer
CarrierFrame
BubbleSensors
(B,C,D,E,F)
PressureSensor
(P2)
PinchValve
(H)
PressureSensor
(P1)
PinchValves
(A,B,C,D,E,F&G)
PeristalAcPump
2DBarcode
Reader
OpAcalDensity
Sensor
“STOP” “START”/”PAUSE” “ADVANCE” “DOORUNLOCK”
Camera
PinchValves
(J&K)
Centrifuge
Chamber
Carrier
Img24Moisture
Sensor
Centrifuge
Chamber
sensor
Figure 2. The Rotea system which includes the single use kit, instrument and accompanying software, provides closed and automated cell processing solutions by collecting cells of interest in a fluidized cell bed. Key Features: • Scalable throughput- continuous processing of up to 20L • Small minimum output volume- As low as 5 mL • Flexible- programmable, multiple processing modes including cell separation, concentration
and washing. The system can easily be adapted by the user to new workflows. • Universal kit (consumable) for different cell types and applications • Small bench top footprint
RESULTS
PBMC RBC0
20
40
60
80
100
Leukopak Processingwith ACK buffer
% o
f Cel
ls R
eco
vere
dFigure 3. T cells processed using the Rotea system exhibit similar quality as compared to Ficoll control throughout expansion. (A, B) Rotea completes PBMC isolation in 30 minutes with thorough platelet and RBC depletion. Additionally, the composition of cells after processing with the Rotea system is comparable to manual density gradient processing.
Figure 4. A) PBMC Isolations from fresh leukopak donors using ACK Buffer for RBC lysis. The average PBMC recovery across 7 donors was ~90%. After Isolation and RBC lysis, on average less than 5% of the starting population of RBCs remained. B) PBMC isolations from frozen leukopak donors. Average recovery across 2 donors was 88% and viability averaged 94% after processing. C) Frozen PBMC using the Rotea system to remove cryopreservation medium and wash into growth medium (buffer exchange). For n=3 Rotea system runs, both viability and recovery of frozen PBMC exceeded 90%.
0
20
40
60
80
100
120
5mL (100M cells/
mL)
10mL (50M cells/mL)
20mL (25M cells/mL)
%
Viability
Recovery
0
10
20
30
40
50
60
70
80
90
100
CD4 CD8
% Before Rotea
After Rotea
0
10
20
30
40
50
60
70
80
90
100
Viability Recovery
%
5x109 T cell wash and concentrate 5x108 T cell concentrate into small volume A B
C
Viabilit
y
Recove
ry0
102030405060708090
100
Per
cent
age
of C
ells
Viability and Recovery of T Cell Wash & Concentrate.
N=10
TRADEMARKS/LICENSING © 2021 Thermo Fisher Scientific Inc. All rights reserved. All trademarks are the property of Thermo Fisher Scientific and its subsidiaries unless otherwise specified. For Research Use Only. Not for use in diagnostic procedures.
CONCLUSIONS • The Rotea system provides highly efficient PBMC isolation from both fresh and frozen leukopaks
across many donors with high recovery and cell quality. It can isolate PBMCs much faster than manual methods while maintaining equivalent or improved quality and cell health
• The Rotea system provides gentle and efficient cultured T cell, and frozen PBMC wash and concentrate with >90% recovery of T cells, and maintenance of viability with flexible input and output volume. The system is also capable of performing wash and concentrate of NK cells with high viability and recovery
• Due to it’s high level of flexibility and programmability, the Rotea system is capable of facilitating many important aspects of cell therapy workflows, from PBMC isolation all the way to cryopreservation
Figure 6. Rotea system T cell wash and concentrate with controllable input and output. A) T cell recovery and viability over 10 runs of T Cell wash and concentrate, both recovery and viability averaged over 90% with low variability. B) Phenotype of T Cells both before and after T cell wash and concentration with the Rotea system. The composition of CD4+ and CD8+ cells is not altered after Rotea system wash and concentrate.
A. Ficoll separation (2 hr)
46%
54%
Cells
Others (platelets)
96%
4%
Leukocytes
RBC
80% T cells
8% B cells
9% Monocytes
3% NK
Leukocyte
CD45-FITC
CD3-eFluor450 CD3-eFluor450 CD3-eFluor450
B & T Monocyte & T NK & T
CD
14-A
PC
CD
19-P
E
CD
56-P
erC
P-eF
luor
710
Leukocyte
CD45-FITC
CD3-eFluor450 CD3-eFluor450 CD3-eFluor450
B & T Monocyte & T NK & T
CD
14-A
PC
CD
19-P
E
CD
56-P
erC
P-eF
luor
710
B. Rotea system separation, no Ficoll (<30 min)
66%
34%
Cells
Others (platelets)
97%
3%
Leukocytes
RBC
80% T cells
8% B cells
9% Monocytes
3% NK
Rotea can isolate PBMCs from a Leukopak in less than 30 minutes, with equivalent performance to Ficoll and the added benefit of closed processing.
Figure 1- NK Cell A) expansion, B) wash and concentration using Rotea. Collaboration with NK Cell Expansion Media team (Erica Heipertz). High input viability of cells is maintained with high recovery (>80%) during processing.
NK Cell Cell Expansion & Harvest Using Rotea
0 10 20 30 40 50 60 70 80
0 5 10 15 20 25
Fold
Exp
ansi
on
Day of Expansion
NK Fold Expansion 97.1 97.2
84.3
0
20
40
60
80
100
Pre-Rotea Viability
Post Rotea Viability
Cell Recovery
Per
cent
age
(%)
NK Cell wash & concentrate recovery A) B)
91% 91%
Viabilit
y
Recove
ry0
20
40
60
80
100
120
Per
cent
age
(%)
Frozen PBMC RecoveryA) B)
A. Ficoll separation (2 hr)
46%
54%
Cells
Others (platelets)
96%
4%
Leukocytes
RBC
80% T cells
8% B cells
9% Monocytes
3% NK
Leukocyte
CD45-FITC
CD3-eFluor450 CD3-eFluor450 CD3-eFluor450
B & T Monocyte & T NK & T
CD
14-A
PC
CD
19-P
E
CD
56-P
erC
P-eF
luor
710
Leukocyte
CD45-FITC
CD3-eFluor450 CD3-eFluor450 CD3-eFluor450
B & T Monocyte & T NK & T
CD
14-A
PC
CD
19-P
E
CD
56-P
erC
P-eF
luor
710
B. Rotea system separation, no Ficoll (<30 min)
66%
34%
Cells
Others (platelets)
97%
3%
Leukocytes
RBC
80% T cells
8% B cells
9% Monocytes
3% NK
Rotea can isolate PBMCs from a Leukopak in less than 30 minutes, with equivalent performance to Ficoll and the added benefit of closed processing.
Figure 5. NK cell expansion and subsequent Wash and concentrate performed on Day 21 of expansion. NK cell viability was maintained and cell recovery was over 84% prior to Rotea system protocol optimization.
C)
94% 88%
Viabilit
y
Recove
ry0
20
40
60
80
100
120
Per
cent
age
(%)
Frozen LP PBMC Isolation
A) B)
Building New Cell Therapy Workflow Solutions by Leveraging the Flexibility of the Rotea System’s Closed Automated Cell Processing Technology
