U.S. patent application number 10/440704 was filed with the patent office on 2003-11-06 for large-scale recombinant adeno-associated virus (raav) production and purification.
Invention is credited to Qu, Quang, Wright, John Fraser.
Application Number | 20030207439 10/440704 |
Document ID | / |
Family ID | 24541304 |
Filed Date | 2003-11-06 |
United States Patent
Application |
20030207439 |
Kind Code |
A1 |
Wright, John Fraser ; et
al. |
November 6, 2003 |
Large-scale recombinant adeno-associated virus (rAAV) production
and purification
Abstract
Methods are provided for large-scale purification of recombinant
AAV (rAAV) virions that were produced in the absence of infectious
adenovirus. Preferably, the rAAV is produced in a host cell line
via triple-transfection with an accessory function vector, an AAV
vector, and an AAV helper vector. The methods include preparing a
lysate from the host cell line and passing that lysate over various
combination of ion exchange chromatography media and/or affinity
chromatography media. The affinity chromatography medium is an AAV
receptor or an antibody with binding affinity for AAV, e.g.,
heparin sulfate. A variety of cation exchange and anion exchange
media are contemplated by the present invention. In certain
embodiment, optional purification steps may be included, such as
filtering the lysate through one or more filters, or treating the
lysate with a nuclease.
Inventors: |
Wright, John Fraser; (Mill
Valley, CA) ; Qu, Quang; (Alameda, CA) |
Correspondence
Address: |
KNOBBE MARTENS OLSON & BEAR LLP
2040 MAIN STREET
FOURTEENTH FLOOR
IRVINE
CA
92614
US
|
Family ID: |
24541304 |
Appl. No.: |
10/440704 |
Filed: |
May 19, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10440704 |
May 19, 2003 |
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09633834 |
Aug 7, 2000 |
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6593123 |
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Current U.S.
Class: |
435/239 |
Current CPC
Class: |
C12N 2750/14151
20130101; C12N 7/00 20130101 |
Class at
Publication: |
435/239 |
International
Class: |
C12N 007/02 |
Claims
What is claimed is:
1. A method of purifying recombinant AAV (rAAV) virions from
contaminants, comprising: (a) introducing an AAV vector into a
suitable host cell; (b) introducing a first nucleic acid comprising
AAV helper function coding regions that are expressed in the host
cell to complement AAV helper functions missing from said AAV
vector, and a second nucleic acid that comprises regions encoding
accessory functions, wherein said second nucleic acid and said host
cell collectively lack a gene necessary for adenovirus production;
(c) culturing the host cell to produce rAAV virions; (d) preparing
a lysate from said host cell provided in step (a); (e) passing the
lysate over an anion exchange chromatography medium, thereby
binding said contaminant to said anion exchange chromatography
medium; and (f) collecting a flow-through containing rAAV (g)
passing the flow-through over an affinity chromatography medium;
and (h) eluting purified rAAV from said affinity chromatography
medium after step (g).
2. The method of claim 1, wherein said lysate is passed over said
anion exchange chromatography medium first and said affinity
chromatography medium second.
3. The method of claim 1, wherein said lysate is passed over said
affinity chromatography medium first and said anion exchange
chromatography medium second.
4. The method of claim 1, wherein said affinity chromatography
medium comprises an AAV binding molecule selected from the group
consisting of an AAV receptor and an antibody with binding affinity
for AAV.
5. The method of claim 4, wherein said affinity chromatography
medium is heparin sulfate.
6. The method of claim 1, wherein said lysate is prepared by
microfluidization of said host cell line.
7. The method of claim 1, further comprising filtering the
lysate.
8. The method of claim 1, wherein said host cell line was cultured
substantially serum-free.
9. The method of claim 1, further comprising treating the lysate
with a nuclease.
10. The method of claim 1, wherein said host cell line was cultured
in a bioreactor.
11. The method of claim 1, wherein said host cell line was
transfected with an accessory function vector, an AAV vector, and
an AAV helper vector.
12. The method of claim 1, wherein the first and second nucleic
acids are on separate vectors.
13. A method of purifying recombinant AAV (rAAV) virions from
contaminants, comprising: (a) providing a host cell comprising rAAV
virions; (b) preparing a lysate from said cell provided in step
(a); (c) passing the lysate over a cation exchange chromatography
medium, thereby binding said rAAV to said cation exchange
chromatography medium; (d) washing said bound rAAV of said cation
exchange chromatography medium; (e) collecting an eluate obtained
in step (d); (f) passing said eluate over an affinity
chromatography medium; (g) eluting purified rAAV from said affinity
chromatography medium after step (g).
14. The method of claim 13, wherein said lysate is passed over said
affinity chromatography medium first and said cation exchange
chromatography medium second.
15. The method of claim 13, wherein said cation exchange
chromatography medium is selected from the group consisting of
sulfo-, phospho, carboxy-, and carboxy-methyl-based resins.
16. The method of claim 13, wherein said affinity chromatography
medium comprises heparin sulfate.
17. The method of claim 13, wherein said lysate is passed over said
cation exchange chromatography medium first and said affinity
chromatography medium second.
18. The method of claim 13, wherein said affinity chromatography
medium comprises an AAV binding molecule selected from the group
consisting of an AAV receptor and an antibody with binding affinity
for AAV.
19. A method of purifying recombinant AAV (rAAV) virions from
contaminants, comprising: (a) providing a host cell comprising rAAV
virions; (b) preparing a lysate from said cell provided in step
(a); (c) passing the lysate over a cation exchange chromatography
medium, thereby binding said rAAV to said cation exchange
chromatography medium; (d) washing said bound rAAV of said cation
exchange chromatography medium; (e) collecting an eluate obtained
in step (d); (f) passing said eluate over an anion exchange
chromatography medium, thereby binding said contaminants to said
anion exchange chromatography medium; and (g) eluting purified rAAV
from said affinity chromatography medium after step (f).
20. The method of claim 20, wherein said affinity chromatography
medium is heparin sulfate.
Description
RELATED APPLICATIONS
[0001] The present application is a continuation patent application
of U.S. patent application Ser. No. 09/633,834, entitled
Large-Scale Recombinant Adeno-Associated Virus (rAAV) Production
and Purification, which was filed Aug. 7, 2000 on behalf of John
Fraser Wright and Quang Qu.
FIELD OF THE INVENTION
[0002] The invention relates to methods for producing and purifying
recombinant adeno-associated virus (rAAV). More particularly, it
relates to methods for producing commercial grade rAAV at large
scale where rAAV was generated in the absence of infectious helper
virus. The methods employ a plurality of column purification steps
that yield purified rAAV. One embodiment of the invention is a
two-column purification system comprising purification over an
anion exchange column and over an affinity column. In another
embodiment, a cation exchange column purification step is
included.
BACKGROUND OF THE INVENTION
[0003] Gene delivery is a promising method for the treatment of
acquired and inherited diseases. A number of viral-based systems
for gene transfer purposes have been described, including
adeno-associated virus (AAV)-based systems. AAV is a
helper-dependent DNA parvovirus that belongs to the genus
Dependovirus. AAV requires coinfection with an unrelated helper
virus, e.g., adenovirus, herpes virus, or vaccinia, in order for a
productive infection to occur. In the absence of a helper virus,
AAV establishes a latent state by inserting its genome into a host
cell chromosome. Subsequent infection by a helper virus rescues the
integrated viral genome, which can then replicate to produce
infectious viral progeny.
[0004] AAV has a wide host range and is able to replicate in cells
from any species in the presence of a suitable helper virus. For
example, human AAV will replicate in canine cells co-infected with
a canine adenovirus. AAV has not been associated with any human or
animal disease and does not appear to alter the biological
properties of the host cell upon integration. For a review of AAV,
see, e.g., Berns and Bohenzky (1987) Advances in Virus Research
(Academic Press, Inc.) 32:243-307.
[0005] The AAV genome is composed of a linear, single-stranded DNA
molecule that contains 4681 bases (Berns and Bohenzky, supra). The
genome includes inverted terminal repeats (ITRs) at each end that
function in cis as origins of DNA replication and as packaging
signals for the virus. The ITRs are approximately 145 bp in length.
The internal nonrepeated portion of the genome includes two large
open reading frames, known as the AAV rep and cap regions,
respectively. These regions code for the viral proteins that
provide AAV helper functions, i.e., the proteins involved in
replication and packaging of the virion. Specifically, a family of
at least four viral proteins is synthesized from the AAV rep
region, Rep 78, Rep 68, Rep 52 and Rep 40, named according to their
apparent molecular weight. The AAV cap region encodes at least
three proteins, VP1, VP2 and VP3. For a detailed description of the
AAV genome, see, e.g., Muzyczka, N. (1992) Current Topics in
Microbiol. and Immunol. 158:97-129.
[0006] The construction of infectious recombinant AAV (rAAV)
virions has been described. See, e.g., U.S. Pat. Nos. 5,173,414 and
5,139,941; International Publication Numbers WO 92/01070 (published
Jan. 23, 1992) and WO 93/03769 (published Mar. 4, 1993); Lebkowski
et al. (1988) Molec. Cell. Biol. 8:3988-3996; Vincent et a!. (1990)
Vaccines 90 (Cold Spring Harbor Laboratory Press); Carter, B. J.
(1992) Current Opinion in Biotechnology 3:533-539; Muzyczka, N.
(1992) Current Topics in Microbiol. and Immunol. 158:97-129; and
Kotin, R. M. (1994) Human Gene Therapy 5:793-801.
[0007] Contemporary rAAV virion production involves introduction of
an AAV vector plasmid and an AAV helper vector plasmid into a host
cell. After the AAV helper plasmid and the AAV vector plasmid
bearing the heterologous nucleotide sequence of interest are
introduced into the host cell (generally by stable or transient
transfection), the cells can be infected with a suitable helper
virus in order to provide the required accessory functions. Most
typically, the helper virus will be infectious adenovirus (type 2
or type 5) or herpes virus, and will, among other functions,
transactivate the AAV promoters present on the helper plasmid
directing the transcription and translation of AAV rep and cap
regions.
[0008] AAV vectors can be engineered to carry a heterologous
nucleotide sequence of interest (e.g., a selected gene, antisense
nucleic acid molecule, ribozyme, or the like) by deleting, in whole
or in part, the internal portion of the AAV genome and inserting
the DNA sequence of interest between the ITRs. The ITRs remain
functional in such vectors allowing replication and packaging of
the rAAV containing the heterologous nucleotide sequence of
interest. The heterologous nucleotide sequence is also typically
linked to a promoter sequence capable of driving gene expression in
the patient's target cells under the certain conditions.
Termination signals, such as polyadenylation sites, can also be
included in the vector.
[0009] AAV helper functions can be provided in trans via an AAV
helper vector. For example, such helper vectors can be plasmids
that include the AAV rep and/or cap coding regions but which lack
the AAV ITRs. Accordingly, such a helper vector could neither
replicate nor package itself. A number of vectors that contain the
rep coding region are known, including those vectors described in
U.S. Pat. No. 5,139,941, having ATCC accession numbers 53222,
53223, 53224, 53225 and 53226. Similarly, methods of obtaining
vectors containing the HHV-6 homologue of AAV rep are described in
Thomson et al. (1994) Virology 204:304-311. A number of vectors
containing the cap coding region have also been described,
including those vectors described in U.S. Pat. No. 5139,941.
[0010] After culturing the host cells with the necessary components
for rAAV production, the host cell is harvested and a crude extract
is produced. The resulting preparation will contain, among other
components, approximately equal numbers of rAAV virion particles
and infectious helper virions. Although rAAV virion particles
produced via adenovirus infection can be purified away from some of
the contaminating helper virus, unassembled viral proteins (from
the helper virus and AAV capsid), and host cell proteins using
known techniques, such preparations contain high levels of
contaminants. Approximately 95% of the contaminants are derived
from adenovirus, and 50% or greater of the total protein obtained
in such rAAV virion preparations is free adenovirus fiber protein.
Because free adenovirus fiber protein tends to co-purify with rAAV
virions, this association makes separation of the two especially
difficult, lowering rAAV virion purification efficiency. Moreover,
adenovirus contaminants may be particularly problematic since many
adenoviral proteins, including the fiber protein, have been shown
to be cytotoxic and highly immunogenic. Preparations of rAAV
containing adenoviral contaminations therefore may damage the
target cell or provoke undesired immune responses in the host.
Varying amounts of several other unidentified adenoviral and host
cell proteins are also present in the preparations. Importantly,
significant levels of infectious adenovirus virions are also
obtained. To inactivate the infectious adenovirus, the preparation
is heat inactivated (56.degree. C. for 1 hour). Heat inactivation,
however, results in an approximately 50% drop in the titer of
functional rAAV virions.
[0011] Therefore, production of rAAV virions using infectious
helper viruses (such as adenovirus type-2, or a herpes virus) is
undesirable for several reasons. Such production methods require
the use and manipulation of large amounts of high titer infectious
helper virus that present a number of health and safety concerns.
Also, concomitant production of helper virus particles in rAAV
producing cells diverts large amounts of cellular resources away
from rAAV virion production likely lowering rAAV virion yields.
Finally, the rAAV yields are even furthered lowered by the
extensive purification required to remove contaminating infectious
helper virus
[0012] Current Purification Methods for rAAV
[0013] Several methods for purifying rAAV have been described in
the literature. While rAAV purified by CsCl density gradients has
been successfully used in human clinical trials, the method is not
suitable for producing commercial scale quantities of rAAV. A
method of purifying rAAV using only cationic column-chromatography
has been described. However, the method fails to remove enough
contaminating DNA and protein to be suitable for commercial use. A
second chromatographic technique designed to purify rAAV produced
using infectious adenovirus has also been described.
[0014] In order to effectively remove and/or inactivate potentially
dangerous helper virus, this method involves several steps,
including chromatography over anion or cation exchange columns as
well as purification through tangential flow filtration or affinity
purification. Even after extensive column purification, the
resulting product typically will require heat inactivation to
destroy any remaining helper virus particles at the expense of a
substantial loss of rAAV, as much as 50%.
[0015] Because this purification system is designed primarily to
remove infectious helper virus (particularly adenovirus), the
system is not optimized to purify rAAV produced without infectious
helper virus. Specifically, many steps are required and each of the
steps results in loss of product rAAV virions, thus reducing the
final yield of the recombinant product. Therefore, significant rAAV
loss is unavoidable using such rAAV purification protocols
increasing both the difficulty and cost of the procedure.
[0016] In sum, all prior purification systems have been designed
primarily to remove and/or inactivate contaminating infectious
helper virus, or are otherwise not suitable for commercial use.
Thus, such systems are unsatisfactory for purifying rAAV produced
in the absence of infectious helper virus, especially for
large-scale production of commercial-grade rAAV. Consequently,
there remains a need to provide a scalable and efficient
purification system capable of separating contaminating protein and
nucleic acid from rAAV prepared in the absence of infectious helper
virus.
SUMMARY OF THE INVENTION
[0017] The present invention involves large-scale purification of
recombinant AAV (rAAV) virions that were produced in the absence of
infectious adenovirus. The methods include preparing a lysate from
the host cell line then passing the lysate over various
combinations of ion exchange chromatography media and/or affinity
chromatography media. The host cell line is preferably cultured in
roller bottles, a bioreactor, or using another technique suitable
for large-scale cell culture.
[0018] In certain preferred embodiments, the rAAV is generated in a
host cell line by triple-transfection with an accessory function
vector, an AAV vector, and an AAV helper vector. The accessory
function vector generally includes accessory functions provided by
one or more adenovirus early region sequences, particularly, the
E1b, E2a, E4, and/or VA RNA regions. The AAV vector includes one or
more heterologous nucleotide sequences of interest flanked by at
least one functional inverted terminal repeat (ITR) sequence.
Finally, the AAV helper vector generally includes the AAV rep
and/or the AAV cap sequences. In certain embodiments, the AAV
helper vector may also have a modified AAV p5 promoter. After
harvesting the transfected cell line, a lysate is formed using
techniques suitable for large-scale production, such as
microfluidization.
[0019] The affinity chromatography medium used for purifying rAAV
will preferably be an AAV receptor or an antibody with binding
affinity for AAV. In a preferred embodiment, heparin sulfate is
used as the affinity chromatography medium. A variety of cation
exchange and anion exchange media are contemplated for use with the
present invention. Suitable cation exchange media include sulfo-,
phospho, carboxy-, and carboxy-methyl-based resins. In one
embodiment, a cation exchange chromatography module is used that
contains a medium known as MUSTANG S.TM.. Suitable anion exchange
media include N-charged amino or imino resins such as STREAMLiNE Q
XL.TM., MUSTANG Q.TM., POROS 50 PI, SEPHAROSE Q, any DEAE, TMAE,
tertiary or quaternary amine, or PEI-based resins.
[0020] Several optional purification steps may also be used with
the present methods, such as filtering the lysate through one or
more filters or treating the lysate with a nuclease. In the certain
embodiments, the methods are optimized to purify rAAV that was
produced in a host cell line cultured in the absence of serum.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 shows the effect of NaCl concentration on AAV
recovery at the microfluidization step.
[0022] FIG. 2 is a Western blot showing concentration of capsid
proteins following purification.
[0023] FIG. 3 is a comparison of AAV production in T-flasks versus
roller bottles.
[0024] FIG. 4 is a comparison rAAV genome recovery following cell
lysis by freeze/thaw versus microfluidization.
[0025] FIG. 5 shows the results of a dot blot comparison of rAAV
recovery after clarification using various filters.
[0026] FIG. 6 shows the percentage of rAAV following
clarification.
[0027] FIG. 7 is a comparison of rAAV recovery following filtration
using two filters versus three filters.
[0028] FIG. 8 is a cation exchange chromatography elution profile
of rAAV-containing material.
[0029] FIG. 9 is a heparin-based affinity chromatography elution
profile of rAAV-containing material.
[0030] FIG. 10 is an anion exchange chromatography elution profile
of rAAV-containing material showing rAAV recovery in the flow
through fractions as well as removal of contaminating protein.
[0031] FIG. 11 shows the removal of nucleic acids through anion
exchange chromatography by agarose gel electrophoresis.
[0032] FIG. 12 is the Q-PCR analysis of anion exchange
chromatography fractions.
[0033] FIG. 13 is a comparison of column-purified rAAV with CsC1
purified rAAV by silver-stained SDS-PAGE.
[0034] FIG. 14 shows recovery of AAV at each step throughout a
purification process using an anion exchange column and a heparin
column.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0035] The invention disclosed herein involves methods for
producing and purifying recombinant adeno-associated virus (rAAV)
virions or particles at large-scale. Large-scale production methods
are necessary to permit the use of rAAV as a gene therapy vector in
large clinical trials and/or in a commercial setting. The methods
of the disclosed invention are also designed to purify rAAV that
was produced without infectious helper virus.
[0036] Unless otherwise indicated, the disclosed invention will
employ conventional methods of virology, microbiology, molecular
biology and recombinant DNA techniques that are well known to those
of ordinary skill of the art. Such techniques are explained fully
in the literature. See, e.g., Sambrook, et al. Molecular Cloning: A
Laboratory Manual (Current Edition); DNA Cloning: A Practical
Approach, vol. I & II (D. Glover, ed.); Oligonucleotide
Synthesis (N. Gait, ed., Current Edition); Nucleic Acid
Hybridization (B. Hames & S. Higgins, eds., Current Edition);
Transcription and Translation (B. Hames & S. Higgins, eds.,
Current Edition); CRC Handbook of Parvoviruses, vol. I & II (P.
Tijessen, ed.); Fundamental Virology, 2nd Edition, vol. I & II
(B. N. Fields and D. M. Knipe, eds.).
[0037] In one embodiment of the present invention, the rAAV virions
or particles to be purified are produced by culture of suitable
host cells following the triple-transfection of such cells with AAV
vector, AAV helper vector, and accessory function vector. By
"vector" is meant any genetic element, such as a plasmid, phage,
transposon, cosmid, chromosome, virus, virion, etc., which is
capable of replication when associated with the proper control
elements and which can transfer gene sequences between cells. Thus,
the term includes cloning and expression vehicles, as well as viral
vectors. The AAV nucleotide sequence used in constructing the AAV
vectors and the AAV helper vectors can be derived from any
adeno-associated virus serotype, including without limitation,
AAV-1, AAV-2, AAV-3, AAV-4, AAV-5, and AAVX7.
[0038] AAV Vectors
[0039] AAV vectors generally have one or more of the AAV wild-type
genes deleted in whole or part, preferably the rep and/or cap
genes, but retain at least one functional flanking inverted
terminal repeat (ITR) sequence. Thus, such AAV vectors can be
constructed to include one or more heterologous nucleotide
sequences flanked directly or indirectly by one or more ITRs.
[0040] Functional ITR sequences are required in cis for the rescue,
replication and packaging of the rAAV virion. While the nucleotide
sequences of AAV ITR regions are known, (See, e.g., Kotin, R. M.
(1994) Human Gene Therapy 5:793-801; Berns, K. I. "Parvoviridae and
their Replication" in Fundamental Virology, 2nd Edition, (B. N.
Fields and D. M. Knipe, eds.) for the AAV-2 sequence), the ITRs
employed in the present invention need not correspond to an AAV
wild-type nucleotide sequence. That is, the ITRs may be altered by
the insertion, deletion or substitution of nucleotides, so long as
the sequences function in the rescue, replication and packaging of
rAAV. Also, the AAV ITRs may be derived from any of several AAV
serotypes, including without limitation, AAV-1, AAV-2, AAV-3,
AAV-4, AAV-5, AAV-6, and AAVX7. Finally, when more than one ITR is
used in an AAV vector, those ITRs need not be identical or derived
from the same AAV serotype or isolate, so long as they function as
intended.
[0041] The recombinant genome of the AAV vector can be constructed
using standard molecular biology techniques that are well known in
the art. For example, see, U.S. Pat. No. 5,173,414; International
Publication Nos. WO 92/01070 (published Jan. 23, 1992) and WO
93/03769 (published Mar. 4, 1993); Lebkowski et al. (1988) Molec.
Cell. Biol. 8:3988-3996; Vincent et al. (1990) Vaccines 90 (Cold
Spring Harbor Laboratory Press); Carter, B. J. (1992) Current
Opinion in Biotechnology 3:533-539; Muzyczka, N. (1992) Current
Topics in Microbiol. and Immunol. 158:97-129; Kotin, R. M. (1994)
Human Gene Therapy 5:793-801; Shelling and Smith (1994) Gene
Therapy 1:165-169; and Zhou et al. (1994) J. Exp. Med.
179:1867-1875.
[0042] AAV vectors can also include control sequences, as well as
selectable markers or reporter genes, enhancer sequences, and other
control elements that allow for the induction of transcription. The
term "control sequences" refers collectively to promoter sequences,
polyadenylation signals, transcription termination sequences,
upstream regulatory domains, origins of replication, internal
ribosome entry sites ("IRES"), enhancers, and the like, which
collectively provide for the replication, transcription and
translation of a coding sequence in a recipient cell. Not all of
these control sequences need be present so long as the selected
gene is capable of being replicated, transcribed and translated in
an appropriate recipient cell.
[0043] Heteroloqous Nucleotide Sequences
[0044] In the context of the present invention, "heterologous
nucleotide sequences" generally refers to nucleic acid sequences
such as coding sequences and control sequences that are not
normally joined together, and/or are not normally associated with a
particular cell.
[0045] The selected heterologous nucleotide sequence used in the
AAV vector can comprise any desired gene that encodes a protein
that is defective or missing from a recipient cell genome.
Alternatively, the selected heterologous nucleotide sequence can
encode a native or non-native protein having a desired biological
or therapeutic effect (e.g., an antiviral function). Suitable genes
for use in the AAV vector include those used for the treatment of
inflammatory diseases, autoimmune, chronic and infectious diseases,
including such disorders as AIDS, cancer, neurological diseases
cardiovascular disease, hypercholestemia; various blood disorders
including various anemias, thalasemias and hemophilia; genetic
defects such as cystic fibrosis, Gaucher's Disease, adenosine
deaminase (ADA) deficiency, emphysema, etc. Heterologous nucleic
acid sequences considered particularly well-suited for use in an
AAV vector include sequences that encode the following proteins:
Hemophilia B Factor IX, Hemophilia A Factor VIII, Gaucher's Disease
Glucocerbrosidase, Sly's Syndrome BetaGlucuronidase, Hurler's
Alpha-Iduronidase, Hereditary Emphysema alpha-1 Antitrypsin,
Beta-Thalassemia EPO, and Parkinson's Diseases Tyrosine kinase
& AADC. Heterologous coding sequence may also comprise
synthetic sequences having codons different from the native
gene.
[0046] In certain embodiments, the selected nucleotide sequence can
correspond to a molecule having an antisense or ribozyme function.
A number of antisense oligonucleotides (e.g., short
oligonucleotides complementary to sequences around the
translational initiation site (AUG codon) of an mRNA) that are
useful in antisense therapy for cancer and for viral diseases have
been described in the art. See, e.g., Han et al. (1991) Proc. Natl.
Acad. Sci. USA 88:4313-4317; Uhlmann et al. (1990) Chem. Rev.
90:543-584; Helene et al. (1990) Biochim. Biophys. Acta.
1049:99-125; Agarwal et al. (1988) Proc. Natl. Acad. Sci. USA
85:7079-7083; and Heikkila et al. (1987) Nature 328:445-449. For a
discussion of suitable ribozymes, see, e.g., Cech et al. (1992) J.
Biol. Chem. 267:17479-17482 and U.S. Pat. No. 5,225,347 to Goldberg
et al.
[0047] AAV Helper Vectors
[0048] AAV helper vectors can be used to provide transient
expression of AAV rep and/or cap genes, thereby complementing the
missing helper functions of the rAAV vector. AAV helper vectors can
be in the form of a plasmid, phage, transposon, cosmid, virus, or
virion. A number of AAV helper vectors have been described, such as
the commonly used plasmids pAAV/Ad and pIM29+45 which encode both
Rep and Cap expression products. See, e.g., Samulski et al. (1989)
J. Virol. 63:3822-3828; and McCarty et al. (1991) J. Virol.
65:2936-2945. A number of other vectors have also been described
which encode Rep and/or Cap expression products. See, e.g., U.S.
Pat. No. 5,139,941.
[0049] Due to homologous recombination events between the AAV ITR
sequences present in the AAV vector and the AAV helper function
sequences present in the helper construct, the use of certain
constructs could potentially generate contaminating wild-type AAV
virions in the rAAV virion stocks. The presence of such wild-type
AAV particles in AAV-based vector systems could lead to the
unintentional spread of recombinant AAV virions or could interfere
with the efficient expression of foreign genes. (The most likely
problem is that wt-AAV will outgrow rAAV in the production thereby
lowering the yield of rAAV.)
[0050] To avoid generating wild-type AAV particles, the disclosed
invention contemplates the use of nucleic acids encoding AAV helper
functions as described in U.S. Pat. No. 6,001,650, hereby
incorporated by reference. Specifically, in certain embodiments of
the disclosed invention, an AAV helper construct is used that
includes an AAV rep coding region, an AAV cap coding region, and a
modified AAV p5 promoter that lacks an intact TATA box. In
particular embodiments, the modified p5 promoter is located 3'
relative to the rep coding region. The use of such constructs will
minimize or eliminate homologous recombination events and thus
minimize the formation of wild-type AAV particles.
[0051] Accessory Function Vectors
[0052] AAV production generally requires coinfeclion with an
unrelated helper virus (e.g., an adenovirus, a herpes virus or a
vaccinia virus) in order to supply necessary "accessory functions."
For example, it has been demonstrated that adenovirus supplies
factors required for AAV promoter expression, AAV messenger RNA
stability and AAV translation. See, e.g., Muzyczka, N. (1992) Curr.
Topics. Microbiol. and Immun. 158:97-129. In the absence of these
"accessory functions," AAV establishes a latent state by insertion
of its genome into a host cell chromosome. On the other hand, upon
supply of these accessory functions, the integrated copy is rescued
and can replicate to produce infectious viral progeny.
[0053] Rather than using infectious helper virus to provide the
necessary accessory functions, the present invention contemplates
that the accessory functions will be provided on a
replication-incompetent accessory function vector. In certain
preferred embodiments, the accessory function vector(s) will
include adenoviral-derived nucleotide sequences necessary for rAAV
virion production. Such sequences can include E1a, E1b, E2a, E4 and
VA RNA regions.
[0054] More specifically, U.S. Pat. No. 6,004,797, incorporated by
reference herein, describes the production of rAAV without
infectious helper virus. For example, instead of infecting with
infectious adenovirus, the host cell is transfected with one or
more vectors having nucleotide sequences from an adenovirus type-2
or type-5 genome that are required for rAAV replication and
packaging but are insufficient to make infectious adenovirus. These
nucleotide sequences include (i) adenovirus VA RNAs, (ii) an
adenovirus E4 ORF6 coding region, (iii) an adenovirus E2a 72 kD
(coding for the E2a 72 kD DNA-binding protein), or any combination
of nucleotide sequences (i), (ii), and (iii). Alternatively, one or
more accessory function vectors can provide other nucleotide
sequences encoding accessory functions. Importantly, these
accessory function vectors lack most of the adenovirus genome,
including the fiber protein. Production of rAAV in this manner,
i.e., without infectious helper virus, minimizes the health and
safety concerns.
[0055] While not being bound by any particular theory, the
accessory functions provided by the adenovirus E1b, E2a, and E4
early genes are thought to be required in AAV DNA replication. The
accessory functions provided by the adenovirus E1b, E4, and VA RNA
gene regions appear to participate in post-transcriptional or
translational events in the AAV life cycle. Regarding the accessory
functions provided by E4, only the E4 34 kD protein encoded by open
reading frame 6 (ORF 6) of the E4 coding region is clearly required
for AAV replication. The accessory functions provided by the
adenovirus gene region E1a are thought to be required as modulators
to activate transcription or expression of the other adenovirus
gene regions, including E1b, E2a, E4 and VA RNA.
[0056] The accessory function vectors of the invention can
alternatively include one or more polynucleotide homologue(s) that
replace the adenoviral gene sequences, so long as each homologue
retains the ability to provide the accessory functions of the
replaced adenoviral gene. Thus, homologous nucleotide sequences can
be derived from another adenoviral serotype (e.g., adenovirus
type-2), from another helper virus moiety (e.g., a herpesvirus or
vaccinia virus), or can be derived from any other suitable
source.
[0057] Further, accessory function vectors constructed according to
the invention can be in the form of a plasmid, phage, transposon or
cosmid. Alternatively, the vector can be in the form of one or more
linearized DNA or RNA fragments that, when associated with the
appropriate control elements and enzymes, can be transcribed or
expresses in a host cell to provide accessory functions.
[0058] Accessory functions vectors can be engineered using
conventional recombinant techniques. Particularly, nucleic acid
molecules can be readily assembled in any desired order by
inserting one or more accessory function nucleotide sequences into
a construct, such as by ligating restriction fragments into a
cloning vector using polylinker oligonucleotides and the like. The
newly formed nucleic acid molecule can then be excised from the
vector and placed in an appropriate expression construct using
restriction enzymes or other techniques that are well known in the
art.
[0059] Members of herpesviridae are also known to act as AAV helper
viruses. In alternative embodiments of the disclosed invention,
particular sequences from herpesviridae capable of assisting in the
production of AAV in a host cell can be used in an accessory
function vector.
[0060] In alternative embodiments, rAAV may be produced using
various cell lines that possess AAV helper and/or accessory
functions necessary to produce rAAV particles, thus obviating the
need for transduction with helper and/or accessory function
vectors.
[0061] Large-Scale Cell Culture for rAAV Production
[0062] One major obstacle in producing rAAV virions for large
clinical trials and commercial use involves the present lack of
commercially feasible large-scale cell culture techniques. The
disclosed invention contemplates the use of various tissue culture
devices that are amenable for use with large-scale cell-culture
protocols. Examples of suitable tissue culture devices include the
use of bioreactors and roller-bottles. One type of bioreactor is a
cell culturing apparatus that has a cylindrical tank and a stirring
apparatus to circulate cells and culture medium. Bioreactors are
capable of producing high-density cell cultures, which in turn
produce large amounts of RaaV after purification. Roller-bottles
are cylindrical tissue culture bottles that are rotated at a given
periodicity. The advantage of using roller-bottles in cell culture
is that roller-bottle techniques are scaleable and thus decrease
the labor and the costs of virion production. Moreover,
roller-bottles are disposable, obviating laborious cleaning and
sterilization and simplifying post-production facility validation.
The roller bottles used are available commercially and a variety of
bottles having different culture surface areas are available. The
methods of the disclosed invention are not limited by the surface
area of any particular roller bottle. Accordingly, various sizes of
roller bottles are contemplated for use with the disclosed
invention.
[0063] A variety of cells lines are contemplated for use in the
large-scale production of rAAV. Particularly suitable for cell
culture of rAAV is Human Embryo Kidney (HEK) 293 adherent cell
lines. Examples of other suitable cell lines to produce rAAV
include: Vero cells, HeLa cells, and CHO cell lines. As used
herein, the term "cell line" refers to a population of cells
capable of continuous or prolonged growth and division in vitro.
Often, cell lines are clonal populations derived from a single
progenitor cell. It is known in the art that spontaneous or induced
changes can occur in karyotype during storage or transfer of such
clonal populations. Therefore, cells derived from the cell line
referred to may not be precisely identical to the ancestral cells
or cultures. Nevertheless, the term "cell line" includes such
variants.
[0064] Once a cell line is selected, the tissue culture device of
choice is seeded with cells at a density suitable to support cell
culture. The density of cells used to seed a particular device will
depend on the size of the device. For example, when the cell
culture device is a roller-bottle with a surface area of about 850
cm.sup.2, a cell density of between
1.times.10.sup.4-1.times.10.sup.9 cells/bottle is used to seed the
bottle. In certain preferred embodiments, roller-bottle having a
surface area of about 850 cm.sup.2 are seeded with cells ranging
from between 1.times.10.sup.7-1.times.10.sup.8, or in one
particularly preferred embodiment, such bottles are seeded at a
density of about 2.times.10.sup.7 cells/bottle.
[0065] A variety of volumes may be used to grow the cells in the
tissue culture device of choice. The volume of medium used will
vary according to the size of the tissue culture device used to
grow the tissue culture cells. When a roller-bottle with a surface
area of about 850 cm.sup.2 is used as the tissue culture device,
the cells are preferably grown in a volume of approximately 200
ml.
[0066] Various growth media may be used in the disclosed invention
to achieve large-scale cell growth. In one embodiment, Delbeco's
Modified Eagle's Medium (DMEM) culture fluid supplemented with 4.5
grams per liter of glucose and 10% fetal calf serum is used to grow
the tissue culture cells of choice. The selection of growth medium
varies depending on the type of cells being cultured. One of skill
in the art will appreciate that there are many alternatives to
DMEM, that other volumes of culture media may be used (preferably
between 100-500 mls), and that the media may be supplemented with
anywhere from 0-20% fetal calf serum. (See WO 00/22152, which is
hereby incorporated by reference).
[0067] Introduction of Vectors into Tissue Culture Cells
[0068] The vectors of the disclosed invention can be introduced
into a cell using a variety of transfection techniques. Such
transfection methods have been described in the art, including
calcium phosphate co-precipitation (Graham et a!. (i973) Virol.
52:456-467), direct micro-injection into cultured cells (Capecchi,
M. R. (1980) Cell 22:479-488), electroporation (Shigekawa et al.
(1988) BioTechniques 6:742-751), liposome mediated gene transfer
(Mannino et al. (1988) BioTechniques 6:682-690), lipid-mediated
transfection (Felgner et al. (1987) Proc. Natl. Acad. Sci. USA
84:74137417), and nucleic acid delivery using high-velocity
microprojectiles (Klein et al. (1987) Nature 327:70-73). Other
acceptable transfection media include strontium phosphate,
polycationic polymers, e.g., Superfect (QIAGEN.TM.), liposomes, and
polyethyleneimine (PEI). (See e.g, WO 00/22152)
[0069] Any of these techniques can be used to introduce one or more
exogenous DNA moieties, such as AAV helper constructs, AAV vector
plasmids, and other vector constructs into suitable host cells.
Generally, the exogenous DNA must traverse the host cell plasma
membrane in order to be exposed to the cell's transcription and
replication machinery. The resulting cell can be transiently
transfected with the exogenous nucleic acid molecule, i.e., the
exogenous DNA will not be integrated into the genome of a
transfected cell, but rather will exist episomally. Alternatively,
the resulting cell can be stably transfected, i.e., the nucleic
acid molecule will become covalently linked with the host cell
genome or will be maintained and replicated as an episomal unit
which can be passed on to progeny cells (e.g., capable of
extrachromosomal replication at a sufficient rate).
[0070] In one embodiment of the invention, the host cells of choice
are triple-transfected with at least one vector encoding a
heterologous nucleotide sequence of interest, at least one vector
encoding AAV helper functions, and at least one vector encoding
viral accessory functions. Triple-transfection is preferably done
using a standard calcium-phosphate mediated transfection (Graham et
al., 1973, J. Virol. 33:739-748) or PET transfection.
[0071] Triple-transfection is preferably done at day-two post cell
seeding. However, transfection can alternatively occur on the day
cell seeding is performed, or may be done on day one, day two, day
three, day four, or day five post cell seeding depending on the
cell seeding density. The cell culture medium is then typically
harvested at day three post-transfection. However, the cells and
culture medium containing the transfected cells may alternatively
be harvested on day zero through day five following transfection,
more preferably between day two and day four following
transfection.
[0072] Once harvested, the cells are analyzed for rAAV production
using various techniques well known in the art. For example,
quantitative PCR may be used to analyze culture medium for rAAV
production. Typically, production in roller bottles will yield
between 1.times.10.sup.9 and 5.times.10.sup.10 vector genomes
(vg)/cm2.
[0073] Concentration of Cells and Buffer Exchange
[0074] Following harvest, the cell culture-containing medium is
often in a large volume. Purification of viral particles from the
cells contained in the large volume of culture medium, typically
100 liters or more, is time sensitive and labor intensive. Although
not an essential step in the production and purification of rAAV,
several techniques can be used to concentrate the rAAV viral
particles, thus simplifying the post-harvest or downstream
processing of the cell culture medium. One technique contemplated
by the present invention is continuous centrifugation. Continuous
centrifugation of the cell culture is performed in order to reduce
the volume of the culture and to permit the buffer exchange that
can, in particular embodiments, facilitate further downstream
processing. Through the process of continuous centrifugation, the
volume of cell culture medium will generally be reduced 10-fold,
thus, for example, reducing the medium containing the cells of
interest from 100 liters down to about 10 liters. In other
embodiments, the cell culture medium is reduced between 2-fold and
100-fold.
[0075] The concentration/buffer exchange protocol can also be
utilized to wash the transformed cells. In one embodiment, the
cells are washed with an appropriate buffer to facilitate further
downstream processing. The washing of the cells serves to eliminate
various waste products and culture medium components that might
otherwise contaminate the final preparation of rAAV particles.
Several suitable buffers are well known in the art, including
various phosphate and bicarbonate buffers. Following condensation
and buffer exchange, the cells are ready to be lysed in order to
recover the rAAV.
[0076] Cell Lysis
[0077] Several techniques are contemplated by the disclosed
invention to achieve lysis of the harvested and concentrated
cultured cells. Examples of suitable cell lysis protocols include:
sonication, multiple freeze/thaw cycles, and osmotic shock. For the
purposes of large-scale purification, however, mechanical lysis,
using a Microfluidizer.TM. (Microfluidics International Corp.,
Newton, Mass.), is a more efficient way to prepare the cell lysate
in large scale.
[0078] The buffer systems used for cell lysis have been found to
significantly affect the efficiency of rAAV release from the cells.
One condition of particular interest is the osmolality of the
solution. In certain embodiments, modification of the ion
concentrations can be used to alter the osmolality of the solution
and facilitate cell lysis and rAAV release. For example, increasing
amounts of NaCl correlate with an increase in rAAV vector release.
As shown in FIG. 1, when normalized to the number of rAAV particles
released at 100nM NaCl, a 2.6-fold, 2.9-fold and 3.2-fold increase
in rAAV release is observed at 200 nM, 500 nM and 1 M NaCl
concentrations, respectively. One skilled in the art will
appreciate that other compounds could be used to alter the
osmolality of the buffer solution.
[0079] In one preferred embodiment of the invention, the cells are
re-suspended in a phosphate buffer containing 20 mM sodium
phosphate and 200 mM NaCl at pH 7.4, and lysed by subjecting the
cells to multiple rounds of homogenization or other mechanical
stress (e.g., Microfluidizer.TM.). The total virus recovered from
this technique is comparable or better than that obtained using
multiple freeze and thaw cycles. Furthermore, this method permits
passing the cells at a flow rate about 650 ml/minute. Consequently,
the methods of the disclosed invention are suitable for
accommodating a large volume of cells and, when used with the
preferred buffer conditions, can be used to achieve a high
efficiency of cell lysis and rAAV release.
[0080] Clarification
[0081] The lysate produced from the lysis of the rAAV-containing
cultured cells will generally be clarified before further
downstream purification steps are performed. Several clarification
techniques are known that can be used in rAAV purification,
including centrifugation and tangential flow filtration.
Alternatively, the cell lysate can be clarified by filtration using
one or more filters of varying pore size. Suitable clarification
techniques will permit a high throughput of lysate, provide ease of
use, are scaleable for use with large volumes, and result in
superior viral vector recovery.
[0082] In one preferred embodiment, the cell lysate is filtered
through a 2.0 p.mu.m ULTIPLEAT PROFILE.TM. filter and then filtered
through a 0.45 .mu.m SUPOR.TM. membrane filter (Pall Corporation,
Port Washington, N.Y.) at a flow-rate of i20 ml per minute. Using
this technique, up to 100% rAAV recovery may be achieved. Following
filtration, the sample is ready for chromatography
purification.
[0083] Chromatography
[0084] The disclosed invention contemplates using a plurality of
chromatographic steps in order to purify rAAV particles from
cellular debris. Three modes of chromatography, used in varying
orders and combinations, are contemplated by the present invention:
cation exchange chromatography, anion exchange chromatography, and
affinity chromatography. The invention also contemplates many
support medium, including agarose, cellulose, silica, and
poly(stryrene-divinylbenzene) (PSDVB). In addition multiple
chromatographic methods can be used including conventional
chromatography, HPLC (High Performance Liquid Chromatography or
High pressure Liquid Chromatography), or perfusion chromatography.
One skilled in the art will also appreciate that the size of the
column (i.e., diameter and length) will depend on several factors
such as the volume of material to be loaded, the concentration of
rAAV to be purified, and the desired resolution or purity.
[0085] In cation exchange chromatography, a negative functional
group is bound to the insoluble support medium. Accordingly, cation
exchange chromatographic media bind positive counter ions when the
incubation period is a sufficient time period to allow for the
positively charged groups to bind to and come to equilibrium with
the negatively charged cation exchanger medium. Neutral molecules
and anions do not bind to the cation exchange medium. Following the
electrostatic binding of species possessing a net positive charge,
the cationic medium is washed, removing non-binding molecules from
the medium. Bound ions are then eluted either by washing the medium
with increasing concentrations of positive ions or by altering the
pH of the medium. The disclosed invention contemplates using a
variety of cation exchange media such as any sulfo-, phosphor
carboxy-, or carboxy-methyl-based cation exchange resins bound to
numerous support medium well known in the art.
[0086] In one embodiment, the cation exchanger is a commercially
available cation exchange module contains a sulfo-based material
called MUSTANG STM (Pall Membrane Technology Corporation,
Pensacola, Fla.). The material has the typical cation exchanger
function, but instead of using typical beads as solid phase to link
the functional group, a membrane-based solid phase is used. This
material is very robust and allows a high flow-rate for
purification due to the pore size of the membrane. rAAV binds to
the MUSTANG S.TM. cation exchanger in a 20 mM sodium phosphate
buffer solution at pH 6.0 having a salt concentration below 200 mM
NaCl. The rAAV can be eluted at salt concentration above 250 mM
NaCl in the same phosphate buffer. Under these conditions, the rAAV
is purified more than 1000-fold and routinely greater than 80% of
the rAAV material loaded is recovered.
[0087] Anion exchange chromatography is analogous to cation
exchange PI.TM. chromatography except that a positive functional
group is bound to the insoluble support medium. Several possible
anion exchange media are known that can be used in such columns
including N-charged amino or imino resins such as POROS 50 PI.TM.,
Q SEPHAROSE.TM., any DEAE, TMAE, tertiary or quaternary amine, or
PEI-based resin. One of skill in that art will appreciate that
isolated recombinant rAAV can be purified on an anion exchange
column either before or after purification on other columns.
[0088] In one embodiment of the present invention, an anion
exchange column is used that contains a material called STREAMLINE
Q XLT.TM. (Pharmacia, Piscataway, N.J.). This material has a strong
anion exchanger function as well as a high loading capacity and a
high chemical stability so that it can be used over a wide pH
range. In passing rAAV-containing material through a STREAMLINE Q
XL.TM. column at 7.0-8.5 pH and under 200 mM NaCl conditions, the
rAAV flows through the column while much of the contaminating
protein remains bound to the column. Under these conditions, the
rAAV is purified more than 2-3 fold and routinely greater than 90%
of the rAAV material loaded is recovered.
[0089] Affinity chromatography is a technique that provides for
ligand specific purification of a target compound. As such, the
technique exploits the structural and functional characteristics
properties of macromolecules by binding the molecules based on
these specific characteristics under certain conditions.
[0090] A variety of different affinity column matrices are
contemplated for use with the disclosed invention. For example,
antibodies directed against coat proteins of rAAV may be used to
generate affinity column media that in turn can be used to purify
rAAV. Another example of an affinity column utilizes one or more
cell receptors of AAV. These receptors can often be produced and
used to generate affinity column media.
[0091] A number of molecules are thought to serve as AAV receptors.
For example, AlphaV-beta5 integrin (Summerford, C., et al., Nat Med
January 5:1 78-82 (1999)), human fibroblast growth factor receptor
1 (Qing K, et al., (Nat Med January 5:1 71-7 (1999)), and a
membrane-associated heparin sulfate proteoglycan (Summerford &
Samulski, J Virol. February 72:2 1438-45 (1998)), have all been
reported as AAV receptors. Any of these receptors or other
molecules can be used to generate affinity chromatography
media.
[0092] One embodiment of the disclosed invention contemplates the
use of heparin as the adsorbent group. Affinity chromatography
media containing heparin are commercially available from a variety
of sources. For example, PerSeptive Biosystems, Inc. (Framingham,
Mass.) markets a heparin-based medium (POROS 20HE.TM.). When POROS
20HE.TM. is used as the affinity chromatography medium, the rAAV
containing solution is applied to the affinity medium and
subsequently eluted with an appropriate salt concentration.
[0093] rAV binds to the POROS 20HE.TM. at a salt concentration of
about 250 mM or less NaCl in the 20 mM phosphate buffer at pH 7.4
and starts to elute at 300 mM NaCl, but elutes more efficiently at
salt concentrations of 400 mM NaCl or higher in the same buffer.
Following loading of rAAV-containing material, the affinity
chromatography medium can be washed with an anionic detergent, such
as 5-15 mM sarcosine or 0.5% sodium deoxycholatic acids having a
salt concentration of between 150-300 mM NaCl in order to remove
protein contaminants from the final rAAV product. In one specific
embodiment, rAAV containing samples in 20 mM phosphate/250 mM NaCl
at pH 7.4 were loaded on POROS 20 HE.TM. affinity columns and the
columns were washed with 3 times the bed volume of 100 mM NaCl, 20
mM phosphate buffer at pH 7.4 buffer containing either 6M urea,
0.5% deocholate acid, or 15 mM sarcosine. The rAAV was eluted from
the columns with 3 bed volumes of 20 mM phosphate/400 mM NaCl at pH
7.4, and the various eluates were compared for protein contaminants
by silver-stained SDS PAGE. Referring to FIG. 2(a), lane 4 is a MW
marker, lane 3 is 6M urea washed sample, lane 2 is 0.5%
deoxycholate acid washed sample, and lane 1 is a 15 mM sarcosine
wash. The sarcosine wash removed the most contaminants from the
rAAV preparation. To verify that the bands on the SDS PAGE gel in
fact represented rAAV capsid proteins VP1, VP2, and VP3, a Western
blot was run using primary monoclonal antibodies to VP1, VP2, and
VP3 conjugated with Horseradish peroxidase (shown in FIG. 2(b)).
Typically, greater than 50 percent of the rAAV is recovered from
heparin affinity chromatography under these conditions.
[0094] Certain embodiments of the disclosed invention contemplate
the use of a cation exchange medium in conjunction with an affinity
chromatography medium to purify rAAV particles from the cellular
milieu released during the lysis process. In one embodiment, the
cell lysate is loaded on a cation exchanger module containing the
MUSTANG S.TM. medium (Pall Membrane Technology Center, Pensacola,
Fla.). Such modules are available commercially in a variety of
sizes, including 10 ml and 100 ml. Following purification over the
cation exchange module or column, the rAAV-containing material is
passed over a heparin-based resin. The column is then washed and
eluted. The purified sample of virions can be analyzed by
silver-stained SDS-PAGE for purity.
[0095] An alternative embodiment of the invention uses an anion
exchange medium in conjunction with an affinity medium in order to
purify rAAV particles for pharmacological use. For example, a rAAV
lysate can be prepared having a concentration of approximately 200
mM NaCl and that lysate can be passed over an anion exchange
column, such as STREAMLINE Q XL.TM., MUSTANG Q.TM. (module), POROS
50 PI.TM., Q SEPHAROSE.TM., any DEAE, TMAE, tertiary or quaternary
amine, or PEI-based resins. In addition to achieving a high level
of purification, the MUSTANG Q.TM. module also permits high
flow-rate processing.
[0096] rAAV is generally recovered from an anion exchange step in
the flow-through fractions (depending on the pH). The salt
concentration and pH of such flow-through fractions can then be
adjusted for purification over a heparin column or for purification
over any other suitable affinity column. It should be noted that
the order of the chromatographic media is not considered to be
important to the ultimate purification of the rAAV particles. Also,
a cation exchange column may optionally be used to further purify
the sample, and treatment with a nuclease can be used, but is not
required. The yields obtained using such combinations are
predictable based on the yields obtained using the individual
column-purification steps.
[0097] rAAV eluted from an ion exchange column and/or affinity
column can be subjected to additional ion exchange or affinity
purification steps (i.e., polishing) as required. In one embodiment
of the invention, eluate purified by combination cation exchange
chromatography and affinity chromatography was polished by passage
over a 16 mm diameter POROS 50 PI.TM. anion exchange column
(Applied Bioscience, Foster City, Calif.) having a volume of 1.6 mL
at a flow rate of approximately 150 cm/hr. rAAV does not bind to
the column at a salt concentration of 400 mM NaCl and at a pH of
between 5.5 and 7.4. DNA and other residual proteins bind to the
anionic exchange membrane.
[0098] Nucleic Acid Digestion
[0099] An optional purification step contemplated in certain
embodiments of the disclosed invention addresses the issue of DNA
contamination of the final rAAV product. During the lysis
procedure, large amounts of cellular DNA are released into the
lysate. This material may affect the purity of the final rAAV
composition. One option for reducing the DNA contamination from the
final rAAV products is to digest the DNA before or during the
chromatography purification steps.
[0100] A variety of DNA digestion methods are contemplated for use
in the disclosed invention. For example, enzymatic and chemical
means of DNA digestion are contemplated for use with the methods of
the disclosed invention. Typically, DNA is digested with nuclease,
such as Dnase I.TM. or BENZONASET.TM., (E. M. Science, Gibstown,
N.J.) before the purification process.
[0101] In one embodiment of the disclosed invention, BENZONASE.TM.
is used to digest DNA during the large-scale rAAV purification
process. The digestion may occur before, after, or during the first
chromatographic purification step. For example, the rAAV containing
cell lysate may be treated with BENZONASE.TM. prior to or during a
step at which rAAV particles are applied to a cationic exchange
medium. Specifically, when that medium is MUSTANG S.TM., the rAAV
will bind to the membrane whereas contaminant DNA and other
contaminants will fail to bind and will be subsequently washed from
the membrane.
[0102] In theory, DNA should not bind the MUSTANG S.TM. membrane.
Nevertheless, there is a possibility that residual DNA will bind to
the membrane due to non-specific binding. To remove such DNA
contamination, techniques have been developed to treat the sample
during the purification while the rAAV is bound to the module S.
That is, BENZONASE.TM. at a concentration of 200 U/ml can be used
to wash the MUSTANG S.TM. membrane after the sample is loaded.
Given the fact that BENZONASE.TM. does not bind to cationic
exchangers, BENZONASE.TM. can be removed from the MUSTANG S.TM. by
washing the module thoroughly.
[0103] Virus Product Concentration
[0104] The rAAV produced by the above-described methods may
optionally be concentrated for storage and use. A number of
concentration protocols are contemplated by the present invention,
including tangential flow filtration. One skilled in the art will
appreciate that many membranes are commercially available in an
extensive range of molecular weight cutoffs or pore sizes.
EXAMPLES
[0105] Particular aspects of the present invention may be more
readily understood by reference to the following examples, which
are intended to exemplify the invention, without limiting its scope
to the particular exemplified embodiments.
Example 1
Cell Culture
[0106] In a sterile environment such as a biosafety cabinet (BSC),
Human Embryo Kidney (HEK) 293 cells suspended in 200 milliliters of
Dulbecco's Modified Eagle's Medium (DMEM) (10% Fetal Calf Serum
(FCS), 1 mM glutamine) were added to each of 10 two liter roller
bottles (850 cm cultivable surface area) at a quantity of
50,000,000 cells per bottle. Alternatively, the cells were
suspended in a smaller quantity of supplemented growth medium,
added to the roller bottles, and medium added to each bottle to
give a final volume of 200 mL. The air in the roller bottles was
displaced with a mixture of 5% CO.sub.2 in air using a sterile
pipette connected to a source of 5% CO.sub.2/air, and the bottles
were capped tightly. The roller bottles were placed in a roller
bottle rack set at a rotation rate of 0.2 revolutions per minute,
in a temperature-controlled environment.
[0107] The roller bottles were incubated for 3 days at 37.degree.
C. At the end of this incubation period, the roller bottles were
removed to a BSC, caps removed, and a solution of calcium phosphate
containing equal quantities of purified bacterial plasmid vectors
encoding rAAV sequences, helper functions, and accessory functions
were added. In particular, 1500 .mu.g of each of plasmids pHLP 19,
pLadeno5, and hFIX9, were added to 150 mL of a 0.3M CaCl.sub.2
solution and mixed. This solution was added to an equal volume of
Transfection Buffer (0.28M NaCl, 0.05M HEPES, 1.5 mM
Na.sub.2HPO.sub.4, pH 7.10). The total volume of the combined
solutions was 300 milliliters.
[0108] Following mixing, 30 milliliters of the Transfection
solution containing plasmids was added to each of the ten roller
bottles (corresponding to addition of 150 .mu.g of each of the
three plasmids to each roller bottle). The bottles returned to the
roller bottle rack for a further incubation period of approximately
16 hours (overnight). After incubation, the roller bottles were
removed from the roller bottle rack, and placed in a BSC.
[0109] For each roller bottle, the growth medium was completely
removed, taking care not to disrupt adherent cells growing on the
walls of the vessels. The growth medium was removed and replaced
with pre-warmed (37.degree. C.) DMEM supplemented with 1 mM
glutamine, but not supplemented with FCS. The roller bottles were
returned to the roller bottle rack, and incubated for a further
three days at 37.degree. C. After incubation, the roller bottles
were removed from the roller bottle rack and placed in a BSC. Two
milliliters of 0.5M ethylene diamine tetraacetate (EDTA) were added
to each bottle (final concentration of EDTA in growth medium was 5
mM), and bottles were gently agitated to remove cells from the
inside surface of the roller bottle. After complete detachment, the
cells containing AAV were removed from the roller bottles and AAV
production was assessed using Q-PCR. Although AAV production using
this method is generally in the range of
5.times.10.sup.9-1.times.1- 0.sup.10 vg/cm for a roller bottle
having a surface area of 850 cm.sup.2, in this particular example
AAV production was 6.5.times.10.sup.9 vg/cm.sup.2. As shown in FIG.
3, AAV produced using similar techniques, but in T-flasks having a
surface area of 225 cm.sup.2, yields only about 2.3.times.10.sup.9
vg/cm.sup.2. Following assessment of AAV production, the cells were
pooled in a sterile container for further processing.
[0110] The manipulation of roller bottles as described in this
example can be performed manually by trained personnel using
appropriate equipment to ensure the sterility of the cultures. For
manipulations of larger numbers of bottles (for example, greater
than or equal to 100 roller bottles), the use of equipment designed
for automation of roller bottle handling can be used. One such
apparatus is The Automation Partnership CellMate.TM. robot arm. For
example, for performing each of the manipulations described above
for 500 roller bottles, use of the CellMate.TM. robot arm
(assembled and distributed by The Automation Partnership, Boston,
Mass.) would replace skilled operators. Advantages of using this
automation system include capability to handle more roller bottles,
higher precision of manipulations, reduced incidence of
contamination, and reduced incidence of personnel injury.
Example 2
Concentration of rAAV-Containing Cells
[0111] Although not essential to the purification of rAAV, cells
harvested in the cell culture media (DMEM medium) were concentrated
using continuous centrifugation. Cells and cell culture medium were
fed in the centrifuge through the input valve continuously, and
concentrated down by low speed centrifugation (1000 rpm to 1200
rpm). The concentrated cells were continuously harvested from the
centrifuge from the bottom of the container to a cell collection
container. The waste medium was discharged from the top of the
centrifuge to the waste container. Since this centrifuge allows the
materials to be continuously fed in and the waste materials
continuously discharged, high throughput was achieved. Using
continuous centrifugation, a 15-fold volume reduction was
achieved.
Example 3
Buffer Exchange
[0112] Although also not essential to the purification of rAAV, the
procedure described in Example 2 was used to exchange the culture
medium in which the cells were grown with a buffer solution of
choice. The starting buffer being used for rAAV purification column
chromatography techniques contains 20 mM sodium phosphate and 200
mM sodium chloride at pH 5.5 or higher. The high throughput of the
continuous centrifugation allows greater than 90% buffer exchange
of rAAV-containing cell solutions.
Example 4
Lysis of Concentrated Culture Medium
[0113] For large-scale rAAV purification, the cells were lysed
using a microfluidization technique. Recovery using this technique
was also compared to that obtained using freeze/thaw lysis
techniques. As shown in FIG. 4, rAAV is more efficiently recovered
after three rounds of microfluidization than after three
freeze/thaw rounds over a variety of salt concentrations. Also,
regardless which technique is used, the salt concentration affected
the efficiency of viral vector release from cells. Specifically,
when sodium chloride in the range of 200-1000 mM was used, the rAAV
vectors were extracted more efficiently than under lower salt
conditions.
[0114] Although not an essential step, following lysis, the cell
lysate was then treated with BENZONASE.TM. to digest the genomic
DNA (described in detail in Example 5 below). After the nuclease
treatment, the lysate was further clarified by filtration. That is,
the cell lysate was sequentially filtered at a flow rate of about
350 ml/min through two filters having pore sizes of 2 .mu.m
(ULTIPLEAT PROFILE.TM.; surface area of approximately 2400
cm.sup.2) and 0.45 .about.tm (SUPORLIFE.TM. 450 DCF, surface area
of approximately 1000 cm.sup.2) (Pall Membrane Technology
Corporation, Pensacola, Fla.). As shown in FIG. 5, recovery of rAAV
was greater than 90% throughout this clarification process. This
high level of rAAV recovery was confirmed in two subsequent
filtration runs. Specifically, as shown in FIG. 6, filtration
through a filter having 2 .mu.m pore size (Step 1) yielded greater
than 90% recovery for both runs #1 and #2, and filtration through a
filter having 0.45 .mu.m pore size (Step 2) also yielded greater
than 90% recovery for both runs #1 and #2. Furthermore, as shown in
FIG. 7, a comparison of a clarification system using only a 2 .mu.m
and 0.2 .mu.m (SUPORLIFE.TM. 200 DCF, surface area of approximately
1000 cm.sup.2) filter to a clarification system using a 2 jim, 0.45
jim, and 0.2 jim filter showed that rAAV recovery is somewhat
better using a two-filter system rather than a three filter
system.
Example 5
Nuclease Digestion of Lysate
[0115] BENZONASE.TM., an endonuclease, was used to digest the
genomic DNA at room temperature (approximately 37.degree. C.). The
efficiency of DNA digestion was compared in two buffer systems,
Buffer A composed of 20 mM sodium phosphate/200 mM sodium
chloride/2 mM MgCl.sub.2 at pH 5.5, and Buffer B composed of 50 mM
Tris/2 mM MgCl.sub.2 at pH 8.5. Use of either Buffer A or Buffer B
with 200 U/ml BENZONASE resulted in the majority of the genomic DNA
being digested to smaller than 800 base pairs.
Example 6
Cation Exchange Chromatography of Concentrated Culture Medium
[0116] The cell lysate from five roller bottles (approximately one
liter without concentration) was loaded on a 10 ml cation exchanger
module containing the MUSTANG 5.TM. medium (Pall Corporation, Port
Washington, N.Y.). FIG. 8 is the elution profile of total protein
as detected spectrophotometrically by measuring absorbance at a 280
nm wavelength. The cell lysate was added to the column after the
column was equilibrated with loading buffer for 3 bed volumes. A
sample prepared in accordance with the previous Examples 1 and 4
was adjusted to 20 mM sodium phosphate, 100 mM sodium chloride 5.5
and loaded on the column at a flow rate of 5 ml/min. The column was
then washed with 3 bed volumes of the loading buffer at the same
flow rate resulting in a significant amount of the unbound protein
being washed from the column. The broad peak between about 12 and
32 minutes represents this contaminating protein. Following the
wash, the rAAV was eluted from the column with 3 bed volumes of 20
mM sodium phosphate/300 mM sodium chloride at a pH of 5.5. The peak
at about 38 minutes in FIG. 8 represents AAV as later determined by
infectious activity and genome titer. The column was then cleaned
with 1M sodium chloride/20 mM sodium phosphate buffer to remove
remaining protein (represented by the peak at about 48 minutes in
FIG. 8). Approximately 80-90% of the rAAV loaded onto the column
was recovered as determined by dot blot.
Example 7
Affinity Chromatography of Concentrated Culture Medium
[0117] In this Example, a heparin-based resin called POROS 20HE.TM.
was used in an affinity column for rAAV purification. This column
is commercially available in 1.6 mL or 30 mL sizes and has a
capacity of approximately 1.5-3.0.times.10.sup.12 vector genomes
per mL. The rAAV eluted from the cation exchanger in Example 6 was
applied to the heparin column in the same buffer at a flow rate of
150 cm/hr but at a salt concentration of 200 mM sodium chloride.
The column was then washed several times with the following buffers
for 3-bed volumes each: 20 mM sodium phosphate/100 mM sodium
chloride buffer at pH 5.5; 20 mM sodium phosphate/200 mM sodium
chloride/5 mM sarcosine at pH 5.5; 20 mM sodium phosphate/100 mM
sodium chloride buffer at pH 5.5; 20 mM sodium phosphate/S50 mM
sodium chloride buffer at pH 5.5; 20 mM sodium phosphate/200 mM
sodium chloride buffer at pH 5.5; 20 mM sodium phosphate/250 mM
sodium chloride buffer at pH 5.5; 20 mM sodium phosphate/300 mM
sodium chloride buffer at pH 5.5; 20 mM sodium phosphate/350 mM
sodium chloride buffer at pH 5.5; and 20 mM sodium phosphate/400 mM
sodium chloride buffer at pH 5.5. As indicated in the elution
profile shown in FIG. 9, AAV was eluted using 300 mM and 350 mM
sodium chloride. Peaks corresponding to washes at other salt
concentrations represent protein contamination. The column was
cleaned with a buffer containing 20 mM sodium phosphate/1 M sodium
chloride buffer at pH 5.5. A purified sample of virions (1 E+10
rAAV particles) was analyzed by silver-stained SDS-PAGE for purity
and only rAAV capsid proteins were detected.
Example 8
Anion Exchange Chromatography of Lysate
[0118] In this Example, an anion exchange column containing the
resin STREAMLINE Q XL.TM. (Pharmacia) was used to purify rAV. 200
mL cell lysate prepared according to the methods described in
Examples 1 and 4 was purified over a 30 mL column. Specifically,
the salt concentration and pH of the lysate was adjusted to 200 mM
NaCl and 7.4, respectively. The sample was then loaded on the
column at a flow rate of 300 cm/hr. Also, three bed volumes of 20
mM sodium phosphate/200 mM sodium chloride at pH 7.4 was added
resulting in a significant amount of the unbound protein being
washed off the column. The elution profile (FIG. 10) shows the
total protein as detected spectrophotometrically by measuring
absorbance at a 280 nm wavelength. It was determined by virus
infectious activity and virus genome titration that rAAV is present
in the flow through fractions, corresponding to the broad peak
between about 40-120 minutes. This purification step resulted in
about a 2-3-fold reduction of contaminating protein and about
100-fold reduction in contaminating nucleic acid. The column was
cleaned with a buffer containing 20 mM sodium phosphate/1 M sodium
chloride, resulting in the release of a significant amount of
contaminating protein from the column (corresponding to the peak at
about 144 minutes).
[0119] As demonstrated by agarose gel electrophoresis (FIG. 11),
the anion exchange column efficiently removed a significant amount
of nucleic acid from the cell lysate. Specifically, no nucleic acid
was detected in the flow through fractions (lanes 3-11 and 14-23)
using this technique. A significant amount of contaminating nucleic
acid did come off the column in the 1 M sodium chloride wash,
corresponding to lanes 26-33, and in a further 2 M sodium chloride
wash corresponding to lanes 34-35 and 38-42.
[0120] Blue cell assays of the purified fractions confirmed that
rAAV-lacZ passed through the resin. Also, as shown in FIG. 12,
Q-PCR analysis revealed that greater than 90% of the rAAV could be
recovered in the flow-through fractions. Other contaminating
cellular materials were likely also removed from the rAAV
preparation, including RNA and lipids. Following passage over the
anion exchange resin, the flow-through fractions were collected for
further purification or storage.
Example 9
Ultrafiltration/Diafiltration (UF/DF) of Column Purified
Material
[0121] The material obtained following column chromatography
purification using a heparin-based resin was concentrated two-fold
and ultrafiltered using ten diafiltration volumes to exchange the
column elution buffer with phosphate-buffed saline, pH 7.1,
containing 5% sorbitol, a buffer formulation compatible with in
vivo injection. The apparatus used for UD/DF was a
hollowfibre-based system termed the MidGee manufactured by A/G
Technology Corporation. The recovery of AAV vector following UT/DF
step was in the range from 60%-90%.
Example 10
Anion Exchange and Heparin Column Purification
[0122] In this Example, rAAV was prepared according to the previous
Examples with the exceptions that no cation exchange column was
used and the lysate was not treated with BENZONASE.TM.. Rather, the
cells were grown and transfected as in Example 1, lysed as in
Example 4, the rAAV-containing material was passed over an anion
exchange column as in Example 8, run on a heparin sulfate affinity
column as in Example 7, and eluted as in Example 7. The yields
obtained in each step were comparable to those obtained in each
individual Example, and the final rAAV purity was assessed by
SDS-PAGE gel electrophoresis.
[0123] Referring to FIG. 13, various fractions from the column
purifications were analyzed by SD S-PAGE. Lane one shows a
molecular weight marker, lane two is empty, lane 3 shows 5 ul of
the flow through from the anion exchange column, lane 4 shows 4 ul
of the flow through material from the heparin sulfate column, lane
5 shows the material from a 0.50% DOC wash of the heparin sulfate
column, lanes 6-9 shows 5, 10, 15, and 20 mL, respectively, of
rAAV-containing material from the purified fractions after 100-fold
concentration in a Centricon.TM. column (Millipore, Bedford,
Mass.), lane 10 is empty, and lane eleven is a CsCl purified
control. The column-purified fractions (lanes 6-9) yielded bands
corresponding to VP1, VP2, and VP3 having comparable purity to the
CsCl-purified control.
[0124] The recovery of AAV at each step throughout this
purification process is shown in FIG. 14. Specifically, virion
recovery is shown for each of three rounds of microfluidization,
for filtration through a 2 um filter, for two washes of this
filter, for the pooled filtrate and wash materials, for filtration
through a 0.2 um filter as well as for two washes of this filter,
and for the pooled filtrate and wash materials (these steps were
performed according to Example 4). Virion recovery is also shown
for the anion exchange column flow-through fraction, for the wash
material, and for the 1 M NaCl and 2 M NaCl eluate (performed
according to Example 8). Finally, virion recovery is shown for the
heparin column flow-through fraction, various washes, and eluate
fractions (performed according to Example 7). rAAV recovery was
monitored using real-time quantitative PCR of representative
samples for each of these major steps in the purification process.
It was found that more than 80% of the total rAAV virions contained
in the starting materials were recovered in the final product.
CONCLUSION
[0125] All publications, patents and patent applications cited
herein are hereby incorporated by reference in their entirety. As
used in this specification and the appended claims, the singular
forms "a," "an," and "the" include plural references unless the
content clearly dictates otherwise. Although the invention has been
described with reference to various embodiments, it should be
understood that various modifications can be made without departing
from the spirit of the invention. Accordingly, the invention is
limited only by the following claims.
* * * * *