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Manoj Kumar ChhikaraMVSc, PhDAssociate Director, R&D
How promising is the development of a
semi-synthetic meningococcal conjugate vaccine ?- a case study
5th Asia Pacific Global Summit and Expo on Vaccines & Vaccination
29th July 2015
Contents
• Need for an affordable multivalent meningococcal conjugate
vaccine
• Challenges and avenues in conjugate vaccine manufacture
• Promises from synthetic vaccine technologies for conjugate
vaccines
• Semi-synthetic conjugate vaccine research at Hilleman Labs
• Conclusions
MeningitisInflammation of meninges
Can be bacterial, viral, sometimes fungal
Bacterial meningitis: Meningitis and /or Septicaemia
Causes: N. meningitidis, Str. pneumoniae, H. influenzae, E. coli, GBS, GASL. monocytogenes and several others
Symptoms: Fever, vomiting, rashes, headache, delirium, stiffness, drowsiness, muscle and/or joint pain
Meningococcal Epidemics
N. meningitidis epidemics: • 1996 epidemic: Africa; 20,000 reported deaths
https://www.nathnac.org/pro/factsheets/documents/meningitis.pdf
• In 2000 and 2001 several hundred pilgrims attending the Hajj in Saudi Arabia were infected with N. meningitidis W. Then in 2002, W emerged in Burkina Faso, striking 13,000 people and killing 1,500. http://www.cdc.gov/meningococcal/global.html
• 2007 epidemic: Burkina Faso; 22,255 suspected cases, 1490 deaths https://www.nathnac.org/pro/factsheets/documents/meningitis.pdf
• 2009 epidemic: 14 countries from African meningitis belt 88,199 suspected
meningitis cases, 5352 deaths. (http://www.who.int/mediacentre/factsheets)
• 2014 epidemic season: 19 African countries; 11 908 suspected cases including 1146 deaths, lowest numbers since 2004 http://www.who.int/mediacentre/factsheets/fs141/en/
• Up to 20% mortality in epidemics and serious disability after survival in several cases
Major Meningococcal serogroups by geography: A, B and C account for 90% of IMD worldwide
B,C,Y
B,CY
B,CW
B,C
A,C,W,X
A,B,CY,W
A,C
A,C
A
B,C
Source :Jafri et al. Population Health Metrics 2013, 11:17
https://www.gov.uk/government/publications/meningococcal-disease-laboratory-confirmed-cases-in-england-and-wales
https://www.gov.uk/government/uploads/system/uploads/attachment_data/file/437901/150622_ACWY_bipartite_letter.pdf
Opportunities in development of cost effective conjugate vaccines • Existing poly-valent meningitis vaccines are effective but are
too expensive to be marketed in developing countries.
• Need to provide the right serogroup combination to provideprotection for the specific needs of the countries/regions
• Need to reduce dependency on one or few low cost vaccinesuppliers
• The existing cost of conjugate vaccines can be reduced byadapting to novel technologies and thermo-stabilization.
GAVI Alliance: Strategic Demand Forecast as of Second Quarter 2014
Based on increasing prevalence of other serogroups the need for cost effective multivalent meningococcal conjugate vaccine is warranted
in year 2011
http://www.meningitisinfo.com/Epidemiology_ssi.aspx
13 serogroups, regional variations
Seroprevalence varying by age groups and time
All ages Infants <1yr
Different time intervals
http://www.meningitisinfo.com/Epidemiology_ssi.aspxCONFIDENTIAL © HILLEMAN LABORATORIES
Complex processes & analytics
PolysaccharideActivated
saccharide
Carrier protein
Bulk Conjugate
1. Identity2. Molecular Size3. Composition4. Protein impurity5. Nucleic acid impurity6. Endotoxin7. Moisture content
1. Number of functional groups2. Mol. Size distribution
1. Identity2. Mol. Size distribution3. Saccharide content4. Protein content 5. Saccharide:protein ratio6. Endotoxin7. Conjugation markers8. Residual reagents9. Sterility
1. Identity2. Purity3. Extent of derivatization4. Endotoxin5. Specific toxicity
1. Identity2. Saccharide content3. Residual moisture (if lyophilized)4. Adjuvant content (if used)5. Preservative content (if used)6. Pyrogen content7. General safety test8. pH9. Sterility10. Physical inspection
CO
NJU
GA
TE
VA
CC
INE
Activation
Conjugation Formulation
1. Novel/improved polysaccharide production processes2. Antigen Synthesis
a. Organic synthesisb. Enzymatic synthesis
3. Reverse engineering (Broader coverage)4. Novel/improved conjugation processes
a. Reductive aminationb. Cyanylationc. Oxime chemistryd. Thio-ether conjugation etc.
5. Novel formulations5. Novel Analytics
a. Sophisticated physico-chemical analysesb. Multiplexed immunoassays (xMAP, MSD etc.)
Novel Technology solutions to Conjugate vaccine development
Research in developing semi-synthetic conjugate vaccines Cryptococcus neoformans: Vaccine (2005), 3961 Clostridium difficile: Chem. Biol. (2011); J. Am. Chem. Soc. (2013) Group A Streptococcus: Bioorg. Med. Chem. Lett. (2013) Vibrio cholerae: Glycoconj. J. (2013) Neisseria meningitidis group W: Ange. Chemie. Int. Ed. (2013) Streptococcus pneumoniae type 14: Russian Chem. Bull. (2014) Bacillus anthracis: Curr. Org. Chem. (2014) Shigella: Chemi. Commn. (2015) Neisseria meningitidis group X: Archivoc (2013); Baielstein J.Org. Chem.
(2014); RSC Adv. (2015)
Why there is no second semi-synthetic vaccine yet?
Questions in front of a manufacturer before adapting a novel technology
Ease of modifying structure ? ?Loss of epitopes during
conjugation? ?
Conjugation yield ? ?
Parameter Conventional technology
Novel technology
GMP requirements ? ?Duration for production ? ?Cost of production ? ?Batch to batch consistency ? ?Host cell impurities (e.g.
Protein/nucleic acid)? ?
Endotoxin content ? ?Residuals ? ?Analytics ? ?Stability ? ?Immunogenicity ? ?
Mening Conjugate Vaccine Program at Hilleman Labs
MeningACWXY
Conventional conjugates (Bacterial
PS and carrier protein)
Semi-synthetic conjugates (Synthetic
PS and bacterial carrier protein)
Options for development
Regional vaccine(s)
Pentavalent ACYWX vaccine
Tech
nolo
gy
Vale
ncy
R&D AT HILLEMAN LABSPolysaccharide production VERSUS Oligosaccharide synthesis
O
COOH
O
HOAcHN
O OHHO
O
COOH
HOAcHN
OHOHO
COOH
HOAcHN
HO OHHO
OO
COOH
HOAcHN
OHOH
O NH2
O COOMeS
OHN
ClH2COCO OClH2COCO
O
O
COOMe
OHN
HO OHOH
O
ON3
O Cl
+
O
COOMe
O
OHN
ClH2COCO OClH2COCO
O
COOMe
O
OHN
OAcOAc
O O
N3
O Cl
O COOH
OH
HOAcHN
HO OHOH
Initiation unit with linkerPropagation unit
Retro-synthesis of Mening C Tetramer
Cell Banking • Extensive characterization
Fermentation• Handling
pathogenic organisms
PS purification
• Several steps
Size reduction
Bacterial Polysaccharide production
• Physical, Chemical
Significant difference in GMP requirements and raw material required for the two options
Oligomers synthesized at Hilleman Labs
OHO
OAcHN
HOOH
P
O
OO OHO
OAcHN
OH
P
O
OO O
HO
OAcHN
OH
P
O
OO OHO
OAcHN
OH
5 NH2
Na
Na
Na
Mening C tetramer and octamer
Mening X tetramer
Mening W tetramer
Mening Y tetramer
Highly defined oligomers
0 .40 .60 .81 .01 .21 .41 .61 .82 .02 .22 .42 .62 .83 .03 .23 .43 .63 .84 .04 .24 .44 .64 .85 .05 .25 .45 .65 .86 .06 .2f1 (ppm )
-5000
0
5000
10000
15000
20000
25000
30000
35000
40000
45000
50000
55000
4.3
2
3. 9
7
11. 3
7
2. 0
5
3. 2
9
26. 0
5
1. 0
8
3. 0
0
1. 2
0
1. 3
9
1. 4
8
1. 9
0
2. 8
1
3. 3
8
3. 5
8
3. 6
9
3. 7
8
3. 8
6
4. 7
0
5. 3
6
1H-NMR 13C-NMR
2030405060708090100110120130140150160170180f1 (ppm )
-5000
0
5000
10000
15000
20000
25000
30000
35000
40000
45000
50000
55000
60000
65000
24. 3
8
27.2
2
27. 8
9
29. 3
2
30.7
4
41. 6
5
55.7
2
57. 8
2
58. 0
4
62. 2
3
62. 5
0
62.7
4
71. 8
5
72. 5
3
72. 9
9
74. 6
6
75. 3
1
76. 5
0
77. 1
8
96. 1
8
96. 5
7
96. 8
9
96. 9
3
97. 0
8
103
. 65
132
. 15
162
. 76
177
. 03
DEPT 2D HSQC 2D COSY
HPSEC
Additional testing: MS; IR; TLC
Advantages in size distribution
MenC PS lots analyzed using PWXL 4000-5000 columns in series (RI signal)
MenC tetramer lots analyzed using PWXL 3000 column (RI signal)
Different Conjugation Methods affect the polysaccharide epitopes
Periodate oxidation of Hib-PRP
Reductive amination of Str. pneumoniae Serotype 19F Polysaccharide
Cyanylation of 19F-PS using CDAPClin Vaccine Immunol 2011 18(2): 327-336
Clin Vaccine Immunol 2011 18(2): 327-336
Synthetic oligosaccharides can be conjugated without impacting OS epitopes with high yields
HN
Freshly prepared Protein-maleimideO
N
O
O
HN
O
SHPolysaccharide
HN
O
N
O
O
NH
O
SPolysaccharide
Crude Conjugate
Mix Protein to PS in 1:30 molar ratio
Overnight mixing at 4°C
Purif ication using 10 kd Amikon Ultra f ilter.
Oligosaccharide & Protein mix is in PBS at ph 6.8.
Same chemistry for all oligosaccharides
Consistent, Repeatable process with high yields
MenC-PS & Conjugate MenC-Tetramer & Conjugate
Sharp contrast in OS and conjugate
profile and minimum
heterogeneity
Conjugate Lot No. OS:Pr Ratio Free OS % Conjugation yieldMenCTM-TT-1 0.25 2.5 21%MenCTM-TT-2 0.25 1.2 32%MenCTM-TT-3 0.24 3.0 38%MenCTM-TT-4 0.28 <1 47%MenCTM-TT-5 0.23 1.5 38%MenCTM-TT-6 0.28 5.9 39%MenCTM-TT-7 0.25 9.9 35%MenCTM-TT-8 0.26 <1 27%
CONFIDENTIAL © HILLEMAN LABORATORIES
MenX-TT Conjugate give rise to high IgG concentration in mice
INFERENCE: 1µg of conjugated MenX-tetramer-TT gives 10-15 fold higher response than vehicle control
Anti-MenX IgG GMC Post dose-3 Study 1-3
0
2000
4000
6000
8000
10000
12000
14000
16000
18000
EU/m
l
Negative control 195 283 672 672 672
Men XTm 1mcg 3512 4287 7235 8843 8786
Study 1 β Tm
Study 2 β Tm
Study 3 β Tm
Study 3 α Tm
Study 3 α Tm
SBA data awaited
Efforts towards automation… Automated synthesis of oligosaccharides as a basis for drug discoveryPeter H. Seeberger & Daniel B. WerzNature Reviews Drug Discovery 4, 751-763 (September 2005)
Automation reduces significant time for organic synthesis
Comparative analysis
Duration for production +++ - Significantly longer time for synthesis, (Scope for Automation)
Parameter Bacterial PS Synthetic OS RemarksGMP requirements - +
Ease of modifying structure - ++Loss of epitopes during
conjugation- ++
Batch to batch consistency - ++ PS from live organisms vs chemical synthesis
Protein/nucleic acid impurities
- ++
Endotoxin content - ++Residuals + + Still under evaluation
Conjugation yield - +
Stability - + Multiple vs Single link and Long vs small repeats
Analytics - + Highly defined oligomers Immunogenicity + +
Cost of production + + Still under evaluation
+ : a positive attribute of the technology - : a negative attribute
1. Among all the other novel technologies, synthetic approaches to develop new conjugate vaccines is an emerging subject
2. Initial successes have paved the way for exploration of synthetic platform technology for other vaccine candidates
3. The advantages of synthetic approach over the conventional approaches have upper hand as compared to the possible short falls
4. The approach may lead to successful candidates which are difficult to be produced by conventional approaches
Conclusions
Acknowledgements
• Dr. Davinder Gill, CEO, Hilleman Labs• Dr. Zimra Israel, VP and Head, R&D, Hilleman Labs• Conjugate Vaccine Program(CVP) teams at Hilleman Labs
• Sandeep Sharma; Nitin Kumar, Sarmad Hanif• Rakesh Rana, Juned Dalal, Deepti Singh• Kishore Harale, Neelesh, Jeetendra• Lab technicians and support staff
• Consultants for CVP at Hilleman Labs• CROs (animal studies, analytics, organic synthesis)