ABSTRACTTo enable adeno?associated viral vectors (AAV) to achieve their maximum potential, next?generation manufacturing processes must be developed to make gene therapies more affordable and accessible. This study focused on the design of two different intensified AAV downstream manufacturing processes at bench and pilot scale. Novel clarification methods were studied at bench scale, including the use of BioOptimal™ MF?SL tangential flow microfilters for continuous removal of cell debris. Membrane adsorbers were used for further clarification, including DNA removal. Single pass tangential flow filtration (SPTFF) was implemented at bench scale by feeding the clarified cell lysate (CCL) into two Pellicon XL50 cassettes with 100?kDa regenerated cellulose membranes. At pilot scale, a multi?membrane staged SPTFF module was designed to concentrate 10?L of AAV CCL. Both SPTFF systems provided 12X inline volumetric concentration with AAV yield >?99% after an appropriate buffer chase. Host cell protein removal was 48% and 37% for the bench and pilot scale processes, respectively. As an initial proof?of?concept, an integrated process was developed at pilot?scale which linked clarification, SPTFF, and affinity chromatography. The integrated process offered an 81% reduction in total operating time (due to the reduced volume of load material for the affinity column after preconcentration by SPTFF), 36% improvement in affinity resin utilization (due to the higher AAV concentration in the column load), and an estimated 10% reduction in raw material costs. These improvements translated to an 8.5?fold increase in overall productivity compared to an equivalent batch process, underscoring the potential for SPTFF to intensify large?scale AAV downstream processing.

» Publication Date: 25/10/2025

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