Engineering Biological Science - Processes and Systems for Haematopoietic Stem Cell Based Therapy Manufacture

Lead Research Organisation: Loughborough University
Department Name: Wolfson Sch of Mech, Elec & Manufac Eng

Abstract

Umbilical cords are traditionally discarded after childbirth as medical waste. However, over the past few decades it has become apparent that the cord contains a small amount of immature blood cells with powerful properties to repair the human body. Cord blood is now frequently used instead of bone marrow to treat childhood blood cancers (leukaemia). Cord blood cells can also be grown to generate very large numbers of red blood cells or platelets for transfusion, or, if processed differently to create immune system cells. More recently cord blood has been proven effective, or is being clinically trialled, for a wide range of serious conditions such as organ failure, childhood brain damage or diabetes.

Despite national cord blood collection and banking programmes since the early 1990's, the success of these new clinical applications will lead to unsustainable demand on already strained stocks of cord blood. In this Fellowship I intend to develop tools to help manufacture large quantities of medicinally valuable cord blood cells from the small samples retrieved at child birth. This will form the basis of a manufactured blood related bio-products industry.

We will use a new technology to grow the cells in small vessels under very controlled conditions. These vessels will let us quickly and efficiently test different physical conditions (such as oxygen and acidity) and novel chemical additives on the growth of the blood cells. We will use engineering approaches to control the cells' environment in novel ways, and understand the relationships between the cells' development. We will demonstrate the conditions and systems that are necessary to grow these cells to large and clinically useful numbers. We will also understand how tolerant the manufacturing process is for repeated production of safe and effective cells.

My proposed research will help the clinical community deliver a new cohort of treatments for serious diseases to patients in the UK as well as help develop an important new economic activity in the UK in the development of these new types of cell based therapies.

Planned Impact

Ex vivo control of proliferation and development of HSCs will create the opportunity for rapid clinical impact for patients suffering from haematological malignancies through a safe and unlimited supply of immunologically matched and consistent quality cells engineered to increase engraftment speed and decrease mortality. It will provide the scientific basis for a fully self-replenishing input cell supply for industrial production of naturally occurring haematopoietic lineages or haematopoietic cells engineered for therapeutic effect. This 'productisation' of cells will drive down costs for health service suppliers, create a manufacturing paradigm with sufficient economic return for product manufacturers, contribute to economic growth in a strategic area for the UK economy (high value bio-manufacturing), and create a UK technology based industry for export. It will bolster research into other therapeutic applications, such as organ support, through offering reproducible cells specifications for clinical trials. It will hasten the reality of manufactured cellular blood products and their manipulation for diverse therapeutic outcomes. The science developed will provide a powerful case study of the potential of interdisciplinary research and provide a pathway for other complex cell therapy developments with detrimental emergent parameters in bio-manufacture.

Publications

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Bayley R (2018) The productivity limit of manufacturing blood cell therapy in scalable stirred bioreactors. in Journal of tissue engineering and regenerative medicine

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Granja C (2020) A quartz crystal resonator for cellular phenotyping in Biosensors and Bioelectronics: X

 
Description The research has developed a mechanism for presentation of soluble proteins in an immobilised form for scalable application in bioreactors and manipulation independently from other soluble medium components. A modelling framework has been developed and captured within a software interface specifically for modelling bioprocesses and their specific operational traits. The modelling has been used to identify limiting operational factors for cell productivity; this has enabled us to specify the volume productivity limits of current systems and also to engineer improvements that deliver more than 3x improvement in system volume productivity.
Exploitation Route Our findings are currently being applied and evaluated by multiple commercial partners for application in industrial manufacture processes, including inclusion in a recent clinical production protocol for a novel class of cell based therapeutic product.
Sectors Chemicals,Healthcare,Manufacturing, including Industrial Biotechology,Pharmaceuticals and Medical Biotechnology

 
Description The efficiency and control outcomes that we are demonstrating in cell culture in the academic setting have shown the potential to significantly reduce bio-manufacturing run times and to dramatically reduce total volume requirements. Our findings are currently being applied by a US based partner company to build an efficient manufacturing process for a very high dose cell based therapeutic product. The impact of our work will make the difference between unfeasible final manufacturing costs and a product that will have real clinical impact. The work is also being evaluated by selected UK partners for potential exploitation. This has enabled, over a period from 2016 to 2021, the establishment of an industrially funded activity within the University attracting over 500,000 GBP of direct funding to the institution. Furthermore, the manufacturing expertise is now embedded in an independent contract research organisation with international partners and in excess of 1M GBP annual turnover as of 2020/2021. Our ambition is that as the modelling and process design approaches we are developing are demonstrated in these early real world industrial case studies that the evident benefits will lead to wider take up across the industry, and this is increasingly evdiecned through the work of our embedded CRO.
First Year Of Impact 2016
Sector Manufacturing, including Industrial Biotechology
Impact Types Economic

 
Description CCMI Scale-Up and Challenges in Manufacturing of ATMP workshop
Geographic Reach Europe 
Policy Influence Type Influenced training of practitioners or researchers
 
Description Advanced Bioprocess
Amount £75,311 (GBP)
Organisation Advanced Bioprocess Services Ltd 
Sector Private
Country United Kingdom
Start 06/2017 
End 12/2017
 
Description Advanced Bioprocess 2
Amount £100,973 (GBP)
Organisation Advanced Bioprocess Services Ltd 
Sector Private
Country United Kingdom
Start 01/2018 
End 12/2018
 
Description Advanced Bioprocess 3
Amount £41,333 (GBP)
Organisation Advanced Bioprocess Services Ltd 
Sector Private
Country United Kingdom
Start 01/2019 
End 12/2019
 
Description CRACKIT [UK Industry]
Amount £96,066 (GBP)
Organisation National Centre for the Replacement, Refinement and Reduction of Animals in Research (NC3Rs) 
Sector Public
Country United Kingdom
Start 01/2017 
End 06/2017
 
Description Cell Therapy Manufacturing
Amount £192,717 (GBP)
Organisation Advanced Bioprocess Services Ltd 
Sector Private
Country United Kingdom
Start 01/2020 
End 12/2025
 
Description Early Career Forum Call
Amount £45,420 (GBP)
Funding ID EP/L015404/1 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 03/2014 
End 03/2016
 
Description FUTURE MANUFACTURING HUB IN TARGETED HEALTHCARE
Amount £10,317,090 (GBP)
Funding ID EP/P006485/1 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 01/2017 
End 12/2023
 
Description Modelling Pluripotent Stem Cell Manufacture - Industrial Studentship
Amount £130,211 (GBP)
Organisation Advanced Bioprocess Services Ltd 
Sector Private
Country United Kingdom
Start 04/2019 
End 03/2022
 
Description Responsive Mode Manufacturing the Future
Amount £406,203 (GBP)
Funding ID EP/R031649/1 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 12/2018 
End 11/2021
 
Description The Pluripotent Stem Cells and Engineered Cell (PSEC) Hub
Amount £4,095,179 (GBP)
Funding ID MR/R015724/1 
Organisation Medical Research Council (MRC) 
Sector Public
Country United Kingdom
Start 06/2018 
End 05/2023
 
Description Wellcome Trust Translational Award
Amount £573,461 (GBP)
Organisation Wellcome Trust 
Department Wellcome Trust Translation Award
Sector Charity/Non Profit
Country United Kingdom
Start 11/2013 
End 04/2017
 
Title Controllable Biological Signalling 
Description The tool is currently under evaluation for IP protection. However, it is a method for enabling presentation of growth factors into a standard industry bioreactor where factors are required at far lower levels than previously reported, and where factors can be introduced and removed non-invasively. 
Type Of Material Technology assay or reagent 
Provided To Others? No  
Impact Provision of tool will be provided after IP protection 
 
Title Supplementary information files for A quartz crystal resonator for cellular phenotyping 
Description Supplementary files for article A quartz crystal resonator for cellular phenotyping. Cell therapy manufacturing is limited by lack of online tools capable of realtime in-process monitoring, particularly of simultaneous changes in multiple orthogonal (mutually independent) parameters. Here, we studied changes in CD36 expression, number density and size (area) of erythroblasts through different stages of erythropoiesis in vitro using a quartz crystal resonator (QCR), integrated with a microscope, 
Type Of Material Database/Collection of data 
Year Produced 2020 
Provided To Others? Yes  
URL https://repository.lboro.ac.uk/articles/dataset/Supplementary_information_files_for_A_quartz_crystal...
 
Title Supplementary information files for A quartz crystal resonator for cellular phenotyping 
Description Supplementary files for article A quartz crystal resonator for cellular phenotyping. Cell therapy manufacturing is limited by lack of online tools capable of realtime in-process monitoring, particularly of simultaneous changes in multiple orthogonal (mutually independent) parameters. Here, we studied changes in CD36 expression, number density and size (area) of erythroblasts through different stages of erythropoiesis in vitro using a quartz crystal resonator (QCR), integrated with a microscope, and flow cytometry in parallel. An analytical model was developed extending the Kanazawa-Gordon theory. Based on this model, independent correlations were established between changes in each QCR parameter, dissipation (?G) and resonance frequency (?-?f?_0), and CD36 expression (from flow cytometry) and cell area (from microscope). The correlation functions were used to derive an acoustic signature (-?G/??f?_0) of the differentiation process that uniquely mapped the relative changes in CD36 expression and late-stage enucleation-related deviations. A method to quantify relative changes in cell area purely from the acoustic parameters was also proposed. This work demonstrated for the first time the potential of an electromechanical tool for online monitoring of concurrently varying orthogonal phenotypic parameters in cell therapy manufacturing.
 
Type Of Material Database/Collection of data 
Year Produced 2020 
Provided To Others? Yes  
URL https://repository.lboro.ac.uk/articles/dataset/Supplementary_information_files_for_A_quartz_crystal...
 
Description Advanced Bioprocess Design Ltd 
Organisation Advanced Bioprocess Design Ltd
Country United Kingdom 
Sector Private 
PI Contribution The partnership is built around a novel software product developed by Advanced Bioprocess Design Ltd for dynamic mechanistic modelling of cell culture systems, particularly for manufacture design. We are the partner research group for the company and have provided software design input, user requirement feedback, and testing of model development in specific relevant processes. We are generating a co-publication strategy of modelling workflow and exemplars for manufacturing in regenerative medicine.
Collaborator Contribution Advanced Bioprocess Design provide extensive and free engineering and software development time input - approximately 20 days a year - for modelling support and user specified Software changes. The company also provide heavily subsidized access to the software which we use across a wide range of projects and teaching.
Impact Multiple evolutions of the new software tool, StemCellCAD. The collaboration is highly interdisciplinary involving cell culture biologists, bio-manufacture engineering, mathematical modelling, and software development.
Start Year 2016
 
Description Advanced Bioprocess Services 
Organisation Advanced Bioprocess Services Ltd
Country United Kingdom 
Sector Private 
PI Contribution We have partnered with Advanced Bioprocess Services to deliver technology and process development expertise to clinical stage therapeutic product companies. These have included pre-clinical bioreactor process development and modelling for several Boston (US) based blood products companies, and process development for leading UK based companies in neural stem cell and immunotherapies. Our contribution has been specifically in novel process model development, novel methods to improve process efficiency, and technology design.
Collaborator Contribution Advanced Bioprocess Services manage the interface with companies seeking process development and provide extensive high value reagents and consumables for project work, either directly or via other collaborating companies, as well as providing access to the most relevant and protected industrial processes for development of our research. Since 2016 Advanced Bioprocess Services have directly funded 258,000 GBP of research and impact activity through the University as of end of 2019
Impact Novel industrially applied processes
Start Year 2016
 
Description Megakaryocyte Culture for Platelet production 
Organisation University of Cambridge
Department Department of Haematology
Country United Kingdom 
Sector Academic/University 
PI Contribution We are taking a novel cell type (as described below) and culturing in a scalable production system. We are applying a novel software based modelling approach to define optimal process operation.
Collaborator Contribution Our partners have produced genetically modified megakaryocytes that can proliferate in a relatively stable form over a long period. They have generated cell stocks for us, transferred analytical protocols and provided training, and provided scientific and technical advice.
Impact Data on megakaryocyte growth dynamics and influences; outputs in preperation
Start Year 2015
 
Description Scottish National Blood Transfusion Service (Manufactured Blood Clinical Trial Development) 
Organisation NHS National Services Scotland (NSS)
Department Scottish National Blood Transfusion Service
Country United Kingdom 
Sector Public 
PI Contribution Generating proof of concept data regarding scaled manufacturing of red blood cells to enable subsequent application for a full Wellcome Trust Translational Award
Collaborator Contribution Providing the laboratory based process to use in the scaled system, and providing cells and reagents at the appropriate point of differentiation to be compatible with the scalable manufacturing systems.
Impact Multidisciplinary; Cell biology, Clinical Haematology, Process Engineering, Manufacturing Engineering Main impact was the generation of data required to successfully bid for Wellcome Trust Translational Award (reported under separate section)
Start Year 2013
 
Title StemCellCAD 
Description This is a software package that allows conceptual description and linking of the dynamics of species in a system. It is tailored for advanced cell human cell cultures so includes common behaviours such as growth, decay, promotion, inhibition amongst others and enables specification of common arising dynamic phenomena such as feedback loops. The software allows data fitting to described models and sensitivity analysis. 
Type Of Technology Software 
Year Produced 2016 
Impact The software product was developed in collaboration with Advanced Bioprocess Design Ltd. ABD developed the software to meet our modelling requirements and supported us through multiple case studies. The software is now being applied in a range of academic and industrial programmes to generate models of a range of culture systems; this has defined further experimental work and identified mechanistic behaviours and operational risks. Outputs in preparation. 
 
Company Name SAFI BIOSOLUTIONS UK LIMITED 
Description As the cell therapy commercialization partner of a 5-year Department of Defense program to manufacture on-demand blood products, Safi Biosolutions and its collaborators are working to 'crack the code' of Cell Therapy 2.0 challenges of manufacturing at appropriate scale, high consistency of product, and economically viable cost of goods by integrating world-leading expertise in cord blood stem cell expansion, bioprocessing optimization, manufacturing scale-up and cryostorage. Lead development programs for manufactured, on-demand cell therapy products include red blood cells for trauma, tailored red blood cells for specific transfusions (e.g. sickle cell disease) and a neutrophil progenitor cell therapy for the treatment of chemotherapy-induced neutropenia. 
Year Established 2021 
Impact Established an economic manufacturing platform for therapeutic blood products
Website https://safi.bio/
 
Company Name ADVANCED BIOPROCESS SERVICES LIMITED 
Description Bioprocess Development Service Provider for Cell and Gene Therapies 
Year Established 2016 
Impact Worked with a range of early stage cell and gene therapy companies to deliver novel, economic, and robust manufacturing processes for pre-clinical models; provided the development services that have directly supported in excess of $20M of private raise.