Francisca Monteiro

Improving baculovirus production at high cell density through manipulation of energy metabolism

The insect cells/baculovirus system is well recognized as a safe and suitable technology to produce heterologous proteins, vaccines and vectors for gene therapy. Efficient and robust production processes, able to deliver higher product concentrations, are however still needed to cope with increased requirements for large-scale manufacture. The work herein presented describes a combined experimental and modelling effort to quantify and environmentally manipulate the metabolism of Spodoptera frugiperda cells, targeting high cell density production of baculovirus vectors with potential application in human gene therapy. Culture medium supplementation with pyruvate or alpha-ketoglutarate at the time of infection resulted in 6-7-fold higher specific baculovirus yields at high cell density when compared to control cultures. This pushed volumetric titers to levels higher than classical low cell density infections. A quantitative description of intracellular pathways is provided using metabolic flux analysis; a direct stimulation of carbon flow through the tricarboxylic acids cycle was observed. Analysis of flux partitioning coefficients at the pyruvate and alpha-ketoglutarate branch-points further revealed a metabolic transition to a more energetically active state, which was confirmed by increased intracellular adenosine triphosphate generation rates. These results represent a cost-efficient and scalable strategy for high cell density production of recombinant baculovirus vectors.

Toward system-level understanding of baculovirus-host cell interactions: from molecular fundamental studies to large-scale proteomics approaches.

Baculoviruses are insect viruses extensively exploited as eukaryotic protein expression vectors. Molecular biology studies have provided exciting discoveries on virus–host interactions, but the application of omic high-throughput techniques on the baculovirus–insect cell system has been hampered by the lack of host genome sequencing. While a broader, systems-level analysis of biological responses to infection is urgently needed, recent advances on proteomic studies have yielded new insights on the impact of infection on the host cell. These works are reviewed and critically assessed in the light of current biological knowledge of the molecular biology of baculoviruses and insect cells.

An integrated analysis of enzyme activities, cofactor pools and metabolic fluxes in baculovirus-infected Spodoptera frugiperda Sf9 cells.

The scarcity of fundamental knowledge on the baculovirus-host cell interaction is a major drawback for the improvement of bioprocesses through Metabolic Engineering. After the first hours post-infection, the virus takes over the control of cellular machinery, leading to the repression of host gene expression and imposing a high metabolic burden to insect cells. Nevertheless, there is a lack of detailed data on the metabolic responses to infection, which are ultimately responsible for system productivity performance. In this work, a further insight into the central metabolism of Sf9 cells is achieved by a combined analysis of enzyme activities, cellular cofactors (ATP and NAD(P)(+)/NAD(P)H) and metabolic fluxes. Hexokinase and isocitrate dehydrogenase were identified as feasible limiting steps of metabolism; carbon and nitrogen metabolism enzymes were differentially regulated during batch cultures. Moreover, alterations occurring after infection demonstrated the importance of maintaining the energetic state of the cells for baculovirus replication, since ATP accumulated in a MOI-dependent way, and the glutamate dehydrogenase anaplerotic pathway was greatly activated. Altogether, cellular de-energization and stress responses are relevant factors in the metabolic burden imposed by infection. The implications for the improvement of bioprocess performance are discussed.

Metabolic profiling of insect cell lines: Unveiling cell line determinants behind system's productivity.

Baculovirus infection boosts the host biosynthetic activity towards the production of viral components and the recombinant protein of interest, hyper‐productive phenotypes being the result of a successful adaptation of the cellular network to that scenario. Spodoptera frugiperda derived Sf9 and Trichoplusia ni derived High Five cell lines have a major track record for the production of recombinant proteins, with High Five cells presenting higher productivities. A metabolic profiling of the two insect cell lines was pursued to underpin specific cellular traits behind productive phenotypes. Multivariate analysis identified cell‐line dependent metabolic signatures linked to productivity. Pathway analysis highlighted cellular pathways of paramount importance in supporting infection and protein production. Moreover, better producer phenotypes proved to be correlated with the capacity of cells to shift their metabolism in favor of energy‐generating pathways to fuel biosynthesis, a scenario observed in the High Five cell line. Metabolomic profiling allowed us to identify metabolic pathways involved in infection and recombinant protein production, which can be selected as targets for further improvement of the system. Biotechnol. Bioeng. 2014;111: 816–828.

Improvement of lentiviral transfer vectors using cis-acting regulatory elements for increased gene expression

Lentiviral vectors are an important tool for gene delivery in vivo and in vitro. The success of gene transfer approaches relies on high and stable levels of gene expression. To this end, several molecular strategies have been employed to manipulate these vectors towards improving gene expression in the targeted animal cells. Low gene expression can be accepted due to the weak transcription from the majority of available mammalian promoters; however, this obstacle can be in part overcome by the insertion of cis-acting elements that enhance gene expression in various expression contexts. In this work, we created different lentiviral vectors in which several posttranscriptional regulatory elements, namely the Woodchuck hepatitis posttranscriptional regulatory element (WPRE) and different specialized poly(A) termination sequences (BGH and SV40) were used to develop vectors leading to improved transgene expression. These vectors combine the advantages of restriction enzyme/ligation-independent cloning eliminating the instability and recombinogenic problems occurring from traditional cloning methods in lentiviral expression vectors and were tested by expressing GFP and the firefly Luciferase reporter gene from different cellular promoters in different cell lines. We show that the promoter activity varies between cell lines and is affected by the lentiviral genomic context. Moreover, we show that the combination of the WPRE element with the BGH poly(A) signal significantly enhances transgene expression. The vectors herein created can be easily modified and adapted without the need for extensive recloning making them a valuable tool for viral vector development.

Bioorthogonal Strategy for Bioprocessing of Specific-Site-Functionalized Enveloped Influenza-Virus-Like Particles

Virus-like particles (VLPs) constitute a promising platform in vaccine development and targeted drug delivery. To date, most applications use simple nonenveloped VLPs as human papillomavirus or hepatitis B vaccines, even though the envelope is known to be critical to retain the native protein folding and biological function. Here, we present tagged enveloped VLPs (TagE-VLPs) as a valuable strategy for the downstream processing and monitoring of the in vivo production of specific-site-functionalized enveloped influenza VLPs. This two-step procedure allows bioorthogonal functionalization of azide-tagged nascent influenza type A hemagglutinin proteins in the envelope of VLPs through a strain-promoted [3 + 2] alkyne–azide cycloaddition reaction. Importantly, labeling does not influence VLP production and allows for construction of functionalized VLPs without deleterious effects on their biological function. Refined discrimination and separation between VLP and baculovirus, the major impurity of the process, is achieved when this technique is combined with flow cytometry analysis, as demonstrated by atomic force microscopy. TagE-VLPs is a versatile tool broadly applicable to the production, monitoring, and purification of functionalized enveloped VLPs for vaccine design trial runs, targeted drug delivery, and molecular imaging.

The role of host cell physiology in the productivity of the baculovirus-insect cell system: Fluxome analysis of Trichoplusia ni and Spodoptera frugiperda cell lines.

The Insect Cell‐Baculovirus Expression Vector System (IC‐BEVS) is broadly used for the production of recombinant proteins and vaccine manufacture, yet the host physiological aspects that contribute to productivity are to be disclosed. This work provides the first quantitative analysis of the metabolic fluxes of High Five cells. This analysis was conducted in comparison with Sf9 cells, another major host for biologicals production via BEVS. Moreover, herein is presented, for the first time, quantitative data of the relative contribution of sugars and amino acids catabolism to the activity of the TCA cycle in Sf9 and High Five cells. High Five cells metabolic activity was markedly influenced by the amino acids concentration in culture medium, which determine the rates of amino acid catabolism, carbon overflow and by‐product formation. This characteristic of High Five cells was reflected in the activities of anaplerotic metabolism and the TCA cycle, which may not work as a true cycle as a function of medium composition. This was not the case for Sf9 cells, in which the glucose carbon incorporation in the TCA cycle was significantly higher and lactate production minor. Following infection, the decrease in by‐product accumulation rates was accompanied by an increase in net ATP synthesis in Sf9 and High Five cells, although through distinct mechanisms cell‐line dependent. The impact of baculovirus infection on cellular metabolic status highlights the capacity of this virus to re‐direct the cellular fluxome toward ATP production to support replication and progeny generation. These results pave the way to deepen our knowledge on the relationship between a host cell and the virus, contributing to disclosing the metabolic determinants that contribute to productivity. Biotechnol. Bioeng. 2017;114: 674–684.

Targeted supplementation design for improved production and quality of enveloped viral particles in insect cell-baculovirus expression system.

The recent approval of vaccines and gene therapy products for human use produced in the Insect Cell-Baculovirus Expression Vector System (IC-BEVS) underlines the high potential and versatility of this platform. The interest in developing robust production processes emerges to cope with manufacturing pressure, as well as stringent product quality guidelines. Previously, we addressed the impact of the baculovirus infection on the physiology of insect host cell lines, identifying key cellular pathways enrolled in heterologous gene/protein expression. In the present work, this knowledge was applied to design tailored media supplementation schemes to boost IC-BEVS production yields and quality of enveloped viral particles: influenza VLPs (Inf-VLP) and baculovirus vectors (BV). The addition of reduced glutathione, antioxidants and polyamines increased the cell specific yields of baculovirus particles up to 3 fold. Cholesterol was identified as the most critical system booster, capable of improving 2.5 and 6-fold cell specific yields of BV and Inf-VLPs, respectively. Surprisingly, the combination of polyamines and cholesterol supplementation improved baculovirus stock quality, by preventing the accumulation of non-infectious particles during viral replication while selectively increasing infectious particles production. In addition, the specific yields of both enveloped viral particles, BVs and Inf-VLPs, were also increased. The correlation between supplement addition and systems productivity was extensively analyzed, providing a critical assessment on final product quantity and quality as drivers of bioprocess optimization efforts.

An Insight into the Physiology of Insect Cells: The Role of Energetic Metabolism on the Cell Density Effect

In the last years, the Baculovirus Expression Vector System (BEVS) has gained increasing interest for its many biotechnologically relevant applications, ranging from single proteins to multi-subunit complexes such as virus like particles or adeno-associated viruses. The decrease in specific productivities that occurs when the cells are infected at high cell densities or “cell density effect” is a major drawback for these applications. In this work, a quantitative analysis of cell density related alterations of the central metabolism of insect cells has been performed. The most relevant metabolites, cofactors and central metabolism enzymes were profiled along cultures and Metabolic Flux Analysis was applied at different cell densities. Our results demonstrate the occurrence of major alterations on enzyme activities and fluxes at high cell densities, which have a profound impact on the energetic state of the cells and correlate well with cellular productivities. Altogether, the results so far obtained provide the rationale for the understanding of the metabolic basis of the cell density effect, also establishing a connection between cellular metabolism and the infection process.