Investigation of an ultrafiltration yield problem for a conjugate vaccine

BIOT 61

Shwu-Maan Lee, LEES4@BAXTER.COM, Bob Kruse, Amy Robinson, John Davis, and Chris Donaldson. Baxter Healthcare Corporation, 12140 Indian Creek Court, Beltsville, MD 20705
The meningitis vaccine (NeisVac-C) is comprised of the de-O-acetylated form of the group C meningococcal polysaccharide conjugated to tetanus toxoid. The polysaccharide purification process includes base treatment and subsequent diafiltration to remove hydrolysed cell impurities. During development, a 100K ultrafiltration membrane was used satisfactorily. Unfortunately, the yield from the first 12 production lots varied from 18 to 100%. Investigation revealed that the ultrafiltration membrane porosity varied with different manufacturer's lots. The corrective action included changing the membrane from 100K to 50K, just prior to our license application. To support the change, we spiked a lab-scale process stream with 200% of the cell impurities and tested the “tightest” 50K membrane available. Even under the worst-case conditions, the impurities were removed to meet the original specifications achieved by the 100K membrane. The change was incorporated into the license application and over 100 lots have since been produced with satisfactory yield and purity.