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Using a closure analysis method to reduce CGT contamination risks

Many cell therapy manufacturing processes use open unit manipulations. As a result, they are at risk of potential contamination that can result in manufacturing batch failure. The processes therefore rely on end-to-end aseptic processing to ensure the final drug product is safe and free of potentially harmful contamination. Addressing these risks has led BioPhorum to publish Cell and gene therapy closed systems – closure analysis of a mock...

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Closure analysis of a mock autologous cell therapy process

In its current state, cell therapy manufacturing comprises several open and manual operations which increase the risk of contamination. Members of BioPhorum’s Cell & Gene Therapy Commercialization workstream have generated a ‘mock’ process detailing the manufacture of a generic autologous CAR-T product operated through a series of process steps combining some open and some closed system elements. The mock process has undergone an end-to-end closure analysis to identify those operations that pose the highest contamination risks, and to provide suggested mitigation solutions to minimize such risks. Suggestions include options that are currently available, as well as potential future ‘desired state’ options. This paper details the full process and summarizes potential risks and possible mitigations. The primary aim of this paper is to demonstrate systematic application of a closure analysis method on an ex vivo gene therapy (also known as gene-modified cell therapy) process so that organizations can apply similar analyses to their own processes. The secondary aim is to propose process closure solutions that companies could implement in their own operations.

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Plug-and-Play audit trail requirements

This document is one of a series, written to address the problems associated with automating equipment that lacks interoperability in the biopharmaceutical industry. It relates to the BioPhorum Stirred Tank Unit Interface Specification referenced in Appendix A, which was the first of its kind and as such, contains a number of introductory sections describing the principles upon which it, and an accompanying series of documents, are based. In turn, these principles relate back to the established standards of S88, S95 and OPC-UA, and the developing ‘plug-and-play’ approach of NAMUR (User Association of Automation Technology in Process Industries), with its module type package (MTP) equipment definition.

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On the road to common solutions in cell and gene therapy

The emerging field of cell and gene therapy (CGT) has only recently started being commercialized and so standard methods for generating therapeutic products continue to change. Companies are developing their own procedures and many are following general biologics processes, which often do not apply to CGT. These divergent processes mean there is often confusion and inconsistency in the field – compounded by significant gaps in information...

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The essential digital capabilities for CGT manufacturing to succeed at scale

Cell and gene therapies (CGTs) is an emerging, high-growth area, but their manufacture is different from established small molecule and biologics platforms in many ways. These range from starter cell variability and traceability for patient safety, to the need for fast turnarounds, very dynamic scheduling and rapid deviation management. All of these, and more, profoundly affect the IT system requirements for CGT. As more CGTs are approved for...

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Commercialization: Gene therapy process map

Viral vector manufacturing is a relatively nascent field, with companies working in many different therapeutic areas, and employing a wide range of processes and procedures. Therefore, members of BioPhorum’s Cell & Gene Therapy Commercialization workstream has generated a set of gene therapy process maps that represent example processes, unit operations and platform technologies being used within in vivo gene therapy manufacturing. These gene therapy process maps are intended to be used as an initial introduction to the in vivo gene therapy manufacture processes and so act as an educational tool for people new to the field. They are also intended to form a general platform baseline for scientists and engineers working within the field to support collaboration enabling process improvements and accelerating commercialization of viral vector manufacturing.

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Commercialization: Cell therapy process map

Standard methodologies for generating therapeutic cell products (with or without gene modification) continue to change as the field matures. BioPhorum has identified significant gaps in publicly available information describing industrial practices for production of cell and gene-modified cell therapies. Therefore, members of BioPhorum’s Cell and Gene Therapy Commercialization workstream have generated a series of cell and gene-modified cell therapy process maps that represent example processes, unit operations and platform technologies being used in manufacturing today. These maps are intended to be used to form a common frame of reference for scientists and engineers
working within the field and support collaboration to enable process improvements benefitting future cell therapy patients by supporting acceleration of commercialization of novel modalities. They are also intended as an education tool for new members to the cell therapy field.

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IT for CGT: Digital capabilities for cell and gene therapy

There are many differences in manufacturing cell and gene therapies (CGTs) compared to established small molecule and biologics platforms and this profoundly affects the IT systems requirements. Some products are personalized so the process includes personal screening and sequencing data, with traceability and data privacy throughout. Starter cell variability adds complexity to a manufacturing process that must have a rapid turnaround, very dynamic scheduling and rapid deviation management. Outcomes must be tracked for the long term to improve patient outcomes as well as to support novel reimbursement models.Industrialization of CGTs therefore needs the support of advanced systems for manufacturing execution, orchestration, traceability, scheduling, patient data and outcome tracking. Some processes will be encapsulated in closed systems, and there may be analytical requirements for continuous process verification and dynamic adjustment. Operators distributed across the globe will be supported remotely by augmented and virtual reality technologies. This paper helps executives and IT professionals to understand the IT needed to support CGT manufacture, and stimulates collaboration across the industry to meet these challenges.

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