The NanoAssemblr Platform: Microfluidics-Based Manufacture of Nanoparticles. Euan Ramsay, Ph.D. Co-Founder & CSO/COO July, 2015

Transcription

1 The NanoAssemblr Platform: Microfluidics-Based Manufacture of Nanoparticles Euan Ramsay, Ph.D. Co-Founder & CSO/COO July, 2015

2 Presentation Overview 1. Introduction to Microfluidics-Based NanoAssemblr Platform for Nanoparticle Manufacture 2. Examples of Nanoparticles Manufactured by the NanoAssemblr Platform 3. Scale-up Manufacture using the NanoAssemblr Platform 2

3 Presentation Overview 1. Introduction to Microfluidics-Based NanoAssemblr Platform for Nanoparticle Manufacture 2. Examples of Nanoparticles Manufactured by the NanoAssemblr Platform 3. Scale-up Manufacture using the NanoAssemblr Platform 3

4 Nanomedicine Development Process Conceptual Nanomedicine API - NanoparticleF ormulation Manufacturing Process Robust Manufacturing Process Scale-up Nanomedicine Product 4

5 Nanomedicine Development Process Conceptual Nanomedicine API - NanoparticleF ormulation Manufacturing Process Robust Manufacturing Process Scale-up Nanomedicine Product NanoAssemblr Benchtop Instrument 5

6 Nanomedicine Development Process Conceptual Nanomedicine API - NanoparticleF ormulation Manufacturing Process Robust Manufacturing Process Scale-up Nanomedicine Product NanoAssemblr Benchtop Instrument Scale-Up Platform 6

7 Nanomedicine Development Process Conceptual Nanomedicine API - NanoparticleF ormulation Manufacturing Process Robust Manufacturing Process Scale-up Nanomedicine Product NanoAssemblr Benchtop Instrument Scale-Up Platform Accelerated Development of Nanomedicines 7

8 The NanoAssemblr Benchtop Instrument Proprietary microfluidics-based instrument Manufacture novel nanoparticles Nucleic acid-lipid nanoparticles Polymer nanoparticles Liposomes NanoAssemblr Benchtop Instrument Microfluidic Cartridge Oil-in-water nanoemulsions Prepare 1.5 ml 20 ml nanoparticles / run Operate at 4 ml/min - 20 ml/min Make > 30 formulations / day Software controlled Easy-to-use Rapid nanoparticle development 8

9 The NanoAssemblr Microfluidic Cartridge Microfluidic Cartridge TOP VIEW Microfluidic Cartridge BOTTOM VIEW Microfluidic Chip Easy-to-use consumable cartridge 9

10 The Magic is in the Microfluidics aqueous Solvent (water miscible) Channel diameter: ~100 µm Staggered Herringbone Mixers Rapid & Controlled Mixing Laminar fluid flow Diffusion mixing Rapid mixing (< 3 ms -1 ) Small reaction volumes (~ 14 nl) Stroock et al., Science 2002 Low energy input Nanoparticles Predictable and reproducible mixing 10

11 Microfluidics Process Parameters Aqueous:Solvent Flow Rate Ratio aqueous Solvent (water miscible) Ratio of the flow rates (ml/min) of the aqueous and solvent input streams Higher aqueous:ethanol flow rate ratios result in more rapid increases in polarity Rapid change in polarity forces the nanoparticle components to organize into the most thermodynamically and energetically favorable structure Process parameters dictate nanoparticle biophysical characteristics 11

12 Microfluidics Process Parameters Total Flow Rate aqueous Solvent (water miscible) The combined flow rates of the aqueous stream and the solvent stream Ranges from 4 ml/min 20 ml/min Total Flow Rate is a surrogate for mixing speed Increased flow rate increases mixing speed At high Total Flow Rates nanoparticles reach limit size Limit size is defined as The smallest achievable lipid particles compatible with the packing of the molecular constituents in an energetically stable structure Process parameters dictate nanoparticle biophysical characteristics 12

13 Presentation Overview 1. Introduction to Microfluidics-Based NanoAssemblr Platform for Nanoparticle Manufacture 2. Examples of Nanoparticles Manufactured by the NanoAssemblr Platform 3. Scale-up Manufacture using the NanoAssemblr Platform 13

14 The NanoAssemblr Platform: Manufacture of Novel Nanoparticles Lipid Nanoparticles Polymer Nanoparticles Liposomes O/W Nanoemulsions 14

15 Lipid Nanoparticles 15

16 Lipid Nanoparticles for the Delivery of RNA Package RNA into nanoparticle core Protect RNA from degradation Facilitate RNA uptake into cells Promote RNA release into the cytoplasm Images courtesy of Prof. Pieter Cullis, University of British Columbia 16

17 RNA-Lipid Nanoparticles are Complex Ionizable Cationic Lipid Cholesterol Phospholipid PEG-lipid Manufacture of RNA-Lipid Nanoparticles is challenging RNA 17

18 Mean % Serum TTR Knockdown Relative to Baseline RNA-Lipid Nanoparticles Represent the Current Clinical Gold Standard for RNAi Patisiran (ALN-TTR02) is Currently in Phase 3 clinical trials for treatment of Transthyretin-Mediated Amyloidosis Treatment (mg/kg) Placebo sirna Dose B.U.Med.Center, July Day Serum TTR levels were measured in separate Phase I study of ALN-PCS, an RNAi therapeutic targeting PCSK9, which uses identical LNP formulation as ALN-TTR02 18

19 Microfluidics Manufactures Solid-Core RNA- Lipid Nanoparticles Images courtesy of Prof. Pieter Cullis, University of British Columbia 19

20 Neutral, Solid-Core RNA-Lipid Nanoparticles Mimic Endogenous Delivery Systems Molecular model: Neutral, Solid-Core RNA-Lipid Nanoparticles Low Density Lipoprotein (LDL): Endogenous Lipid Nanoparticles Wasan K. M. et al. (2008) Impact of Lipoproteins on the Biological Activity & Disposition of Hydrophobic Drugs: Implications for Drug Discovery. Nat. Rev. Drug Disc. 7: 84-99

21 Neutral, Solid-Core RNA-Lipid Nanoparticles Mimic Endogenous Delivery Systems Wasan K. M. et al. (2008) Impact of Lipoproteins on the Biological Activity & Disposition of Hydrophobic Drugs: Implications for Drug Discovery. Nat. Rev. Drug Disc. 7: 84-99

22 Solid-core RNA-Lipid Nanoparticles Associate with ApoE In Vivo PEG-lipid dissociates and ApoE associates after injection ApoE LDL receptor, scavenging receptor on hepatocytes Images courtesy of Prof. Pieter Cullis, University of British Columbia 22

23 Ionizable Cationic Lipids Mediate Maximum Endosomal Escape ph reduced below pka of cationic lipid Cationic lipids combine with anionic lipids to induce nonbilayer structures and release of sirna Images courtesy of Prof. Pieter Cullis, University of British Columbia 23

24 Residual FVII (%) Solid-Core RNA-Lipid Nanoparticles Mediate Sustained Liver Gene Knockdown In Vivo Brij mg/kg 0.05 mg/kg 0.1 mg/kg 0.3 mg/kg 0.5 mg/kg 1 mg/kg EC 50 EC Day 24

25 Can ApoE-Medicated Targeting be Used for Other Tissues? LDL receptor family members: LDLR, LRP1, VLDLR, ApoER2, LRP4, LRP1B and Megalin Need to design novel nanoparticles to deliver RNA beyond the liver 25

26 Microfluidics Enables Rapid Development of Novel RNA-Nanoparticles Reproducibility Rapid Development Encapsulation Efficiency Ease-of-Use Size Incumbent Technology Speed Novel Nanoparticles Compositional Space NanoAssemblr Multi-Function Nanoparticles Seamless Scale-Up 26

27 RNA-Lipid Nanoparticle Size Dictated by Manufacturing Process Changing sirna-lnp Process (Cationic Lipid:DSPC:Cholesterol:PEG) RNA-Lipid Nanoparticles reach Limit Size at high Total Flow Rates 27

28 RNA-Lipid Nanoparticle Size Dictated by Lipid Composition Limit Size is dependent on RNA-Lipid Nanoparticle composition 28

29 % Total Injected Dose % Total Injected Dose % Total Injected Dose sirna-lnp In Vivo Behavior Particle Size Influences sirna-lnp Pharmacokinetics & Biodistribution 100 Blood Liver Spleen Time (hr) Time (hr) Time (hr) sirna-lnp Particle Diameter: Red = 43 nm (5% PEG) Green = 78 nm (5% PEG) Blue = 140 nm (5% PEG) Grey = 78 nm (1.5% PEG)

30 30

31 30 nm sirna-lnp Enables Liver Gene Knockdown by Subcutaneous Injection 31

32 32

33 Targeted sirna-lnp 33

34 34

35 In Vivo Gene Knockdown in T-Lymphocytes 35

36 Microfluidics for Targeted Nanoparticles Molecular Assembly Line Step-wise reactions Post-insertion for targeting Programmable mixing Targeted medicines Multi-functional agents Bespoke medicines 36

37 Manufacture of Multi-Functional Nanoparticles Sequential Addition of Cationic (XTC) and Anionic (PS) Lipids

38 38

39 Encapsulation of Gold Nanoparticles 39

40 Liposomes 40

41 Liposome Size Dictated by Manufacturing process Limit size Liposomes are dictated by the Flow Rate Ratio 41

42 Liposome Size Dictated by Lipid Composition POPC:Cholesterol:PEG-DSPE (3%) Liposome size and polydispersity is dependent on cholesterol content 42

43 .com by University of British Columbia on 06/16/15 nly. ahealthcare.com /lpr ISSN: (print), (electronic) J Liposome Res, Early Online: 1 7! 2015 Informa Healthcare USA, Inc. DOI: / RESEARCH ARTICLE Production of lim it size nanoliposom al system s with potential utility as ultra-sm all drug delivery ag ents Igor V. Zhigaltsev, Ying K. Tam, Alex K. K. Leung, and Pieter R. Cullis Department of Biochemistry and Molecular Biology, Faculty of Medicine, University of British Columbia, Vancouver, Canada Abstract Previous studies from this group have shown that limit size lipid-based systems defined asthe smallest achievable ag gregates compatible with the packing properties of their molecular constituents can be efficiently produced using rapid microfluidic mixing technique. In this work, it is shown that similar procedures can be employed for the production of homogeneously sized unilam ellar vesicular systems of nm size range. These vesicles can be remotely loaded with the protonable drug doxorubicin and exhibit adequate drug retention properties in vitro and in vivo. In particular, it isdemonstrated that whereas sub-40 nm lipid nanoparticle (LNP) systems consisting entirely of long-chain saturated phosphatidylcholines cannot be produced, the presence of such lipids may have a beneficial effect on the retention properties of limit size systems consisting of mixed lipid components. Specifically, a 33-nm diam eter doxorubicin-loaded LNP system composed of 1-palmitoyl-2-oleoyl phosphatidylcholine (POPC), 1,2-dipalmitoyl phosphatidylcholine (DPPC), cholesterol, and PEGylated Keyw ords Doxorubicin, herringbone micromixer, limit size nanoparticles, liposome, microfluidic mixing History Received 9 December 2014 Revised 23 February 2015 Accepted 1 March 2015 Published online 9 April

44 y University of British Columbia on 06/16/15 Drug retention, % Drug Retention in Small Liposomes DOI: / Production of limit si Time, h Figure 2. Drug retention in 22 nm POPC/Chol/DSPE-PEG /35/3 (squares) and 33 nm POPC/DPPC/Chol/DSPE-PEG /20/35/3 (diamonds) systems determined in vivo. LNP formulations containing trace amounts of the tritiated lipid [ 3 H]-CHE were loaded with 14 C-labeled doxorubicin at a drug-to-lipid ratio 0.1 mol/mol and then injected intravenously into CD1 mice at a lipid dose of 50mg/kg. Plasma samples taken at the indicated time points were analyzed for lipid and drug content by liquid scintillation counting as described in M aterials and methods section. Each data point represents mean values ±SD from each group of mice (n ¼ 4)

45 45

46 Encapsulation of Hydrophobic Propofol 46

47 47

48 Design of Experiment Studies 48

49 Polymer Nanoparticles 49

50 Cellax TM Polymer-Drug conjugates 100nm 100nm NanoAssemblr TM Vortex 50

51 Nanoparticle Size Dictated by Polymer Concentration Cellax TM Polymer-Drug conjugates Particle size is dictated by polymer concentration 51

52 52

53 Polymer Composition Dictates Biophysical Characteristics 53

54 54

55 Polymer-mediated Anti-Cancer Activity 55

56 O/W Nanoemulsions 56

57 Particle size, nm Nanoemulsion Droplet Size Dictated by Manufacturing Process B 70 POPC/triolein (60/40 mol/mol) Aqueous/ethanol flow rate ratio Zhigaltsev, I.V. Et al., Langmuir 2012, 28,

58 Particle size, nm Nanoemulsion Droplet Size Dictated by Emulsion Composition Actual diameter Theoretical diameter POPC/Triolein ratio, mol/mol Zhigaltsev, I.V. Et al., Langmuir 2012, 28,

59 Presentation Overview 1. Introduction to Microfluidics-Based NanoAssemblr Platform for Nanoparticle Manufacture 2. Examples of Nanoparticles Manufactured by the NanoAssemblr Platform 3. Scale-up Manufacture using the NanoAssemblr Platform 59

60 Assessment of the Robustness of the Manufacturing Process Design of Experiment (DoE) variables Lipid Concentration Flow Rate Mixing Conditions Lipid:RNA Ratio Stable Results = Robust Process = Scalable Process 60

61 Microfluidics Enables Seamless Scale-Up Microfluidic Mixer Aqueous (RNA) Solvent (Lipids) Continuous Flow Pumps Microfluidic Mixer Microfluidic Mixer Microfluidic Mixer Microfluidic Mixer Dilution Buffer Exchange & Nanoparticle Concentration RNA - Nanoparticles Parallelized Microfluidic Mixers 61

62 Microfluidics Enables Seamless Scale-Up Microfluidic Mixer Aqueous (RNA) Solvent (Lipids) Continuous Flow Pumps Microfluidic Mixer Microfluidic Mixer Microfluidic Mixer Microfluidic Mixer Dilution Buffer Exchange & Nanoparticle Concentration RNA - Nanoparticles Parallelized Microfluidic Mixers 62

63 Diameter (nm) PDI Continuous Flow Scale-up Manufacture of RNA-Lipid Nanoparticles Using Single Mixer Cumulative Fraction (ml) Seamless transfer of optimized manufacturing parameters 63

64 Microfluidics Enables Seamless Scale-Up Microfluidic Mixer Aqueous (RNA) Solvent (Lipids) Continuous Flow Pumps Microfluidic Mixer Microfluidic Mixer Microfluidic Mixer Microfluidic Mixer Dilution Buffer Exchange & Nanoparticle Concentration RNA - Nanoparticles Parallelized Microfluidic Mixers 64

65 4x Parallelized Microfluidic Mixer Manifold System 65

66 Diameter (nm) PDI Microfluidic Parallelization Enables RNA- Lipid Nanoparticle Scale-Up X Mixer 2X Mixer 4X Mixer 12 ml/min 24 ml/min 48 ml/min Parallelization of microfluidic mixers enables greater throughput 66

67 Diameter (nm) PDI On-Chip Microfluidic Parallelization Produces Equivalent RNA-LNP X Mixer Chip 4X Manifold 4X On-Chip 48 ml/min 48 ml/min Multiple options for increased throughput by parallelization 67

68 16x Parallelization Enabled Through 4x Mixer Cartridges in 4x Manifold System 16x Parallelization Enables > 20L Batches in 2 h 68

69 Microfluidics Enables Seamless Scale-Up Microfluidic Mixer Aqueous (RNA) Solvent (Lipids) Continuous Flow Pumps Microfluidic Mixer Microfluidic Mixer Microfluidic Mixer Microfluidic Mixer Dilution Buffer Exchange & Nanoparticle Concentration RNA - Nanoparticles Parallelized Microfluidic Mixers 69

70 High Quality RNA-Lipid Nanoparticle Product After Microfluidics After Buffer Exchange After RNA Concentration Amenable to Industry Standard Post-Manufacture Processing 70

71 Microfluidics Enables Seamless Scale-Up Microfluidic Mixer Aqueous (RNA) Solvent (Lipids) Continuous Flow Pumps Microfluidic Mixer Microfluidic Mixer Microfluidic Mixer Microfluidic Mixer Dilution Buffer Exchange & Nanoparticle Concentration RNA - Nanoparticles Parallelized Microfluidic Mixers 71

72 Design for GMP Manufacturing Continuous flow pumps 8X parallelized mixers in disposable manifold Disposable fluid path for product contacting materials

73 Design for GMP Manufacturing 8 x 12 ml/min Microfluidic Mixer Array 288 ml/min 24 ml/min Dilution Pump Solvent Metering Pump Dilution Reagent Bag Tee Pinch Valve 384 ml/min To Post-processing Solvent Reagent Bag 72 ml/min 96 ml/min Tee Aqueous Metering Pump Pinch Valve Aqueous Reagent Bag Sample Switch Waste 8X Scale-up System 73

74 Diameter (nm) PDI 8X Scale-Up Instrumentation Produces High-Quality RNA-LNP Cumulative Fraction (ml) 8X Scale-up system processes 5.75 L/hr 74

75 GMP Program in Development Pumping system selected GMP-compliant Disposable COC microfluidic cartridges under development Working with drug development partner to transfer technology to CMO for scale-up and GMP manufacturing Fully disposable fluid path using USP Class 5/6 materials Targeting a GMP-ready system by end-of-year

76 Summary 1. The Microfluidics-Based NanoAssemblr Platform enables simple, rapid & reproducible manufacture of novel nanoparticles 2. The NanoAssemblr Platform can be used to manufacture several different types of nanoparticles 3. Process parameters can be used to dictate nanoparticle biophysical characteristics such as particle size 4. The NanoAssemblr Platform enables seamless scale-up by parallelization of microfluidic devices 76

77 Contact Information Nepa Gene Co., Ltd. Sales Team Shioyaki, Ichikawa, Chiba, JAPAN phone: fax:

78 Extra Slides 78

79 Reproducible RNA-Lipid Nanoparticles Independent of Operator or Site Operator Automated Instrumentation Removes Operator Variability 79