The Development of a Robust Chemically Defined Media

TM
(EX-CELL CD NS0) for NS0 & Myeloma Cell Lines
Lynn A. Davis1, Misa I. Gray1, Jessica J. Jones1, Scott L. Wilson1, Sandy K. McNorton1, Manisha Sahni1,
Nan Lin2, Genova A. Richardson2, Michael W. Wathen1, and Matthew V. Caple2
Cell Sciences and Development, SAFC Biosciences 13804 W. 107th Street, Lenexa, Kansas 66215, USA1, 2909 Laclede Avenue, Saint Louis, MO 63103, USA2

Abstract
Figure 4. Protein Productivity results of 4 NS0-GS subclones
With 30 years of successful recombinant protein and antibody expression, the NS0 cell line continues to be an Final Titers post Media Development & Optimization
over the course of the Media Development project for the
excellent choice for mammalian gene expression. To support the need for higher cell densities, viability and 350 Screens chosen base media and the optimization of that base media.
protein productivity, a new NS0 formulation was developed. Chemically defined (CD) formulations from the 300 Component Opt-1 All cells lines were passaged several times in each media (19

Titer IgG (ug/mL)

SAFC Biosciences media library were screened for growth and productivity with four NS0 clones expressing a Component Opt-2 in-house CD and ACF formulations) to allow for adaptation
250 Component Opt-3 before each study. Various components and groupings of
recombinant human IgG. The best media from this screening was then optimized through multiple rounds of
200
EX-CELL NS0 components were tested in triplicate. After passaging, the cell
component group titrations. The additional rounds of media optimization increased the productivity of all four Competitor 1 lines were seeded in TPP tubes at 3x105 cells/mL. Cell viability
clones and reduced the variable levels of productivity observed between clones from 5-fold to 2-fold. The resulting 150 and density measurements were taken daily. While each cell
EX-CELLTM CD NS0 is a chemically defined media containing recombinant proteins that surpasses the current 100 line had unique growth and productivity characteristics,
SAFC Biosciences catalog offering as well as a competitor’s CD Hybridoma media in growth, viability, culture improvements in these properties were made for each cell line.
50 The new optimized media (EX-CELLTM CD NS0) showed
longevity and productivity for the NS0 clones utilized in these experiments.
0 significant improvement in growth, viability (not shown) and
Using EX-CELLTM CD NS0 media peak viable cell densities of >6X106 viable cells/mL were routinely measured by 3 E11 4B7 4D11 5D2 productivity over EX-CELLTM NS0 and a Competitor’s
Cedex counting compared to the competitor’s CD Hybridoma reaching 3X106 viable cells/mL. The cell viabilities Cell Line hybridoma’s media.
were 80% or better through day 6 of a batch cell culture growth curve and the final protein productivity was 3-4X
that of the competitor’s CD Hybridoma media.
In conclusion, we have developed a new CD media for NS0 cell lines exhibiting improved cell growth, improved Figure 5. Growth Curve of cell line 5D2 in 3 lots of EX-CELLTM
5D2 GS-NS0 Growth Curve in EX-CELL CD NS0 CD NS0 (LM), one lot of dry powder media (DPM),
viability, increased culture longevity, improved productivity and ease of adaptation from serum containing media. EX-CELLTMNS0 and Competitor 1 hybridoma media. 5D2 cells
The new EX-CELLTM CD NS0 media supports both GS and non-GS myeloma/hybridoma cell lines and is available 7.00E+06 100.0
LM Lot 8L0473
were passaged several times in each media to allow for
90.0 LM Lot 8L0474
in both liquid and dry powder forms. 6.00E+06
80.0 LM Lot 8L0475 adaptation. After passaging, 5D2 cells were seeded in 125 mL

VCD cells/mL
5.00E+06 70.0 DPM Lot 8M0567 shake flakes at 3x105 cells/mL. Cell viability and density

Viability
Competitor 1
4.00E+06
60.0
EX-CELL NS0 measurements were taken daily. 5D2 cells reached significantly
Materials and Methods 3.00E+06
50.0
40.0
LM Lot 8L0473
LM Lot 8L0474
higher peak VCD in EX-CELLTM CD NS0 and demonstrated
LM Lot 8L0475
greater longevity as compared to Competitor1. 5D2 cells in
30.0
Cell Line & Vector Development 2.00E+06
20.0
DPM Lot 8M0567 EX-CELLTM CD NS0 reached a maximum cell density of
The NS0 parental cell line and vectors (pEE12.4 and pEE6.4) were licensed from Lonza Biologics. The heavy and 1.00E+06
10.0
Competitor 1
EX-CELL NS0
approximately 6x106 cells/mL on Day 6. 5D2 cells in
light chain genes from an anti-rabies humanized IgG (SO47) were used to create the final plasmids following 0.00E+00 0.0 Competitor 1 media reached maximum cell density of 3.2x106
D1 D2 D3 D4 D5 D6 D7 D8 D9
cells/mL on Day 4 and then rapidly declined. Data represents
the Lonza protocol for construction. These plasmids were electroporated into the NS0 parental cell line using a Days in Culture the mean viable cell density for triplicate flasks.
Single-pulse Square Wave Setting set at 225 V and 30 msec (BTX Electroporator). Cells were allowed to recover
in Dulbecco’s Modified Eagle’s media (SAFC Biosciences, Product Number 51435) with GS supplement (Sigma
Aldrich, Product Number G9785) and 10% FBS (SAFC Biosciences). Expressing cells were then selected by Figure 6. Productivity results from Growth Curve of cell line
5D2 GS-NS0 Productivity
incubating in L-glutamine free media +/- 7.5 mM MSX (Sigma-Aldrich, Product Number M5379) for 3 weeks. 5D2 in 3 lots of EX-CELLTM CD NS0 (LM), one lot of dry powder
400.00
LM Lot 8L0473 media (DPM), EX-CELLTM NS0 and Competitor 1 hybridoma
Cell Line Screening 350.00 media (Figure 5). Minimal lot to lot variation was observed for
LM Lot 8L0474
The transfected Masterwell cell lines were expanded from 96 well plates using Dulbecco’s Modified Eagle’s media Titer IgG (mg/L) 300.00 the liquid media (LM) and dry powder lot. The productivity for
LM Lot 8L0475
(SAFC Biosciences, Product Number 51435) with GS supplement (Sigma Aldrich, Product Number G9785) and all lots of EX-CELLTM CD NS0 were 3 times greater than
250.00 DPM Lot 8M0567
10% FBS (SAFC Biosciences) to 24 well plates and tested for productivity using the Guava PCA-96. Those cell EX-CELLTM NS0 or a Competitor’s hybridoma media. Data
200.00 Competitor 1
lines that continued to grow and produce were expanded and the serum concentration was reduced to 1% as the represents the mean productivity levels for triplicate flasks. See
150.00 EX-CELL NS0 Figure 5 for Growth Curve.
cell lines were scaled up to 125 mL shake flasks. Four cell lines were subcloned using limiting dilution and four
100.00
subclones with diverse growth and productivity characteristics were studied as stated above. The subclones were
adapted to serum free media and scaled up for characterization in EX-CELLTM NS0 (SAFC Biosciences, Product 50.00

Number 14650C). Cholesterol (Sigma-Aldrich, Product Number S5542) was added to a final concentration of 2X 0.00
Day 7 Day 8 Day 9 Day 10
as the serum was decreased. All studies were run at 37 °C in a humidified incubator at 5% C02. Days
Media Screens
Nineteen in-house CD and ACF media supplemented with GS (1X) and Cholesterol (2X) were used in the initial
screening with the four NS0-GS cell lines. The studies were performed using TPP tubes in triplicate in a Kuhner Figure 7. Growth Curve of cell line 4B7 in 3 lots of EX-CELLTM
4B7 GS-NS0 Growth Curve in EX-CELL CD NS0
shaking incubator (Appropriate Technical Resources, Laurel MD) at 200 rpm. Typically 30 mL of media was CD NS0 (LM), one lot of dry powder media (DPM), EX-CELLTM
9.00E+06 100.0
LM Lot 8L0473 NS0 and Competitor 1 hybridoma media. 4B7 cells were
used per TPP tube seeded with 3x105 cells/mL. EX-CELLTM NS0 (SAFC Biosciences, Product Number 14650C) 90.0
8.00E+06 LM Lot 8L0474 passaged several times in each media to allow for adaptation.
and a competitor’s hybridoma media were used as controls. Samples were pulled daily for growth, viability and 7.00E+06
80.0 LM Lot 8L0475 After passaging, 4B7 cells were seeded in 125 mL shake flakes
NOVA analysis. Productivity and spent media analysis samples were pulled beginning on Day 6 and continuing 70.0
DPM Lot 8M0567
at 3x105 cells/mL. Cell viability and density measurements
VCD cells/mL

6.00E+06 Competitor 1
until the viability was 50% or below. Once the base media was identified the optimization of various component 60.0
EX-CELL NS0
were taken daily. 4B7 cells reached significantly higher peak
Viability

5.00E+06
group titrations commenced. The final formulation chosen (EX-CELLTM CD NS0) was CD and ACF containing 50.0 LM Lot 8L0473 VCD in EX-CELLTM CD NS0 and demonstrated greater longevity
recombinant proteins.
4.00E+06
40.0 LM Lot 8L0474 as compared to Competitor 1. 4B7 cells in EX-CELLTM CD NS0
3.00E+06
30.0
LM Lot 8L0475 reached a maximum cell density of approximately 7.8x106
Bioreactor and Feed Studies DPM Lot 8M0567 cells/mL on Day 6. 4B7 cells in Competitor 1 media reached
2.00E+06
20.0
Bioreactor runs were conducted in 3 L stirred tank bioreactors (Applikon, Inc., Schiedam, Holland THE Competitor 1
maximum cell density of 4.62x106 cells/mL on Day 7. Data
1.00E+06 10.0 EX-CELL NS0
NETHERLANDS). Bioreactors were seeded at 3x105 cells/mL in EX-CELLTM CD NS0 and Competitor’s media. represents the mean viable cell density for triplicate flasks.
0.00E+00 0.0
Dissolved oxygen (DO) and pH were monitored online and controlled using air, O2, N2, CO2 and 7.5% NaHCO3, D1 D2 D3 D4 D5 D6 D7 D8 D9
respectively. Temperature was maintained at 37 °C using a heating blanket. Samples (5 mL) were collected daily Days in Culture

to monitor cell density, viability and metabolic consumption/production (data not shown). All IgG titers were
determined using a HPLC by injecting 25uL of spent cell culture media into a 2.1mm × 30mm POROS A20 Protein
Figure 8. Productivity results from Growth Curve of cell line
A Column (Applied Biosystems, CA, USA) connected to an Alliance HPLC with PDA detection (Waters, MA, USA). 4B7 GS-NS0 Productivity 4B7 in 3 lots of EX-CELLTM CD NS0 (LM), one lot of dry powder
400.00 media (DPM), EX-CELLTM NS0 and Competitor 1 hybridoma
LM Lot 8L0473
Number of 350.00 media (Figure 7). Minimal lot to lot variation was observed for
LM Lot 8L0474
CV40 Poly A transectants/ the liquid media (LM) and dry powder lot. The productivity for
Transfection 300.00
Titer IgG (mg/L)

ciones
250.00
LM Lot 8L0475 all lots of EX-CELLTM CD NS0 were 3 times greater than
(-) Gln, (+/-) MSX
Heavy Chain CDS AmpR DPM Lot 8M0567 EX-CELLTM NS0 and the productivity was 1.6 – 2 times greater
>200 200.00
“Masterwell” (MW)Transfectants Competitor 1 than the Competitor’s hybridoma media. Data represents the
150.00
78 EX-CELL NS0 mean productivity levels for triplicate flasks. See Figure 7 for
Promoter 3 Guava Productivity Screen 100.00
Growth Curve.
50.00
Characterization of MW Transfectants
Growth and Productivity 14 0.00
GS cDNA Secretion Population Heterogeneity Analysis Day 7 Day 8 Day 9 Day 10
Promoter 1
Days
Single -Cell Cloning 4

SV40 poly A SV40

Characterization of Single -Cell Clones Figure 9. Batch and fed batch Bioreactors using the NS0-GS
Light Chain CDS 32
Growth and Productivity 5D2 GS-NS0 Bioreactor 5D2 cell line performed in duplicate. 5D2 cells were expanded
Media Development on Best 4 Subclones
Promoter 2 Work in 7.00E+06 100.00 EX-CELL CD NS0 + feed1 in one lot of EX-CELLTM CD NS0 or the competitor’s media.
progress
6.00E+06
90.00 EX-CELL CD NS0
Competitor 1
Bioreactors were inoculated with 3x105 cells/mL. The fed batch
Figure 1. Anti-rabies GS Expression Vector Figure 2. Cell Line Generation Work Flow 80.00 EX-CELL CD NS0 + feed 2 cultures were fed on Day 3 with one of two proprietary feed
VCD cells/ml

5.00E+06 EX-CELL CD NS0 + feed1

70.00
EX-CELL CD NS0
blends. All the bioreactors were temperature shifted on Day 4
60.00
4.00E+06 Competitor 1 to 33 °C. Samples were collected daily for growth, viability and
Viability

50.00 EX-CELL CD NS0 + feed 2

metabolite consumption. Productivity samples were collected
Results 3.00E+06
40.00 Day3 - Feed
Day4 - Temp. shift to 33 °C beginning on Day 8. 5D2 cells reached significantly higher
2.00E+06 30.00
20.00 peak VCD in EX-CELLTM CD NS0 and demonstrated greater
Secretion Population Heterogeneity Analysis of the Anti-Rabies NS0-GS Single-Cell Clones 1.00E+06
10.00 longevity as compared to Competitor 1. 5D2 cells in EX-CELL
0.00E+00 0.00 CDTM NS0 reached a maximum cell density of approximately
0 1 2 3 4 5 6 7 8 9 10 11 12
Days in Culture
6x106 cells/mL on Day 6. 5D2 cells in Competitor 1 media
reached maximum cell density of 2.5x106 cells/mL on Day 4.

Figure 10. Productivity results from batch and fed batch

5D2 GS-NS0 Bioreactors Bioreactor studies performed with cell line 5D2 in 1 lot of
600.0 EX-CELLTM CD NS0 (LM) and Competitor 1 hybridoma media in
D8
500.0 D9
duplicate. The productivity of EX-CELLTM CD NS0 batch was 3
times greater than Competitor’s hybridoma media. With
Titer mg/L

400.0 D10
D11 Proprietary Feed 1 the productivity was 5 times that of the
300.0
D12 Competitor’s hybridoma media and with Proprietary Feed 2 the
200.0 D13 productivity was 4 times that of the Competitor’s hybridoma
100.0 D14 media. See (Figure 9) for Growth Curve.
0.0
EX-CELL EX-CELL EX-CELL Competitor 1
CD NS0 CD NS0 + CD NS0 +
Figure 3. Cell Xpress secretion heterogeneity analysis results from 14 single-cell clones derived from two “Masterwell” transfectant feed 1 feed 2
populations. Parental NS0 cells were included as control. Mean values are indicated by black. Secretion Average Area Intensity Media
is normalized to parental NS0. The LEAP system (Laser-Enabled Analysis and Processing, Cyntellect, San Diego, CA) is a unique
laser-based cell processing system that combines cell imaging and laser-mediated cell manipulation in an automated and high-
throughput manner via large field-of-view optics and galvanometer steering. It allows the user to efficiently identify, select and
monitor expansion of high recombinant protein secreting clones. It also enables analysis of IgG-secretion heterogeneity and
purification of transfected populations by eliminating non-producers Conclusions
TM
The new product EX-CELL CD NS0, offers the following advantages over other products:
• Ease of adaptation from SAFC Biosciences media formulations or Competitor’s media into
EX-CELLTM CD NS0
• Growth was consistently higher in EX-CELLTM CD NS0 compared to current market offerings in a variety of vessels
• Productivity in EX-CELLTM CD NS0 was 1.7-3.8 times higher than in either the NS0 control media (EX-CELLTM NS0)
or the Competitor’s CD Hybridoma media
• Demonstrated consistency and equivalency of the liquid media formulation to the dry powder formulation for
EX-CELLTM CD NS0
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