Protein Formulations Research Articles

Protein Engineering and HDX Identify Structural Regions of G-CSF Critical to Its Stability and Aggregation.

The protein engineering and formulation of therapeutic proteins for prolonged shelf-life remain a major challenge in the biopharmaceutical industry. Understanding the influence of mutations and formulations on the protein structure and dynamics could lead to more predictive approaches to their improvement. Previous intrinsic fluorescence analysis of the chemically denatured granulocyte colony-stimulating factor (G-CSF) suggested that loop AB could subtly reorganize to form an aggregation-prone intermediate state. Hydrogen deuterium exchange mass spectrometry (HDX-MS) has also revealed that excipient binding increased the thermal unfolding transition midpoint (Tm) by stabilizing loop AB. Here, we have combined protein engineering with biophysical analyses and HDX-MS to reveal that increased exchange in a core region of the G-CSF comprising loop AB (ABI, a small helix, ABII) and loop CD packed onto helix B and the beginning of loop BC leads to a decrease in Tm and higher aggregation rates. Furthermore, some mutations can increase the population of the aggregation-prone conformation within the native ensemble, as measured by the greater local exchange within this core region.

Quantifying methionine sulfoxide in therapeutic protein formulation excipients as sensitive oxidation marker

Methionine is a common excipient used in therapeutic protein liquid formulations as stabilizer and antioxidant. The oxidation of methionine to methionine sulfoxide can be regarded as a sensitive marker of oxidative stress for drug product storage conditions. In this study, a sensitive HPLC method for the quantification of methionine sulfoxide in formulated protein product was developed and qualified according to regulatory requirements using a SIELC® Primesep 100 column with UV detection. The separation involves a mixed-mode mechanism including reversed phase and cationic exchange modalities. The operating range of the method was established between 1 µM and 35 µM of methionine sulfoxide. In this testing range, the method was shown to be linear (R2 > 0.99), accurate (Recovery 92.9 – 103.6%, average recovery = 99.8 ± 1.4%) and precise (intermediate precision at LoQ, CV = 2.9%). The developed test system was successfully applied to study the effects of temperature and storage conditions on methionine sulfoxide formation in complex therapeutic antibody formulations.

Photo-Oxidation of Therapeutic Protein Formulations: From Radical Formation to Analytical Techniques.

UV and ambient light-induced modifications and related degradation of therapeutic proteins are observed during manufacturing and storage. Therefore, to ensure product quality, protein formulations need to be analyzed with respect to photo-degradation processes and eventually protected from light exposure. This task usually demands the application and combination of various analytical methods. This review addresses analytical aspects of investigating photo-oxidation products and related mediators such as reactive oxygen species generated via UV and ambient light with well-established and novel techniques.

A General Small-Angle X-ray Scattering-Based Screening Protocol for Studying Physical Stability of Protein Formulations.

A fundamental step in developing a protein drug is the selection of a stable storage formulation that ensures efficacy of the drug and inhibits physiochemical degradation or aggregation. Here, we designed and evaluated a general workflow for screening of protein formulations based on small-angle X-ray scattering (SAXS). Our SAXS pipeline combines automated sample handling, temperature control, and fast data analysis and provides protein particle interaction information. SAXS, together with different methods including turbidity analysis, dynamic light scattering (DLS), and SDS-PAGE measurements, were used to obtain different parameters to provide high throughput screenings. Using a set of model proteins and biopharmaceuticals, we show that SAXS is complementary to dynamic light scattering (DLS), which is widely used in biopharmaceutical research and industry. We found that, compared to DLS, SAXS can provide a more sensitive measure for protein particle interactions, such as protein aggregation and repulsion. Moreover, we show that SAXS is compatible with a broader range of buffers, excipients, and protein concentrations and that in situ SAXS provides a sensitive measure for long-term protein stability. This workflow can enable future high-throughput analysis of proteins and biopharmaceuticals and can be integrated with well-established complementary physicochemical analysis pipelines in (biopharmaceutical) research and industry.

A guide to studying protein aggregation.

Disrupted protein folding or decreased protein stability can lead to the accumulation of (partially) un- or misfolded proteins, which ultimately cause the formation of protein aggregates. Much of the interest in protein aggregation is associated with its involvement in a wide range of human diseases and the challenges it poses for large-scale biopharmaceutical manufacturing and formulation of therapeutic proteins and peptides. On the other hand, protein aggregates can also be functional, as observed in nature, which triggered its use in the development of biomaterials or therapeutics as well as for the improvement of food characteristics. Thus, unmasking the various steps involved in protein aggregation is critical to obtain a better understanding of the underlying mechanism of amyloid formation. This knowledge will allow a more tailored development of diagnostic methods and treatments for amyloid-associated diseases, as well as applications in the fields of new (bio)materials, food technology and therapeutics. However, the complex and dynamic nature of the aggregation process makes the study of protein aggregation challenging. To provide guidance on how to analyse protein aggregation, in this review we summarize the most commonly investigated aspects of protein aggregation with some popular corresponding methods.

Effects of model tear proteins and topical ophthalmic formulations on evaporation inhibition and biophysical property of model tear lipid nanofilm in vitro

Biophysical property and water evaporation retardation through a lipid nanofilm can be altered by model tear protein and topical ophthalmic formulation. Evaporation rate and dynamic surface pressure were measured using a sessile drop technique. Water evaporations from 5 individual protein solutions, their mixture, and 6 ophthalmic formulations were quantified. Biophysical property and evaporation through model lipid nanofilms spread on model electrolyte solutions, tear protein solutions, and ophthalmic formulations were assessed. Model lipid nanofilms spread on electrolyte solution reduced evaporative fluxes by 43–60%. Evaporative fluxes from individual protein solutions without lipids were 3–19% lower than from electrolytes solution. Evaporative fluxes through lipid nanofilms were decreased by the presence of albumin or lactoferrin in solutions but increased by lysozyme and mucin. Evaporative fluxes from ophthalmic formulations were 10–43% lower than from electrolyte solution. Evaporations through lipid nanofilms spread on formulations were higher than through lipids on electrolyte solution. Model lipid nanofilms spread on Diquas appeared more rigid than on electrolyte solution but showed softening when spread on Refresh Mega-3. Some proteins and ophthalmic formulations altered model lipid nanofilms evaporative barriers. Ophthalmic formulation induced changes in biophysical property of model lipid nanofilms in vitro may suggest possible tear film destabilization in vivo.

Differential effect of polyol and sugar osmolytes on the refolding of homologous alpha amylases: A comparative study

Polyol and sugar osmolytes are known to enhance the stability of proteins, however, their role in assisting protein folding is not well understood. We asked whether these osmolytes have the same effect during refolding of a pair of thermophilic and mesophilic proteins. Herein, we have chosen α-amylases from Bacillus licheniformis (BLA) and Bacillus amyloliquefaciens (BAA) as thermophilic like and mesophilic counterparts respectively, having similar structures but differing thermostability. The effect of a series of polyols with varying number of -OH groups from 2 to 6 (Ethylene glycol, glycerol, erythritol, xylitol and sorbitol) and sugars (trehalose and sucrose) has been studied on the refolding of BLA and BAA. Our study demonstrates that glycerol, sorbitol and trehalose are the efficient cosolvents for BAA refolding, while comparatively less effective for BLA. Urea induced destabilization of BLA and BAA is differently compensated by polyol and sugar osmolytes during refolding. This suggests that the early species formed during BLA and BAA refolding are differently susceptible towards urea, indicating differential nature of their refolding pathways. Addition of trehalose at different times during refolding showed that the presence of trehalose is essential at the early stages of refolding. It is one of the first systematic study wherein the comparative effect of polyol and sugar assisted refolding of thermophilic and mesophilic protein has been carried out. The study highlights the differential effect of protein-osmolyte interactions during refolding of thermophilic and mesophilic proteins which may have implications in protein formulations, refolding and inhibition of aggregation.

New Horizons: Next-Generation Insulin Analogues: Structural Principles and Clinical Goals.

Design of "first-generation" insulin analogues over the past 3 decades has provided pharmaceutical formulations with tailored pharmacokinetic (PK) and pharmacodynamic (PD) properties. Application of a molecular tool kit-integrating protein sequence, chemical modification, and formulation-has thus led to improved prandial and basal formulations for the treatment of diabetes mellitus. Although PK/PD changes were modest in relation to prior formulations of human and animal insulins, significant clinical advantages in efficacy (mean glycemia) and safety (rates of hypoglycemia) were obtained. Continuing innovation is providing further improvements to achieve ultrarapid and ultrabasal analogue formulations in an effort to reduce glycemic variability and optimize time in range. Beyond such PK/PD metrics, next-generation insulin analogues seek to exploit therapeutic mechanisms: glucose-responsive ("smart") analogues, pathway-specific ("biased") analogues, and organ-targeted analogues. Smart insulin analogues and delivery systems promise to mitigate hypoglycemic risk, a critical barrier to glycemic control, whereas biased and organ-targeted insulin analogues may better recapitulate physiologic hormonal regulation. In each therapeutic class considerations of cost and stability will affect use and global distribution. This review highlights structural principles underlying next-generation design efforts, their respective biological rationale, and potential clinical applications.

Combination of high throughput and structural screening to assess protein stability – A screening perspective

High throughput screening for measuring the stability of industrially relevant proteins and their variants is necessary for quality assessment in the development process. Advances in automation, measurement time and sample consumption for many techniques allow rapid measurements with minimal amount of protein. However, many methods include automated data analysis, potentially neglecting important aspects of the protein's behavior in certain conditions. In this study we implement small angle X-ray scattering (SAXS), typically not used to assess protein behavior in industrial screening, in a high throughput screening workflow to address problems of contradicting results and reproducibility among different high throughput methods. As a case study we use the lipases of Thermomyces lanuginosus and Rhizomucor miehei, widely used industrial biocatalysts. We show that even the initial analysis of the SAXS data without performing any time-consuming modelling provide valuable information on interparticle interactions. We conclude that recent advances in automation and data processing, have enabled SAXS to be used more widely as a tool to gain in-depth knowledge highly useful for protein formulation development. This is especially relevant in light of increasing accessibility to SAXS due to the commercial availability of benchtop instruments.

Immunogenicity of full-length P. vivax rPvs48/45 protein formulations in BALB/c mice

BackgroundPvs48/45 is a Plasmodium vivax gametocyte surface protein involved in the parasite fertilization process. Previous studies showed that Pvs48/45 proteins expressed in Escherichia coli (E. coli) and Chinese hamster ovary (CHO) cells were highly immunoreactive with sera from malaria-endemic areas and highly immunogenic in animal models. Here the immunogenicity in mice of three different vaccine formulations was compared. MethodsRecombinant (r) Pvs48/45 proteins were expressed in E. coli and CHO, purified, formulated in Alhydrogel, GLA-SE and Montanide ISA-51 adjuvants and used to immunize BALB/c mice. Animals were immunized on days 0, 20 and 40, and serum samples were collected for serological analyses of specific antibody responses using ELISA and immunofluorescence (IFAT). Additionally, ex-vivo transmission-reducing activity (TRA) of sera on P. vivax gametocyte-infected human blood fed to Anopheles albimanus in direct membrane feeding assays (DMFA) was evaluated. ResultsMost immunized animals seroconverted after the first immunization, and some developed antibody peaks of 106 with all adjuvants. However, the three adjuvant formulations induced different antibody responses and TRA efficacy. While GLA-SE formulations of both proteins induced similar antibody profiles, Montanide ISA-51 formulations resulted in higher and longer-lasting antibody titers with CHO-rPvs48/45 than with the E. coli formulation. Although the CHO protein formulated in Alhydrogel generated a high initial antibody peak, antibody responses to both proteins rapidly waned. Likewise, anti-Pvs48/45 antibodies displayed differential recognition of the parasite proteins in IFAT and ex vivo blockade of parasite transmission to mosquitoes. The CHO-rPvs48/45 formulated in Montanide ISA-51 induced the most effective ex vivo parasite blockage. ConclusionsThree out of six vaccine formulations elicited antibodies with ex vivo TRA. The CHO-rPvs48/45 Montanide ISA-51 formulation induced the most stable antibody response, recognizing the native protein and the most robust ex vivo TRA. These results encourage further testing of the vaccine potential of this protein.

The influence of sodium caseinate and β-casein concentrate on the physicochemical properties of casein micelles and the role of tea polyphenols in mediating these interactions

The influence of different casein-based ingredients on the physicochemical properties of native casein micelles (CMs) was studied. Sodium caseinate (SCN) and β-casein concentrate (BCC) were mixed with milk protein concentrate (MPC) at different ratios (1:3, 1:1, 3:1), at a total protein concentration of 20 g/L. Tea polyphenols (TPP) were added to select samples to investigate their effect on CM-SCN and CM-BCC interactions. The results demonstrated decreasing structural integrity of CMs and increased levels of non-micellar casein, due to addition of SCN to MPC, which led to a decreasing turbidity over time and an increase in surface hydrophobicity. Addition of BCC to MPC resulted in an increase in turbidity over time and a decrease in surface hydrophobicity of the system. TEM images suggested that small micelles from BCC interacted with the surface of CMs. The SDS-PAGE results show that CMs in samples with TPP dissociated less, indicating that TPP stabilized the CMs structure. In conclusion, the two casein ingredients, SCN and BCC, have a different effect on the colloidal and physicochemical properties of CMs in MPC suspensions. This study will contribute to a greater understanding of the effect of mixed protein formulation strategies on the functional properties of beverage systems.

Effect of Fatty Acid Composition in Polysorbate 80 on the Stability of Therapeutic Protein Formulations

PurposePolysorbate excipients are commonly used as surfactants to stabilize therapeutic proteins in formulations. Degradation of polysorbates could lead to particle formation and instability of the drug formulation. We investigated how the fatty acid composition of polysorbate 80 impacts the degradation profile, particle formation, and product stability under stress conditions.MethodsTwo polysorbate 80-containing therapeutic protein formulations were reformulated with either Polysorbate 80 NF synthesized from a fatty acid mixture that contains mainly oleic acid (≥58%) or a version of polysorbate 80 synthesized with high oleic acid (>98%). Stress conditions, including high temperature and esterase spiking, were applied and changes to both the polysorbate and the therapeutic protein product were investigated for stability, purity, innate immune response and biological activity.ResultsThe addition of esterase and storage at 37°C led to significant hydrolysis of the polysorbate and increases in sub-visible particle formation for both polysorbates tested. The fatty acid composition of polysorbate 80 did not directly alter the stability profile of either therapeutic protein as measured by size exclusion chromatography, or significantly impact innate immune response or biological activity. However, formulations with Polysorbate 80 NF showed greater propensity for sub-visible particle formation under stress conditions.ConclusionsThese results suggest that composition of fatty acids in polysorbate 80 may be a promoter for sub-visible particulate formation under the stress conditions tested but may not impact protein aggregation or biological activity.

Adjustment of specific residual moisture levels in completely freeze-dried protein formulations by controlled spiking of small water volumes

The residual moisture (RM) level strongly impacts the stability of freeze-dried biopharmaceuticals. On the one hand, the RM should not be too high to keep the reaction potential of water molecules low and to avoid a decrease in the glass transition temperature through the plasticizing effect of water. On the other hand, overdrying has been described to negatively impact protein stability. Consequently, an optimal RM has to be established and justified for approval by authorities. Therefore, end products with different RM are analyzed over storage. The different RM levels are typically obtained by slightly varying the lyophilization process itself; but deviations from the original process are critical. Additionally, samples can be taken during lyophilization runs, e.g. at the end of primary drying or after the ramp into secondary drying. This, however, does not allow for good control over the RM. Here we present the adaption of a headspace water spiking technique using a microliter syringe to precisely increase and adjust the RM. This technique is suitable to reproducibly introduce water in the microliter scale to achieve RM of less than 1% [w/w] with high precision depending on the dry cake weight. In addition, we show that by using different fill volumes and cake densities, an equal three-dimensional water distribution throughout the whole cake can be achieved. Furthermore, potential limitations and risks in manual RM introduction are discussed.

3D Printing of Soy Protein- and Gluten-Based Gels Facilitated by Thermosensitive Cocoa Butter in a Model Study

In this study, formulation of soy protein- and gluten-based gel materials for 3D printing in a model study has been successfully developed employing thermosensitive cocoa butter to investigate its feasibility for preparing meat analogues. The influence of protein, starch, and sodium alginate on extrusion formability and printing accuracy was investigated. The extrusion formability of doughs of soy protein isolate was notably better than that of pea protein. Addition of appropriate amounts of cocoa butter, Tween-80, and sodium alginate was essential to achieve superior 3D printing performance. Thermosensitive cocoa butter provided fluidity to the doughs during 3D printing above room temperature and retained the shape upon solidification at room temperature. SEM-EDS, FT-IR, and solid-state NMR investigations revealed that the hydrogen bonding interaction of the soy protein and gluten network generated the fundamental continuous fibrous architecture of the gels. The developed strategy in this study would be valuable for formulating materials for 3D printing.

Use of Peptide Microarrays for Fast and Informative Profiling of Therapeutic Antibody Formulation Conditions.

Methods to optimize the solution behavior of therapeutic proteins are frequently time-consuming, provide limited information, and often use milligram quantities of material. Here, we present a simple, versatile method that provides valuable information to guide the identification and comparison of formulation conditions for, in principle, any biopharmaceutical drug. The subject protein is incubated with a designed synthetic peptide microarray; the extent of binding to each peptide is dependent on the solution conditions. The array is washed, and the adhesion of the subject protein is detected using a secondary antibody. We exemplify the method using a well-characterized human single-chain Fv and a selection of human monoclonal antibodies. Correlations of peptide adhesion profiles can be used to establish quantitative relationships between different solution conditions, allowing subgrouping into dendrograms. Multidimensional reduction methods, such as t-distributed stochastic neighbor embedding, can be applied to compare how different monoclonals vary in their adhesion properties under different solution conditions. Finally, we screened peptide binding profiles using a selection of monoclonal antibodies for which a range of biophysical measurements were available under specified buffer conditions. We used a neural network method to train the data against aggregation temperature, kD, percentage recovery after incubation at 25 °C, and melting temperature. The results demonstrate that peptide binding profiles can indeed be effectively trained on these indicators of protein stability and self-association in solution. The method opens up multiple possibilities for the application of machine learning methods in therapeutic protein formulation.

Recent Developments in the Formulation and Use of Polymers and Particles of Plant‐based Origin for Emulsion Stabilizations

The main scope of this Review was the recent progress in the use of plant-based polymers and particles for the stabilization of Pickering and non-Pickering emulsion systems. Due to their availability and promising performance, it was discussed how the source, modification, and formulation of cellulose, starch, protein, and lignin-based polymers and particles would impact their emulsion stabilization. Special attention was given toward the material synthesis in two forms of polymeric surfactants and particles and the corresponding formulated emulsions. Also, the effects of particle size, degree of aggregation, wettability, degree of substitution, and electrical charge in stabilizing oil/water systems and micro- and macro-structures of oil droplets were discussed. The wide range of applications using such plant-based stabilizers in different technologies as well as their challenge and future perspectives were described.

Inhibition of biofilm formation of Geobacillus stearothermophilus in calcium-reduced milk protein formulation is associated with calcium, sodium and bacteria growth history: A preliminary study

The effect of total calcium, sodium concentration and bacteria growth history was investigated on biofilm formation of Geobacillus stearothermophilus in milk formulations. Biofilm cell numbers of three G. stearothermophilus strains were compared in two milk formulations (MF1 and MF2) over 18 h. MF1 and MF2 had similar compositions but MF2 had relatively high sodium and low calcium concentrations. Biofilm formation of all three strains was lower (P < 0.05) in MF2 than in MF1, but the inhibition of MF2 was dependent on the growth history of bacterial inocula. Supplementation of MF1 with sodium decreased (P < 0.05) biofilm formation at 18 h for dairy isolates A1 and P3. Supplementation of MF2 with 26 mm calcium increased (P < 0.05) biofilm formation of A1 at 18 h, and P3 at 10 h. The cationic profile of MF2 seemed to be important in reducing biofilms of G. stearothermophilus.

US FDA-approved therapeutic antibodies with high-concentration formulation: summaries and perspectives.

Thirty four (34) of the total US FDA approved 103 therapeutic antibody drugs, accounts for one third of the total approved mAbs, are formulated with high protein concentration (100 mg/mL or above) which are the focus of this article. The highest protein concentration of these approved mAbs is 200 mg/mL. The dominant administration route is subcutaneous (76%). Our analysis indicates that it may be rational to implement a platform formulation containing polysorbate, histidine and sucrose to accelerate high concentration formulation development for antibody drugs. Since 2015, the FDA approval numbers are significantly increased which account for 76% of the total approval numbers, i.e., 26 out of 34 highly concentrated antibodies. Thus, we believe that the high concentration formulations of antibody drugs will be the future trend of therapeutic antibody formulation development, regardless of the challenges of highly concentrated protein formulations.

Dietary advanced glycation end-products, 2-monochloropropane-1,3-diol esters and 3-monochloropropane-1,2-diol esters and glycidyl esters in infant formulas: Occurrence, formulation and processing effects, mitigation strategies.

Infant formula contains thermal processing contaminants, such as dietary advanced glycation end-products (dAGEs), glycidyl esters (GEs), 2-monochloropropane-1,3-diol esters and 3-monochloropropane-1,2-diol esters (MCPDEs). This systematic review aimed to gain insights into the occurrence of these contaminants in different types of infant formula, to understand potential effects of the formulation and processing of infant formulas on these contaminants, as well as into possible mitigation strategies. The occurrence of dAGEs in infant formula depends on the recipes and processing conditions. Hydrolyzed protein formulations promote dAGEs formation in infant formula since peptides are more prone to glycation than intact proteins, which is reflected in high dAGEs concentration in hypoallergenic infant formula. Different carbohydrates in recipes result into different glycation extents of infant formula: maltodextrin containing formulas contained less dAGEs than those with lactose. Concerning mitigation strategies, applying ultra-high-temperature (UHT) treatment during milk processing leads to less dAGEs formation than using in-bottle sterilization. Although data are limited, evidence showed that encapsulation of raw ingredients or the use of antioxidants or enzymes in recipes is promising. The occurrence of MCPDEs and GEs in infant formula fully depends on the vegetable oils used in the recipe. High levels of these contaminants can be found when relatively high amounts of palm oils or fats are used. The mitigation of MCPDEs and GEs should therefore be performed on fats and oils before their application to infant formula recipes. Data and knowledge gaps identified in this review can be useful to guide future studies.

Polysorbate 80 controls Morphology, structure and stability of human insulin Amyloid-Like spherulites

Amyloid protein aggregates are not only associated with neurodegenerative diseases and may also occur as unwanted by-products in protein-based therapeutics. Surfactants are often employed to stabilize protein formulations and reduce the risk of aggregation. However, surfactants alter protein-protein interactions and may thus modulate the physicochemical characteristics of any aggregates formed. Human insulin aggregation was induced at low pH in the presence of varying concentrations of the surfactant polysorbate 80. Various spectroscopic and imaging methods were used to study the aggregation kinetics, as well as structure and morphology of the formed aggregates. Molecular dynamics simulations were employed to investigate the initial interaction between the surfactant and insulin. Addition of polysorbate 80 slowed down, but did not prevent, aggregation of insulin. Amyloid spherulites formed under all conditions, with a higher content of intermolecular beta-sheets in the presence of the surfactant above its critical micelle concentration. In addition, a denser packing was observed, leading to a more stable aggregate. Molecular dynamics simulations suggested a tendency for insulin to form dimers in the presence of the surfactant, indicating a change in protein-protein interactions. It is thus shown that surfactants not only alter aggregation kinetics, but also affect physicochemical properties of any aggregates formed.