==== Front Vaccines (Basel) Vaccines (Basel) vaccines Vaccines 2076-393X MDPI 33036359 10.3390/vaccines8040589 vaccines-08-00589 Article Improving Influenza HA-Vlps Production in Insect High Five Cells via Adaptive Laboratory Evolution Correia Ricardo 12 Fernandes Bárbara 12 Alves Paula M. 12 Carrondo Manuel J.T. 1 Roldão António 12* 1 IBET, Instituto de Biologia Experimental e Tecnológica, Apartado 12, 2780-901 Oeiras, Portugal; rccorreia@ibet.pt (R.C.); bfernandes@ibet.pt (B.F.); marques@ibet.pt (P.M.A.); mjtc@ibet.pt (M.J.T.C.) 2 ITQB NOVA, Instituto de Tecnologia Química e Biológica António Xavier, Universidade Nova de Lisboa, Av. da República, 2780-157 Oeiras, Portugal * Correspondence: aroldao@ibet.pt; Tel.: +351-214469418 07 10 2020 12 2020 8 4 58907 9 2020 05 10 2020 © 2020 by the authors.2020Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (http://creativecommons.org/licenses/by/4.0/).The use of non-standard culture conditions has proven efficient to increase cell performance and recombinant protein production in different cell hosts. However, the establishment of high-producing cell populations through adaptive laboratory evolution (ALE) has been poorly explored, in particular for insect cells. In this study, insect High Five cells were successfully adapted to grow at a neutral culture pH (7.0) through ALE for an improved production of influenza hemagglutinin (HA)-displaying virus-like particles (VLPs). A stepwise approach was used for the adaptation process, in which the culture pH gradually increased from standard 6.2 to 7.0 (ΔPh = 0.2–0.3), and cells were maintained at each pH value for 2–3 weeks until a constant growth rate and a cell viability over 95% were observed. These adapted cells enabled an increase in cell-specific HA productivity up to three-fold and volumetric HA titer of up to four-fold as compared to non-adapted cells. Of note, the adaptation process is the element driving increased specific HA productivity as a pH shift alone was inefficient at improving productivities. The production of HA-VLPs in adapted cells was successfully demonstrated at the bioreactor scale. The produced HA-VLPs show the typical size and morphology of influenza VLPs, thus confirming the null impact of the adaptation process and neutral culture pH on the quality of HA-VLPs produced. This work strengthens the potential of ALE as a bioprocess engineering strategy to improve the production of influenza HA-VLPs in insect High Five cells. adaptive laboratory evolutioninsect High Five cellsbaculovirus expression systeminfluenza HA-VLPsimproved production ==== Body 1. Introduction Influenza is a major burden to global healthcare systems, often causing pandemics with massive death-tolls [1,2]. Prophylactic vaccination still remains the most efficient approach to reduce influenza disease [3]. Due to the high tendency of influenza viruses to accumulate 3–4 amino acid substitutions per year and to genetically reassort amongst viruses in animal reservoirs [4], vaccine composition needs to be updated and new vaccines need to be formulated, produced and administrated on an annual basis, if not more often in the case of pandemics. Thus, the development of fast, economical and flexible vaccine production platforms to quickly cope with the need for high quantities of vaccine shots has become a worldwide key healthcare priority. Vaccine manufacturing platforms based on cell culture allow superior process control and flexibility, potentially improving the responsiveness to influenza epidemics or pandemics [5]. Mammalian cells have been extensively explored and proven efficient for the production of influenza vaccines [6,7]. Virus-like particles (VLPs) allow for a high level of antigen display, thus showing high potential to be used as vaccines. The insect cell-baculovirus expression vector system (IC-BEVS), which allows for a fast production of high protein titers, has proven to be efficient to produce complex VLPs [8], including influenza VLPs similar to those produced by mammalian cells [9]. The use of non-standard values of cell culture parameters such as pH, temperature or dissolved oxygen concentration has often been shown to significantly impact the growth performance and recombinant protein production yields in different cell hosts [10,11,12]. Most reports refer to the use of single or multiple shifts in such parameters as effective means to enhance cell performance [13,14]. Alternatively, the use of adaptive laboratory evolution (ALE), i.e., adaptation of cells to efficiently grow under such non-standard culture conditions, through consecutive sub-culturing under these selective pressures allows for the selection of cell populations with an enhanced fitness. Besides improving cell growth [15] by enabling beneficial mutations to arise [16], this process also leads to more efficient energy utilization, the use of non-conventional substrates [17], tolerance to byproducts of interest [18,19], or even the development of thermo-resistant strains [20]. Importantly, ALE has been suggested as an approach to maximize recombinant protein titers in both prokaryotes and animal cells [21,22]. However, it has been poorly explored in insect cells. Recently, adaptation to hypothermic culture conditions has proven efficient to significantly increase the production of HIV1 Gag VLPs using stable insect cell lines [23]. Additionally, ALE has proven to be efficient to increase the production of Chikungunya VLPs by more than 11-fold using IC-BEVS with insect Sf-21 cells adapted to a higher pH [24]. Thus, we have hypothesized that adaptation to higher culture pH could also have an impact on the production of other VLPs using insect cells. In this work, High Five insect cells were adapted to grow at neutral pH and their capacity to produce influenza A hemagglutinin-displaying virus-like particles (HA-VLPs) was assessed, aiming at developing a platform for a faster production of influenza vaccine candidates. 2. Materials and Methods 2.1. Cell Line and Culture Media High Five insect cells (Invitrogen, kindly provided by Redbiotec AG, Schlieren, Switzerland) were routinely sub-cultured at 0.3–0.5 ×106 cell.mL−1 every 2–3 days when cell concentration reached 2–3 ×106 cell.mL−1 in serum-free Insect-XPRESSTM medium (Lonza, Basel, Switzerland) (herein mentioned as CMpH6.2) using 125–500 mL shake flasks (Corning, New York, NY, USA) with a 10% working volume, and maintained at 27 °C in a shaking incubator (Inova 44R – Eppendorf, Hamburg, Germany) set to 100 RPM and with 2.54 cm shaking diameter. 2.2. Adaptation of Insect Cells to Neutral pH Culture medium containing a 1:1 mixture of Insect-XPRESSTM medium and a chemically defined solution containing 50 mM HEPES, 124 mM Sucrose, 5 mM Glucose, 50 mM NaCl, 20 mM KCl, 3 mM CaCl2, 10 mM MgSO4 and 0.1% (w/v) Pluronic F-68 [24] was used for the adaptation process of High Five cells to neutral pH (hereon referred to as CMpH7). The pH was adjusted to the desired value by adding NaOH 1 M and sterile filtered using a 0.22 µm Stericup (Millipore, Burlington, MA, USA). A stepwise approach was used for the adaptation process, in which culture pH was gradually increased from standard 6.2 to 6.5, 6.8 and finally to 7.0, and cells maintained in each pH value for approximately 2–3 weeks until a constant growth rate and cell viability over 95% were observed. To circumvent medium acidification during cell growth, culture pH was monitored daily using a benchtop probe (Crison, Barcelona, Spain) and adjusted by aseptically adding sterile NaOH 1M at a proportion of 15 µL/pH unit/mL of culture. Master cell banks were prepared prior to each pH increase by re-suspending cells in CryStore CS10 freezing medium (Sigma, St. Louis, MO, USA) and freezing at −80 °C using a Coolcell cell freezing container (Biocision, Larkspur, CA, USA). 2.3. Baculovirus Amplification and Storage Recombinant baculoviruses containing influenza M1 (from A/California/06/2009 H1N1 strain) and HA (from A/Brisbane/59/2007 strain) genes were kindly provided by Redbiotec AG (Schlieren, Switzerland). An amplification of baculovirus stocks was performed as described elsewhere [25]. Briefly, insect Sf-9 cells (cultivated in Sf-900TM II medium (Gibco, Waltham, MA, USA)) were infected at a concentration of 1 × 106 cell/mL using a multiplicity of infection of 0.1 plate-forming units per viable cell (pfu/cell). When a cell viability of approximately 80% was reached, the supernatant was harvested by centrifugation at 200× g and 4 °C for 10 min and centrifugation at 2000× g and 4 °C for 20 min. The clarified supernatant was aliquoted appropriately and stored at 4 °C until further use. 2.4. Production of HA-Displaying VLPs VLPs displaying HA were produced in 250 mL shake flasks (10% working volume) and in 0.5 L glass stirred-tank bioreactors. In shake-flask cultures, cells were cultured in 500 mL shake flasks (Corning, NY, USA) with a 10% working volume in either CMpH6.2 (for non-adapted cells) or CMpH7 (for adapted cells). Infection experiments were performed in 250 mL shake flasks (Corning, NY, USA), with a 10% working volume, and at different cell concentrations at the time of infection (CCIs; 1 × 106, 2 × 106 and 3 × 106 cell.mL−1) and multiplicity of infection (MOI; 0.1, 1 and 10 pfu.cell−1). At the time of infection, a complete medium exchange was performed by centrifugation at 200 g at room temperature for 10 min. Bioreactor runs were operated in computer-controlled BIOSTAT Qplus 0.5 L vessels (Sartorius, Göttingen, Germany) using adapted cells at generation 53 after the establishment of the master cell bank. Culture mixing was achieved by equipping the bioreactor with one Rushton impeller and varying the agitation rate from 70 to 270 rpm. Gas was supplied through a ring sparger at a flow rate of 0.01 vvm, and the percentage of O2 in the gas mixture varied between 0 and 100%, to maintain the pO2 (partial pressure of oxygen) setpoint at 15% of air saturation. The bioreactor headplate included multiple ports for temperature, pH and pO2 probes as well as for additions (i.e., culture medium, cells and baculovirus) and the sampling/harvesting of the cell culture. Culture pH was controlled at 7.0 by adding NaOH 1 M. Bioreactors were operated at a working volume of 0.3 L, inoculated at a cell concentration of 2 × 106 cell.mL−1, and infected immediately at an MOI of 1 pfu.cell−1. 2.5. Purification of HA-Displaying VLPs Culture bulk from bioreactor runs was harvested and centrifuged at 4 °C, 200 g, for 10 min (for cell removal) and at 4 °C, 2000 g, for 20 min (for further clarification). The clarified supernatant was filtered using a 0.22 µm Stericup (Millipore, Burlington, MA, USA), and HA-VLPs were concentrated/purified using a (scheme 1) polyethylene glycol (PEG) precipitation method followed by size-exclusion chromatography, or (scheme 2) anion-exchange chromatography. In scheme 1, proteins were precipitated overnight with PEG (8.5% w/v) and NaCl (0.3 M). The precipitated proteins were centrifuged at 4500 g and 4 °C for 30 min, pellets were re-suspended in buffer containing HEPES and NaCl, and the concentrated protein content was purified by size-exclusion chromatography with a Superdex200 10/300 column (GE Healthcare, Chicago, IL, USA). The fractions corresponding to the HA-VLPs peak were pooled and sterile filtered using a Whatman cellulose regenerated membrane filter. In scheme 2, HA-VLPs were purified using a SartoBind Q capsule (Sartorius Stedim Biotech, Göttingen, Germany) according to manufacturer’s instructions. Specifically, elution buffer was composed by HEPES (50 mM) and NaCl (300 mM) at pH 7.4. The fraction corresponding to HA-VLPs was collected and sterile filtered using a Whatman cellulose regenerated membrane filter. Trehalose (pH 7.4) was added to the purified material to a final concentration of 15% (w/v) using a stock solution of 65% (w/v) previously prepared. The resulting purified material was stored at −80 °C (long-term storage) or at 4 °C (short-term storage). 2.6. Analytics 2.6.1. Cell Concentration and Viability Cell counting was performed in a Fuchs–Rosenthal hemocytometer chamber (Brand, Wertheim, Germany) and viability was assessed using the trypan-blue exclusion method. 2.6.2. Hemagglutination Assay The HA titer was determined using the hemagglutination assay as described elsewhere [26]. Briefly, in-process and purified samples (25 µL) were serially diluted 1:1 with DPBS(-/-) 1X (Gibco, Waltham, MA, USA) in V-bottom 96-well plates (Thermo Scientific, Waltham, MA, USA) and gently mixed 1:1 with 1% chicken erythrocytes (Lohmann, Cuxhaven, Germany). Plates were incubated at 4 °C for 30 min. The HA titer was estimated as being the inverse of the highest dilution of sample that completely inhibited hemagglutination. 2.6.3. SDS-PAGE and Western Blot In-process and purified samples were denatured by mixing with 1× LDS Sample Buffer (ThermoFisher Scientific, Waltham, MA, USA, stock solution at 4×) and 1× Sample Reducing Agent (ThermoFisher Scientific, Waltham, MA, USA, stock solution at 10×) and heating for 10 min at 70 °C. Denatured samples were loaded into a 4−12% NuPAGE Bis-Tris protein gel (ThermoFisher Scientific, Waltham, MA, USA), using MOPS running buffer (ThermoFisher Scientific, Waltham, MA, USA) and SeeBlue Plus2 Prestained Standard (ThermoFisher Scientific, Waltham, MA, USA) as a molecular weight marker. After electrophoresis (50 min at 200 V and 400 mA), proteins were transferred to a nitrocellulose membrane using the iBlot system (ThermoFisher Scientific, Waltham, MA, USA). Membranes were blocked for 1 h at room temperature with a blocking solution composed of Tris-Buffered Saline (Sigma, St. Louis, MO, USA) with Tween-20 (Millipore, Burlington, MA, USA) and 5% (w/v) skim milk (Millipore, Burlington, MA, USA), and incubated overnight at room temperature with primary antibodies diluted in blocking solution. For HA identification, a mouse monoclonal antibody (IRR, Manassas, VA, USA, FR-494—mouse monoclonal antibody to recombinant H1 HA from influenza A/Brisbane/59/2007 (H1N1)) was used at a dilution of 1:2000. M1 protein was identified using a goat polyclonal antibody (Abcam, Cambridge, UK, Cat# ab20910) at a dilution of 1:2000. Secondary anti-mouse or anti-goat IgG antibodies conjugated with alkaline phosphatase were used at a dilution of 1:2000 for identification of HA and M1, respectively. Protein band detection was performed by covering membranes with NBT/BCIP 1-Step (Thermo Scientific, Waltham, MA, USA) for 10 min; membranes were then scanned with a benchtop scanner device. 2.6.4. Baculovirus Titration Baculovirus titers were determined using the MTT assay [27,28] (for infectious particles) or qPCR (for total baculovirus genome copies) as described elsewhere [29]. Briefly for qPCR, culture samples were firstly treated with DNAse (Roche, Basel, Switzerland) to eliminate free residual baculovirus DNA prior to quantification. Baculovirus DNA was extracted using the High Pure Viral Nucleic Acid Kit (Roche Life Science, Mannheim, Germany). For the qPCR, a master mix was prepared using the LightCycler 480 SYBR Green I Master (04707516001; Roche Life Science, Mannheim, Germany), a final concentration of 0.5 μM of reverse and forward primers for the ie1 baculovirus gene region, and PCR-grade water. The qPCR was performed in 96-well white plates (04729692001; Roche Life Science, Mannheim, Germany) using a LightCycler 480 Instrument II (Roche Life Science, Mannheim, Germany). 2.6.5. Nanoparticle Tracking Analysis The concentration and size distribution of HA-VLPs were measured using the NanoSight NS500 (Nanosight Ltd., Salisbury, UK). The samples were pre-diluted with DPBS(-/-) 1X (Gibco, Waltham, MA, USA) to cope with the instrument’s range of analysis (108–109 particles.mL–1). All measurements were performed at 22 °C. Sample videos (60 seconds) were analyzed with the Nanoparticle Tracking Analysis (NTA) 2.3 Analytical software. Capture settings (shutter and gain) were adjusted manually. 2.6.6. Transmission Electron Microscopy Analysis The conformation and size of purified influenza HA-VLPs from bioreactor runs were assessed by negative staining TEM using a Hitachi H-7650 Transmission Electron Microscope (JEOL, Tokyo, Japan). For sample preparation, 10 μL of purified HA-VLPs was fixed for 1 min in a copper grid previously coated with Formvar-carbon (Electron Microscopy Sciences, Hatfield, PA, USA). Grids were then washed three times with water and finally stained with 1% (v/v) uranyl acetate for 2 min. Grids containing fixed samples were left to air dry and immediately analyzed. 2.7. Mathematical Equations 2.7.1. Mathematical Equations for Estimation of HA Production Rate The specific HA production rate, rHA, is given by: (1) rHA(HA titer.106 cell−1.h−1)=ΔHA∫0tX dt , 0400 nm) in purified HA-VLP samples. Overlapping bars represent the three bioreactor runs. The average percentage of HA-VLPs in the expected size range of 100–250 nm is highlighted; (E) negative-staining transmission electron microscopy of purified HA-VLPs. Scale bar represents 100 nm. ==== Refs References 1. Cox N.J. Subbarao K. Global Epidemiology of influenza: Past and present Annu. Rev. Med. 2000 51 407 421 10.1146/annurev.med.51.1.407 10774473 2. Simonsen L. The global impact of influenza on morbidity and mortality Vaccine 1999 17 S3 S10 10.1016/S0264-410X(99)00099-7 10471173 3. Houser K. Subbarao K. Influenza vaccines: Challenges and solutions Cell Host Microbe 2015 17 295 300 10.1016/j.chom.2015.02.012 25766291 4. Smith D.J. 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