The 2009 H1N1 pandemic has highlighted that however well a nation prepares for the emergence of a new influenza virus strain, the mechanics of producing the vaccine remain perhaps the greatest obstacle to a successful immunization program.
The manufacturing process approved in the US for both the seasonal and 2009 H1N1 pandemic vaccine is a lengthy one. The seasonal vaccine, with its three strains can take at least 8 months from strain identification to becoming available. The single strain pandemic H1N1 vaccine took 5 months from strain identification to distribution.
The egg-based manufacturing process requires generation of a seed virus, growth of the virus in eggs, isolation of the hemagglutinin antigen from virus, QC testing of the monovalent bulk antigen, formulation, fill, and finally QC testing of the finished vaccine. Difficulties that can occur during the process, such as slow virus growth and low yields, both increase the time to vaccine availability and decrease the amount of vaccine available — undesirable outcomes, especially in a pandemic scenario.
Sure enough, the worst came true for the 2009 H1N1 pandemic vaccine. Manufacturers encountered both slow virus growth and low yields of hemagglutinin. During Novartis’s October 22nd third quarter earnings call, CEO David Vasella stated that the H1N1 strain had yields of about 23% of a normal influenza yield.
The difficulties associated with producing a vaccine from an egg-adapted virus leads to the obvious question of why there is not a recombinant flu vaccine production technology. Recombinant proteins, which can be produced in weeks rather than months, have been around since the commercial production of insulin by Eli Lilly in 1982.
To date there are no approved recombinant influenza vaccines, although several are in development. Protein Sciences’ Flublok, an investigational seasonal recombinant influenza vaccine, which has been discussed before on this blog, is the nearest thing to an approved recombinant vaccine in the US. It is produced in insect cells using the baculovirus expression system, the same technology used to produce Cervarix, GSK’s HPV vaccine. Protein Sciences estimates that the cloning, expression, and manufacture of Flublok can be accomplished in under 2 months.
Protein Sciences began development of Flublok in the mid ’90s under three different INDs held by the NIH/NIAID, only sponsoring the last five clinical trials themselves. They finally submitted their BLA over 10 years later, in April 2008. The VRBPAC met on November 19th to review the safety and effectiveness of Flublok. The committee was asked to answer three specific questions.
- Do the available clinical data support an indication in the prevention of flu caused by subtypes A & B included in the vaccine in adults 18 – 49 years of age, 50-64 years of age, and 65 years and older?
- Do the available data support the safety in adults 18 years and older?
- Please comment on what additional studies, if any, should be requested post-licensure
In summary, the committee was less than impressed. Members voted in favor of the vaccine for only the 18-49 age group in answer to Question 1, and they voted against the vaccine in answer to Question 2. Several suggestions were made in response to Question 3, including additional safety studies in subjects over 65 years of age, and properly powered efficacy studies, especially in the over 65 population.
However the committee did recognise the benefit of the potentially faster egg-free production, especially in the context of a pandemic, but these theoretical benefits did not sway the committee in favor of the vaccine.
Given Flublok’s lukewarm debut at the advisory committee it will still be a while before a recombinant seasonal flu vaccine is approved, with the indication likely limited to the the less at-risk 18-49 year old population. Insurmountable though it seems approval of a recombinant seasonal flu vaccine is not the finish line — people can’t get vaccinated until there is adequate manufacturing capacity to produce the vaccine.