VintaBio has presented new data demonstrating the significant advantages of its proprietary VintaProcess platform for adeno-associated virus (AAV) vector production at the American Society of Gene and Cell Therapy (ASGCT) 28th Annual Meeting in New Orleans.
The company's hyper-intensified manufacturing approach optimizes the performance of VintaCell (a specialized HEK293 cell line) to generate high yields of viral vectors in a compact footprint, potentially solving a major commercial scalability challenge in gene therapy production.
Extended Production Window Enhances Vector Quality
Unlike traditional AAV manufacturing methods that rely on suspension cultures with short production windows, VintaProcess employs an adherent, perfusion-based system built around the proprietary VintaCell and polymer-free transfection reagent VintaFect. The system leverages a densely packed fixed-bed bioreactor that enables cells to remain in their natural environment and continuously produce vectors over an extended period.
The study presented at ASGCT explored vector kinetics and cell behavior over 3-, 5-, and 7-day production runs using timed, fractional supernatant harvests. Results demonstrated that the platform can produce more than 8E14 total viral genomes at harvest in a hyper-intensified reactor smaller than a 12-ounce soda can.
"This study confirms that our VintaProcess platform enables a more natural, efficient, and scalable approach to AAV manufacturing," said Junwei Sun, M.S., M.B.A., Co-founder of VintaBio. "By extending production time and leveraging our proprietary perfusion-based adherent culture technology, we can achieve high yields and quality with less processing complexity, ultimately offering better quality viral vectors for gene therapy developers."
Improved Full Capsid Ratio Without Cell Lysis
A key advantage of the VintaProcess platform is that approximately 90% of the viral genome yield is present in the supernatant, eliminating the need for cell lysis and significantly reducing residual host cell protein burden. This represents a substantial improvement over conventional methods that typically require cell disruption to harvest viral particles.
The quality of vector production, as defined by full-to-empty capsid ratio, also improves over the 7-day production period. Starting with harvest at Day 3, VintaProcess can achieve greater than 50% full capsids in the supernatant, significantly enhancing product quality and reducing downstream processing requirements.
"Unlike traditional suspension systems, our perfusion-based adherent approach significantly improves full capsid content using an extended vector production duration," Sun explained in a separate statement. "This shift enables scalable, more efficient manufacturing and reduces complexity across the entire process."
Perfusion Method Extends Cell Viability
The VintaProcess employs a perfusion via recirculation transfection method that enables host cells to remain metabolically active for up to 12 days post-transfection. This approach is less toxic to VintaCells, allowing for longer production periods compared to conventional methods.
The platform eliminates the need to force growth of anchorage-dependent cells into suspension systems and reduces costly facility footprints by delivering high-yield AAV production in a compact, benchtop system. Combined with its low impurity profile, VintaProcess appears well-suited for both clinical and commercial-scale manufacturing.
Addressing Gene Therapy Manufacturing Challenges
The data presented at ASGCT highlight VintaBio's potential contribution to addressing critical manufacturing challenges in the gene therapy field. By improving the full-to-empty capsid ratio upstream, the platform aims to reduce the burden on downstream purification, shorten production timelines, and enhance dosing accuracy.
These improvements could ultimately support faster, more reliable delivery of gene therapies to patients by simplifying the manufacturing process while maintaining high quality standards.
VintaBio's approach aligns with growing industry recognition that optimizing vector manufacturing is essential for unlocking the full potential of gene therapy. As the field continues to mature, innovations in production technology will likely play a crucial role in expanding patient access to these transformative treatments.
About VintaBio
VintaBio is a viral vector manufacturing technology company delivering its proprietary innovations through end-to-end CMO services. The company was founded by gene therapy pioneers and is committed to accelerating access to life-changing therapies by providing customers with high-yield, high-purity vectors and a streamlined path to regulatory and clinical success.
