Development of mRNA vaccines during SARS-Cov-2 pandemics led to a revolution in medicine and options for therapeutic applications of mRNA molecules now seem limitless. The key to efficient and cost-effective mRNA production lies in a good understanding of both product- and process parameters involved in mRNA synthesis during in vitro transcription reaction (IVT). During IVT reaction not only target mRNA, but also by-products are formed, such as double-stranded RNA (dsRNA) which is a very potent immune system stimulant. dsRNA formation is dependent on mRNA sequence but can also be affected by IVT reaction parameters. In this study, we built a model of IVT reaction for enhanced green fluorescent protein (eGFP) gene construct with MODDE, a Design-of-Experiments software. Factors which were investigated comprised the ratio between concentration of Mg2+ and total nucleotide triphosphate (NTP) concentration, absolute concentrations of NTPs, DNA template and T7 RNA polymerase (RNAP). mRNA concentration and NTP consumption were measured by HPLC analysis and dsRNA content was estimated with the dot blot method. The aim of the study was to investigate which settings lead to the highest mRNA production, highest yields, most cost-effective mRNA production and lowest dsRNA content. We statistically evaluated the model and improved it with additional reactions. Results fit the model well and the model showed a high prediction power for further experiments. We showed that for high mRNA production, Mg2+ to total NTP molar ratio of approximately 1 and high concentrations of plasmid and RNAP are required, while both too low and too high concentrations of NTPs, lead to lower mRNA production. We observed that high mRNA production does not necessarily result in high cost-effectiveness. Furthermore, we showed that higher Mg2+ to total NTP molar ratio increases dsRNA content while higher NTP concentrations decrease it. This means that high mRNA production and low dsRNA content can be achieved during similar conditions of IVT reaction. Optimal batch reaction designed using the model was predicted at Mg2+ to total NTP molar ratio of 0,9, NTP concentration of 10,4 mM, plasmid concentration of 100 ng/μL and RNAP concentration of 8,1 U/μL. We produced 10 mg/mL of mRNA in 90 min and demonstrated that experimental results of the reaction match well with the results predicted by the model. Taking into account our findings, we performed fed-batch reaction with which we further improved mRNA production and cost-effectiveness of the process.
|