Impurity Clearance | Viral Vectors

Targeted HCP & DNA removal to protect affinity capture and create a cleaner, more robust purification workflow.
> 10 %

HCP reduction observed in HEK293-derived viral vectors

1.4- 0

LRV under selected conditions

+ 0 %

Higher AAV recovery observed with combined HCP clearance + affinity capture workflow

Impurity burden can affect the process before final purity is measured.

Viral vector process streams can contain complex mixtures of host cell proteins, residual nucleic acids, chromatin, cellular material and process debris.

These impurities may affect multiple stages of the downstream workflow:

Broad-spectrum polishing technologies can reduce impurity burden, but viral vector purification requires a careful balance between clearance and recovery. The process must remove smaller contaminants without unnecessarily binding, retaining or losing the vector.

Where Current HCP Clearance Strategies Fall Short

Existing approaches to HCP management in AAV purification have four compounding limitations.

01

Non-Selective Polishing Leaves Residual HCPs

Current polishing strategies for AAV processes, typically based on ion exchange and size exclusion chromatography, achieve bulk impurity reduction but lack selectivity for the specific HCP species that persist through affinity capture. A subset of HCPs co-purifies with the vector and is not resolved by conventional polishing.

02

HCP Fouling Limits Affinity Resin Lifetime

HCPs, DNA, and cell debris adsorb irreversibly to affinity resin matrices across cycles, accumulating in a way that compresses dynamic binding capacity and creates batch-to-batch variability. Resin fouling is one of the dominant but least-controlled drivers of AAV DSP cost of goods.

03

Upstream Variability Compounds Downstream Complexity

Variable upstream culture conditions create inconsistent impurity profiles in the clarified harvest. When feedstream HCP burden is unpredictable, affinity capture eluate quality is unpredictable. This variability is difficult to address within the affinity step itself.

04

Process Economics Require a Better Approach

The combined cost of affinity resin replacement, yield losses from fouled columns, and additional polishing steps represents a significant and largely unaddressed cost burden. Selective pre-affinity HCP clearance has the potential to change the economics of the entire downstream sequence.

Purpose-Designed, Affinity-Driven Impurity Control

Our unique flow-through impurity-control approach combines a synthetic peptide affinity ligand ensemble with a porous, hydrophilic resin matrix.  

Exploiting the size difference between viral vectors and smaller process-related contaminants the porous shell excludes large viral vector particles from entering the resin core. Smaller HCPs and nucleic-acid-associated impurities can access the core, where they bind to the HCP-affinity ligand ensemble. The outcome is targeted impurity reduction while the viral vector remains in the product flow.

Protect Affinity Capture Resin

Reducing HCP, DNA and process-debris burden before capture may help limit fouling and support more consistent affinity-resin performance.

Preserve Vector Recovery

The flow-through design is intended to reduce impurity burden without making the viral vector the binding target.

Reduce Polishing Pressure

More selective impurity control may reduce the burden placed on later polishing steps and simplify the clearance strategy.

Improve Process Consistency

Better control of the feed entering or leaving affinity capture may improve recovery consistency and downstream reproducibility.

This application falls under our NAVIGATE program,  connecting you with process expertise, new purification technologies, new insights and collabration opportunities to shape and implement a GMP-ready solution.

Moving Beyond Non-Selective Polishing: Reproducible, Proteomics-Informed HCP Clearance for Viral Vector Processes

Evaluating AAV capture? Discover AvXcelTM

Our serotype-agnostic, alkaline-stable AAV affinity resin with flexible elution properties for higher recovery and preserved viral activity.

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Chris Major

CEO

Chris is responsible for identifying investment opportunities, assessing strategic fit within the portfolio, and supporting growth-related operational initiatives. A serial entrepreneur with over 20 years of bioprocessing experience, he has deep expertise across upstream and downstream technologies. Prior to BioProcess360, he founded and led the Purolite Bioprocessing division, growing it from zero revenue in 2015 to $80M in six years. The business was acquired by Ecolab (NYSE: ECL) in 2021 for $3.7BN. Earlier, Chris helped pioneer single-use technology at WAVE Bioreactors, later acquired by GE Healthcare (now Cytiva), and held senior roles at GE and Merck Millipore. He holds an MSc in Biotechnology and attended Harvard Business School. Outside work, Chris enjoys biking, paddleboarding, live music, and spending time with his two daughters.