Lentiviral vectors are important tools for gene transfer because of their ability to transduce a number of cell types without the need for host cells to be dividing. As a result, investigators are using them as gene delivery vehicles in clinical applications. Since lentiviral vectors play such a vital role in gene therapy, they need to be manufactured at large scale for clinical trials. But, large-scale production using CGMP methods can present a number of challenges.

To address these challenges, the authors of this case study developed a process that allows for extensive scale-up in a safe, sterile, and reproducible system to produce clinical-grade lentivirus. This manufacturing process is very efficient and can be carried out using minimal staff (two operators for production of each subbatch). It provides the extensive scale-up capacity necessary to produce CGMP-grade lentivirus, and it has been used successfully in several completed and on-going phase 1–2 ex-vivo gene therapy clinical trials.