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ADC Process Development

ADC Process Development

BOC Sciences specializes in the process development and optimization of antibody-drug conjugates (ADCs). With an advanced technology platform and an experienced scientific team, we provide global clients with one-stop customized services from proof-of-concept to GMP production. Our mature conjugation technology system covers various types of linker-payloads and conjugation strategies, enabling precise DAR control and enhancing product stability and consistency. Through modular development processes, high-standard analytical systems, and stringent quality control, BOC Sciences is committed to accelerating the development of ADC candidate molecules, minimizing process transfer risks, and providing regulatory support compliant with international standards such as FDA/EMA. Our professional capabilities serve as a solid foundation for the efficient advancement and successful submission of ADC projects.

Complexity and Challenges of ADC Process Development

Comprehensive  Product Line

Heterogeneity in Conjugation and Control of DAR

Wide DAR distribution can lead to fluctuations in efficacy and toxic side effects. We achieve precise DAR control and batch-to-batch consistency through customized conjugation strategies and real-time analytical techniques.

Competitive  Pricing

Balancing Linker Chemical Stability and Biodegradability

If the linker is chemically unstable or has uncontrollable degradation, drug release efficiency will be affected. BOC Sciences designs intelligent linkers to achieve a balance between blood stability and controlled release within tumors.

Flexible  Ordering Options

Controllability and Scalability of Drug Loading

Difficulty in controlling drug loading or instability during scale-up may hinder process translation. BOC Sciences has established a modular drug-loading platform to ensure DAR is controllable and reproducible at different scales.

Strict  Quality Control Testing

Reproducibility of Conjugation Efficiency and Purification Strategy in Scale-Up

Lab-scale processes often lose efficiency or product purity during scale-up. We provide comprehensive process characterization and parameter window studies to ensure consistent conjugation efficiency and purification during scale-up.

Process Development and Optimization Solutions for ADCs

In the ADC process development stage, the goal is to transform candidate molecules screened in early discovery into products suitable for large-scale production, ensuring process stability, reproducibility, and production efficiency. BOC Sciences understands the importance of process development for the final quality and commercial success of ADCs. With years of experience in biologics development, advanced equipment, and a rigorous quality management system, we tailor a complete set of scientific and efficient process development solutions for clients, covering key aspects such as conjugation process optimization, purification process establishment, formulation development, and process scale-up.

Conjugation Process Optimization

The primary task of process development is to optimize conjugation reaction conditions to achieve the target DAR and uniform product distribution. BOC Sciences designs systematic experiments for different conjugation strategies (e.g., random conjugation, site-specific conjugation), adjusting key parameters including:

  • Antibody concentration and buffer system: Select optimal pH, salt concentration, and buffer type based on antibody stability to ensure the antibody structure remains intact during conjugation.
  • Molar ratio of payload: Precisely adjust the ratio of payload to antibody to avoid excessive conjugation causing aggregation or low conjugation reducing efficacy.
  • Reaction time and temperature: Optimize the reaction rate to balance efficiency and antibody stability, and prevent adverse by-products from overreaction.
  • Amount of reducing agents and catalysts: In cysteine-based conjugation, strictly control the amount of reducing agent to avoid excessive reduction and structural damage to the antibody.

Purification Process Establishment

Purification is a core step to ensure ADC quality, directly affecting product safety and efficacy. BOC Sciences is equipped with various advanced purification instruments, including Protein A columns, ion exchange columns, hydrophobic interaction columns, and size exclusion columns, allowing flexible combination of multiple purification strategies for efficient separation.

  • Capture and intermediate purification: Rapidly recover the antibody portion via Protein A affinity chromatography, removing host cell proteins and other impurities.
  • Post-conjugation purification: Use ion exchange chromatography to separate unconjugated antibodies from conjugated products, precisely adjusting pH and salt concentration to achieve high-resolution separation.
  • Multidimensional purification: Combine various chromatographic modes to remove small molecule impurities, free payloads, and incomplete conjugates, ensuring product purity meets clinical-grade standards.
  • Endotoxin removal and virus clearance: Rely on strict process design and validation workflows to ensure biosafety indicators meet cGMP requirements.

Formulation Development and Stability Studies

Given the complexity and variability of ADC structures, rational formulation design is particularly critical. BOC Sciences offers comprehensive formulation optimization services, including buffer systems, stabilizers, pH adjustments, and preservative screening, to ensure ADC stability and activity during storage and transport.

  • Antibody structure protection: Select suitable stabilizers for ADCs (e.g., sugars, amino acids, surfactants) to reduce protein aggregation and precipitation.
  • Prevention of payload degradation: Optimize pH and add antioxidants to prevent payload degradation and cleavage of conjugation bonds.
  • Lyophilization process development: For ADC products requiring lyophilization, optimize the lyophilization curve to maintain product quality during freeze-drying and reconstitution.
  • Long-term and accelerated stability studies: Conduct stability testing under multiple temperatures and humidity levels per ICH guidelines to support clinical studies and subsequent market applications.

Process Scale-Up and Technology Transfer

The ultimate goal of successful process development is to enable smooth scale-up from lab to pilot and even commercial production. BOC Sciences offers a range of reactors and purification equipment from 1 L to 1000 L, supporting process scale-up and continuous manufacturing process development.

  • Pilot scale-up: Conduct 10 L and 50 L scale pilot production in GMP-compliant facilities to verify process stability.
  • Technical documentation: Provide complete process development documents (process flow diagrams, batch records, change control, etc.).
  • Technology transfer support: Seamlessly connect with CDMO and client production facilities to ensure successful scale-up and GMP production.

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Core Advantages Drive Customized ADC Solutions

01

Integrated One-Stop CDMO Platform

BOC Sciences has a multidisciplinary team in organic chemistry, protein engineering, analytical science, and biologics. This enables effective integration of antibody engineering, linker synthesis, toxin chemistry, and analytical method development.

02

GMP Facilities and Compliance System

BOC Sciences operates GMP manufacturing facilities that meet international standards, equipped with strict quality management systems and audit compliance capabilities, supporting production from preclinical to NDA stages.

03

Efficient Purification and Scale-Up Support

Equipped with advanced chromatography and membrane separation systems, we apply the QbD approach for process parameter window studies to achieve efficient separation, remove free toxins and process impurities, and ensure smooth GMP scale-up.

03

Responsive and Flexible Collaboration Mechanism

Compared to large multinational CDMO platforms, BOC Sciences offers cost-effective service solutions with rapid response and flexible project execution models to help clients control R&D costs and improve overall efficiency while ensuring quality.

One-Stop Service Workflow from Design to Delivery

Scheme Design and Contract Customization

Requirement Analysis and Project Evaluation

  • Clients submit project information (antibody, linker, payload, target indication, etc.);
  • Technical teams from both parties engage in in-depth communication to assess project feasibility and identify key challenges;
  • Confirmation of project objectives and milestone phases;
  • Collection of regulatory and quality compliance requirements.

Payload/Linker Synthesis

Customized Development Plan Formulation

  • Determine the appropriate conjugation strategy (e.g., reductive amination, thiol conjugation, click chemistry, etc.);
  • Recommend suitable linkers and payloads;
  • Draft preliminary development plan and timeline.

Scheme Design and Contract Customization

Small-Scale Process Screening and Optimization

  • Optimize antibody reduction conditions and control modification sites (e.g., partial Cys reduction, glycosylation site modification, etc.);
  • Determine the optimal linker/drug ratio and conjugation method;
  • Control the drug-to-antibody ratio (DAR) within an ideal range (e.g., DAR 2–4);
  • Study key parameters affecting conjugation efficiency and purity (pH, temperature, reaction time, etc.);
  • Establish preliminary relationships between critical quality attributes (CQAs) and process parameters.

Analysis, Purification and Characterization

Pilot Scale-Up and Process Optimization

  • Scale up the small-scale process to pilot scale (10–100 L);
  • Evaluate scalability of buffer preparation, conjugation reactions, and purification steps;
  • Assess process stability and product consistency through multiple batches;
  • Monitor key indicators: DAR, monomer purity, free toxin residue, aggregation levels, etc.;
  • Establish efficient purification processes (e.g., chromatography, ultrafiltration, etc.) to remove free drug and polymers;
  • Optimize final formulation conditions to enhance formulation stability.

cGMP Manufacturing and Filling

Analytical Method Development and Quality Control

  • Develop multiple methods such as HIC, SEC, and LC-MS to determine DAR, purity, and molecular integrity;
  • Conduct comprehensive testing for residual solvents, free toxins, endotoxins, etc.;
  • Provide complete COA, analytical method SOPs, and method validation reports;
  • Registration support documents can be established in accordance with cGMP requirements.

Result Delivery

Technology Transfer and GMP Production Support

  • Conduct small-scale validation production in GMP-compliant environments;
  • Complete GMP documentation system including batch records, deviation management, and release standards;
  • Provide technical transfer documentation package (Tech Transfer Package);
  • Assist clients with process audits and regulatory submission support.

Frequently Asked Questions

Frequently Asked Questions

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