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Manufacturing has been the key factor limiting rollout of vaccination during the COVID-19 pandemic, requiring rapid development and large-scale implementation of novel manufacturing technologies. ChAdOx1 nCoV-19 (AZD1222, Vaxzevria) is an efficacious vaccine against SARS-CoV-2, based upon an adenovirus vector. We describe the development of a process for the production of this vaccine and others based upon the same platform, including novel features to facilitate very large-scale production. We discuss the process economics and the "distributed manufacturing" approach we have taken to provide the vaccine at globally-relevant scale and with international security of supply. Together, these approaches have enabled the largest viral vector manufacturing campaign to date, providing a substantial proportion of global COVID-19 vaccine supply at low cost.

Original publication

DOI

10.1002/bit.27945

Type

Journal article

Journal

Biotechnol Bioeng

Publication Date

01/2022

Volume

119

Pages

48 - 58

Keywords

adenovirus, distributed manufacturing, vaccine, Animals, COVID-19, COVID-19 Vaccines, ChAdOx1 nCoV-19, Drug Industry, Escherichia coli, Geography, HEK293 Cells, Humans, Pan troglodytes, SARS-CoV-2, Technology, Pharmaceutical, Vaccination, Vaccine Development