Despite the promising results exhibited by VLPs, it is important to highlight that only a few VLP-based formulations have been approved and commercialized. These formulations were exclusively approved for vaccination, which is linked to the high immunogenicity of VLPs. This can severely hamper their use as imaging and/or drug delivery tools. Furthermore, there are several hurdles related to VLP and expression host selection, functionalization, scalability, downstream processing, and stability. All these factors must be taken into consideration when developing novel VLP-based tools.
4.1. Selection of VLP Type and Expression Platform
Most of the marketed VLPs are non-enveloped, due to their simplicity. Production of non-enveloped single-protein capsid VLPs is typically performed in
Escherichia coli or yeast, and both systems allow for high production yields and easy scale up [
148]. Furthermore, yeast expression systems can provide PTMs, which can play a pivotal role in VLP function [
148]. Interestingly, due to their simplicity, these VLPs can be produced in cell-free environment. Non-enveloped multiple-capsid protein VLPs, on the other hand, are typically produced in the baculovirus-insect expression system [
148]. This system can also provide high yields and PTMs, but it is not as easily scalable and regulated as
E.coli and yeast, and requires more complex purification processes [
148]. Production in microbial cells typically entails cell lysis, which can release cell-derived impurities and consequently affect the downstream processing [
149]. Moreover, the production process of non-enveloped VLPs typically generates non-uniform particles [
150]. To overcome these hurdles, these VLPs typically undergo
in vitro disassembly and reassembly, which has proved to improve stability [
151] and immunogenicity [
152]. The main advantages of non-enveloped VLPs include their well-characterized nature and their stability, given that they are less sensitive to external conditions (purification, temperature or sheer force) than enveloped VLPs [
153]. This justifies that most FDA-approved VLPs are non-enveloped. Nonetheless, they are not as suitable for the presentation of membrane proteins as enveloped VLPs, due to the origin of their envelope [
84]. Even so, the advantages presented by these VLPs justify that most VLP-based platforms developed in recent years for drug delivery and imaging are non-enveloped.
Enveloped VLPs are structurally more complex than non-enveloped VLPs, since they attain their lipidic envelope from their expression platform during assembly and budding [
19]. Indeed, this type of VLP can present one or several glycoproteins on their lipidic membrane, which function as target antigens and can therefore elicit an immune response and prompt the production of neutralizing antibodies [
19,
154]. For this reason, production of enveloped VLPs requires eukaryotic expression platforms [
19]. The major issue with enveloped VLPs is their poor biophysical characterization given that they are not as structurally uniform as non-enveloped VLPs [
148,
153]. Moreover, as abovementioned, enveloped VLPs are more sensitive to external conditions than non-enveloped VLPs, which means their immunogenicity, integrity and stability can be more easily compromised [
153]. Enveloped VLPs also require correct folding and glycosylation for adequate function as vaccine formulations [
153]. These challenges deem enveloped VLPs more difficult to work with and consequently to implement in the clinical setting, but strategies such as computational design, genetic engineering,
in vitro assembly and novel processing and purification methods can be explored to circumvent these limitations [
153].
Regarding expression hosts, each platform has its advantages and disadvantages, which are depicted in
Table 3.
4.2. VLP Preparation
VLP production typically entails three steps: production (or upstream processing), purification (or downstream processing), and formulation (for VLP-based vaccines) [
19,
20]. Production starts with cloning of the viral genes that encode the proteins of interest, followed by expression and assembly in the expression systems [
19,
20]. The produced VLPs are then transferred to the solution through cell lysis [
19,
20]. Clarification is performed to eliminate most aggregates and cell contaminants [
19,
20]. Further purification is typically required to attain integral VLPs, followed by a concentration step, and a final polishing step is done to remove any remaining residual nucleic acids and proteins [
19,
20]. Formulation typically entails the incorporation of adjuvants and extra ingredients to obtain a safe and efficient vaccine [
19,
20].
Besides selection of the most adequate expression system, it is also critical to select the most suitable culture mode, since it affects concentration, productivity, and yield [
153,
155]. There are three different culture modes for VLP production: continuous cultivation, batch and fed batch [
153,
155]. Continuous cultivation typically ensures the highest productivity, since it relies on cultures in a log phase, and therefore allows to obtain continuous production [
153,
155]. This culture mode has been reported for VLP production in different expression platforms, such as insect cells [
156] and mammalian cells [
157]. The main advantages of this culture mode include a short turn-around period, reduced number of production steps and continuous downstream processing [
153,
155]. Within continuous production, there are different methods: chemostat, morbidostat, stressostat and turbidostat [
153,
155]. Among these, chemostat is the most frequently used mode, as it permits to modulate growth rates and product formation. Notwithstanding, this method is also associated with a high contamination risk and low product concentrations [
153,
155]. In the batch mode, all the required nutrients are added only at the start of the culture process, and this brings a low contamination risk [
153,
155]. The main drawbacks of such a method include low viral titers, low productivity, temperature sensitivity and product and substrate inhibition [
153,
155]. Substrate inhibition can be overcome by diminishing the lag phase, which is what occurs the fed-batch mode [
153,
155]. In this method, the exponential growth phase can be augmented by selective incorporation of nutrients, and it is possible to increase the period of culture to attain higher cell densities [
153,
155]. Nonetheless, scale-up is costly since there is an inefficient use of culture medium [
153,
155]. Factor such as cost, cell growth, yield, contamination, particle size, cell lysis, among others, need to be considered when selecting the culture mode [
153,
155]. It is also important to note that these culture modes were only tested to produce VLP-based vaccines. The studies that report the design and evaluation of VLPs for other applications, namely imaging and drug delivery, are carried out at a small scale, and do not account for scale up. Studies focused on the production process of VLPs for such applications are thus required, to determine whether it is possible to attain such VLPs with high stability and productivity, for further implementation in the medical field.
Regarding VLP assembly, different factors are at play. Single or multi-capsid proteins must assemble in expression platforms or cell-free systems, and this assembly may rely on interactions with scaffolding proteins and/or nucleic acids [
36,
153]. For example, it has been reported that adeno-associated virus (AAV) relies on the assembly-activating protein (AAP) for VLP assembly [
58]. Another example is HIV-1 Gag VLPs, which utilize RNA as a scaffold for assembly [
158]. Such molecules must be carefully considered during VLP assembly because they can severely affect VLP applications by increasing their immunogenicity [
36]. Moreover, factors such as ionic strength, pH, temperature, and stoichiometry heavily influence VLP assembly, and so optimal conditions must be fine-tuned to avoid VLP malformation [
36,
153].
Downstream processing is a critical step in VLP preparation, as it allows to separate a myriad of proteins from the desired VLPs [
36,
153]. When VLPs are attained through transduction, viral vectors are used to deliver genetic material to cells, which originates proteins of similar size and molecular weight and consequently makes the separation process more burdensome [
153]. Transfection, on the other hand, does not rely on viral vectors, and thus facilitates separation [
153]. Serum supplements possess a high protein content, which can hamper purification, and so the utilization of serum-free media may also be beneficial [
153]. Regarding cell lysis, as previously mentioned, this step is only necessary for non-secreting expression systems, as certain insect and mammalian cells secrete VLPs into the cell supernatants [
20]. For non-secreting platforms, treatment with detergent-bearing solutions is sufficient for most eukaryotic cells, but other platforms, such as bacterial, yeast and plant cells, possess a cell wall and therefore require mechanical treatment for VLP release, which could hamper their integrity [
20]. Ultracentrifugation is typically used to achieve purity, but this process is laborious, is not scalable and increases the risk of VLP aggregation [
20]. Chromatography methods are thus utilized to circumvent these limitations, but these processes may require additional steps in VLP processing, which can also be a disadvantage [
20]. Additionally, precautions should be taken to ensure that the formulation of VLP-based vaccines is of high quality [
159]. Lastly, conditions such as ion and salt concentrations, as well as pH, must be meticulously controlled during each downstream processing step, as they greatly impact VLP aggregation [
20].
After downstream processing, VLPs must be characterized to ensure quality and consistency [
20,
148]. Before characterization, ammonium sulfate or PEG are employed to precipitate high molecular weight VLPs and therefore eliminate low molecular weight impurities [
20]. It is critical to ensure precipitate purity before moving on to downstream analysis, since precipitation can prompt VLP disassembly [
20,
153]. Biochemical characterization techniques to detect the structural proteins of VLPs include enzyme-linked immunosorbent assay (ELISA), sodium dodecyl sulfate (SDS)-polyacrylamide gel electrophoresis (PAGE) and western blot (WB) [
20,
153]. Notwithstanding, through these techniques it is not possible to distinguish between integral, partially assembled or unassembled VLPs [
20]. Furthermore, these methods display low sensitivity, demand high volumes and are time-consuming, which impacts downstream studies [
153]. Techniques such as high-performance liquid chromatography (HPLC), SDS-capillary gel electrophoresis and matrix-assisted laser desorption/ionization-time of flight mass spectrometry (MALDI-TOF MS) have emerged as alternatives to the classical biochemical characterization methods. Regarding biophysical characterizations, several methods can be explored: transmission electron microscopy, to detect particle size and polydispersity; atomic force microscopy (AFM), to determine VLP morphology; dynamic light scattering (DLS) to assess particle aggregation, among others[
153]. Sample preparation for some of these techniques involves drying, which can introduce artifacts into the samples [
153]. Cryo-EM can be used to overcome this handicap, as it employs VLPs in solution, but it is only feasible for sufficiently homogenous samples [
153]. Lastly, rigorous measurement of particle size and quantification is necessary for correct VLP dosing, and it is highly demanding [
153]. Approaches such as nanoparticle track analysis (NTA) or electrospray-differential mobility analysis (ES-DMA) can be used to accurately keep track of batch-to-batch consistency, which is particularly useful for VLP-based vaccine formulations [
153].