Chinese Journal of Catalysis ›› 2026, Vol. 80: 92-112.DOI: 10.1016/S1872-2067(25)64860-1

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Engineering of enzymatic modules for mRNA manufacturing: Advances in catalytic regulation and process integration

Shiyi Chea,b, Zhengjun Lib, Zhiguo Sub, Zhikao Lia, Aibing Yua, Minsu Liua,c,*(), Songping Zhangb,*()   

  1. aARC Research Hub for Smart Process Design and Control, Department of Chemical and Biological Engineering, Monash University, Clayton, Victoria 3800, Australia
    bState Key Laboratory of Biopharmaceutical Preparation and Delivery, Institute of Process Engineering, Chinese Academy of Sciences, Beijing 100190, China
    cDepartment of Materials Science and Engineering, Monash University, Clayton, Victoria 3800, Australia
  • Received:2025-06-09 Accepted:2025-09-06 Online:2026-01-18 Published:2026-01-05
  • Contact: Minsu Liu, Songping Zhang
  • About author:Minsu Liu (Monash University) is a senior research fellow at Monash Suzhou Research Institute and a senior lecturer at Department of Materials Science and Engineering, Monash University. He has obtained his B.E. (Hon. 1) and Ph.D. from the University of New South Wales (Australia) and Monash University (Australia), respectively. Before joining Monash, Dr. Liu worked as postdoctoral fellow at Monash University (2017‒2018) and Tsinghua University (2018‒2020). Dr. Minsu Liu is expertise in the research of nanofabrication, 2D materials, self-assembly, and thermal management. He has published more than 50 peer-reviewed journal articles with more than 2000 citations, and applied/granted more than 50 patents.
    Songping Zhang (Institute of Process Engineering, Chinese Academy of Sciences) received her B.S. in 1998 and Ph.D degree in 2002 from Tianjin University, China. From 2002‒2004, she did postdoctoral research at Lund University, Sweden. Afterward, she joined Institute of Process Engineering in Jan. 2005. Prof. Zhang’ research direction focusses on biomedicine engineering, specializing in the synthesis, assembly, purification, and formulation of biomacromolecules including mRNA, proteins, recombinant virus like particles vaccine antigens, et al. She has published over 150 research papers and holds more than 40 invention patents, with multiple achievements succeed in industrial applications. She serves as an editorial board member for J. Chromatogr. A and Biochem. Engin. J.
  • Supported by:
    National Natural Science Foundation of China(22478401);Strategic Priority Research Program of the Chinese Academy of Sciences(XDB1250000);Australian Research Council (ARC)(IH230100010)

Abstract:

The clinical efficacy of mRNA-based therapeutics is critically dependent on the structural integrity of the mRNA molecule, which in turn is governed by the efficiency and robustness of its manufacturing process. Unlike conventional small-molecule synthesis, mRNA manufacturing relies on complex enzymatic cascades involving biomacromolecules with dynamic conformations as templates, intermediates, and catalysts. Key enzymatic modules, including plasmid linearization for DNA template preparation (Module 1), in vitro transcription (IVT) synthesis (Module 2), capping modification (Module 3) of mRNA, and different nucleases-aided removal of impurities (Module 4), are highly interdependent, each with specific catalytic enzymes and auxiliary cofactors. These modules present major engineering challenges of low efficiency and lack of modular compatibility across the multi-step enzymatic processes. Moreover, traditional approaches such as multienzyme immobilization or compartmentalization often fail to meet the demands of high-throughput, continuous and scalable manufacturing. This review systematically summarizes recent advances in the engineering of enzymatic modules for mRNA manufacturing, emphasizing challenges in catalytic regulation, module integration and process intensification. The potential strategies for improving reaction compatibility and enabling process integration and intensification are discussed, providing insights into future directions for engineering mRNA synthesis at scale.

Key words: mRNA manufacturing, Enzymatic modules, Catalytic regulation, Process integration, Multienzyme reaction