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Lyu F, Zhao YH, Zuo XX, Nyide B, Deng BH, Zhou MX, Hou J, Jiao JJ, Zeng MQ, Jie HY, Olaniran A, Lu Y, Khoza T. Thermostable vacuum foam dried Newcastle disease vaccine: Process optimization and pilot-scale study. Appl Microbiol Biotechnol 2024; 108:359. [PMID: 38836885 PMCID: PMC11153293 DOI: 10.1007/s00253-024-13174-7] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/15/2023] [Revised: 04/24/2024] [Accepted: 05/04/2024] [Indexed: 06/06/2024]
Abstract
Vacuum foam drying (VFD) has been shown to improve the thermostability and long-term shelf life of Newcastle Disease Virus (NDV). This study optimized the VFD process to improve the shelf life of NDV at laboratory-scale and then tested the optimized conditions at pilot-scale. The optimal NDV to T5 formulation ratio was determined to be 1:1 or 3:2. Using the 1:1 virus to formulation ratio, the optimal filling volumes were determined to be 13-17% of the vial capacity. The optimized VFD process conditions were determined to be at a shelf temperature of 25℃ with a minimum overall drying time of 44 h. The vaccine samples prepared using these optimized conditions at laboratory-scale exhibited virus titer losses of ≤ 1.0 log10 with residual moisture content (RMC) below 3%. Furthermore, these samples were transported for 97 days around China at ambient temperature without significant titer loss, thus demonstrating the thermostability of the NDV-VFD vaccine. Pilot-scale testing of the NDV-VFD vaccine at optimized conditions showed promising results for up-scaling the process as the RMC was below 3%. However, the virus titer loss was slightly above 1.0 log10 (approximately 1.1 log10). Therefore, the NDV-VFD process requires further optimization at pilot scale to obtain a titer loss of ≤ 1.0 log10. Results from this study provide important guidance for possible industrialization of NDV-VFD vaccine in the future. KEY POINTS: • The process optimization and scale-up test of thermostable NDV vaccine prepared through VFD is reported for the first time in this study. • The live attenuated NDV-VFD vaccine maintained thermostability for 97 days during long distance transportation in summer without cold chain conditions. • The optimized NDV-VFD vaccine preparations evaluated at pilot-scale maintained acceptable levels of infectivity after preservation at 37℃ for 90 days, which demonstrated the feasibility of the vaccine for industrialization.
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Affiliation(s)
- Fang Lyu
- Institute of Veterinary Immunology & Engineering, National Research Center of Engineering and Technology for Veterinary Biologicals, Jiangsu Academy of Agricultural Sciences, Nanjing, 210014, China
- Department of Biochemistry, School of Life Sciences, College of Agriculture, Engineering & Science, University of KwaZulu-Natal, Pietermaritzburg, 3209, South Africa
- GuoTai (Taizhou) Center of Technology Innovation for Veterinary Biologicals, Taizhou, 225300, China
- School of Animal Medicine, Nanjing Agricultural University, Nanjing, 210095, Jiangsu, China
| | - Yan-Hong Zhao
- Institute of Veterinary Immunology & Engineering, National Research Center of Engineering and Technology for Veterinary Biologicals, Jiangsu Academy of Agricultural Sciences, Nanjing, 210014, China
- School of Animal Medicine, Nanjing Agricultural University, Nanjing, 210095, Jiangsu, China
| | - Xiao-Xin Zuo
- Institute of Veterinary Immunology & Engineering, National Research Center of Engineering and Technology for Veterinary Biologicals, Jiangsu Academy of Agricultural Sciences, Nanjing, 210014, China
- Jiangsu Key Laboratory for Food Quality and Safety-State Key Laboratory Cultivation Base, Ministry of Science and Technology, Nanjing, 210014, China
| | - Babalwa Nyide
- Department of Biochemistry, School of Life Sciences, College of Agriculture, Engineering & Science, University of KwaZulu-Natal, Pietermaritzburg, 3209, South Africa
| | - Bi-Hua Deng
- Institute of Veterinary Immunology & Engineering, National Research Center of Engineering and Technology for Veterinary Biologicals, Jiangsu Academy of Agricultural Sciences, Nanjing, 210014, China
- GuoTai (Taizhou) Center of Technology Innovation for Veterinary Biologicals, Taizhou, 225300, China
- School of Animal Medicine, Nanjing Agricultural University, Nanjing, 210095, Jiangsu, China
| | - Ming-Xu Zhou
- Institute of Veterinary Immunology & Engineering, National Research Center of Engineering and Technology for Veterinary Biologicals, Jiangsu Academy of Agricultural Sciences, Nanjing, 210014, China
- GuoTai (Taizhou) Center of Technology Innovation for Veterinary Biologicals, Taizhou, 225300, China
| | - Jibo Hou
- Institute of Veterinary Immunology & Engineering, National Research Center of Engineering and Technology for Veterinary Biologicals, Jiangsu Academy of Agricultural Sciences, Nanjing, 210014, China
| | - Jia-Jie Jiao
- Institute of Veterinary Immunology & Engineering, National Research Center of Engineering and Technology for Veterinary Biologicals, Jiangsu Academy of Agricultural Sciences, Nanjing, 210014, China
- School of Animal Medicine, Nanjing Agricultural University, Nanjing, 210095, Jiangsu, China
| | - Min-Qian Zeng
- Institute of Veterinary Immunology & Engineering, National Research Center of Engineering and Technology for Veterinary Biologicals, Jiangsu Academy of Agricultural Sciences, Nanjing, 210014, China
- School of Animal Medicine, Nanjing Agricultural University, Nanjing, 210095, Jiangsu, China
| | - Hong-Ying Jie
- Institute of Veterinary Immunology & Engineering, National Research Center of Engineering and Technology for Veterinary Biologicals, Jiangsu Academy of Agricultural Sciences, Nanjing, 210014, China
| | - Ademola Olaniran
- Department of Microbiology, School of Life Sciences, Engineering & Science, College of Agriculture, University of KwaZulu-Natal, Durban, 4000, South Africa
| | - Yu Lu
- Institute of Veterinary Immunology & Engineering, National Research Center of Engineering and Technology for Veterinary Biologicals, Jiangsu Academy of Agricultural Sciences, Nanjing, 210014, China.
- GuoTai (Taizhou) Center of Technology Innovation for Veterinary Biologicals, Taizhou, 225300, China.
- School of Animal Medicine, Nanjing Agricultural University, Nanjing, 210095, Jiangsu, China.
- School of Pharmacy, Jiangsu University, Zhenjiang, 212013, China.
| | - Thandeka Khoza
- Department of Biochemistry, School of Life Sciences, College of Agriculture, Engineering & Science, University of KwaZulu-Natal, Pietermaritzburg, 3209, South Africa.
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Liu Y, Zhang S, Wang S, Zhang C, Su X, Guo L, Bai X, Huang Y, Pang W, Tan F, Tian K. Screening and Stability Evaluation of Freeze-Dried Protective Agents for a Live Recombinant Pseudorabies Virus Vaccine. Vaccines (Basel) 2024; 12:65. [PMID: 38250878 PMCID: PMC10821108 DOI: 10.3390/vaccines12010065] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/11/2023] [Revised: 12/28/2023] [Accepted: 01/06/2024] [Indexed: 01/23/2024] Open
Abstract
Infection of pigs with the pseudorabies virus (PRV) causes significant economic losses in the pig industry. Immunization with live vaccines is a crucial aspect in the prevention of pseudorabies in swine. The TK/gE/gI/11k/28k deleted pseudorabies vaccine is a promising alternative for the eradication of epidemic pseudorabies mutant strains. This study optimized the lyophilization of a heat-resistant PRV vaccine to enhance the quality of a live vaccine against the recombinant PRV rHN1201TK-/gE-/gI-/11k-/28k-. The A4 freeze-dried protective formulation against PRV was developed by comparing the reduction in virus titer after lyophilization and after seven days of storage at 37 °C. The formulation contains 1% gelatin, 5% trehalose, 0.5% poly-vinylpyrimidine (PVP), 0.5% thiourea, and 1% sorbitol. The A4 freeze-dried vaccine demonstrated superior protection and thermal stability. It experienced a freeze-dried loss of 0.31 Lg post-freeze-drying and a heat loss of 0.42 Lg after being stored at a temperature of 37 °C for 7 consecutive days. The A4 freeze-dried vaccine was characterized through XRD, FTIR, and SEM analyses, which showed that it possessed an amorphous structure with a consistent porous interior. The trehalose component of the vaccine formed stable hydrogen bonds with the virus. Long-term and accelerated stability studies were also conducted. The A4 vaccine maintained viral titer losses of less than 1.0 Lg when exposed to 25 °C for 90 days, 37 °C for 28 days, and 45 °C for 7 days. The A4 vaccine had a titer loss of 0.3 Lg after storage at 2-8 °C for 24 months, and a predicted shelf life of 6.61 years at 2-8 °C using the Arrhenius equation. The A4 freeze-dried vaccine elicited no side effects when used to immunize piglets and produced specific antibodies. This study provides theoretical references and technical support to improve the thermal stability of recombinant PRV rHN1201TK-/gE-/gI-/11k-/28k- vaccines.
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Affiliation(s)
- Yan Liu
- National Research Center for Veterinary Medicine, Luoyang 471000, China; (Y.L.); (S.Z.); (S.W.); (C.Z.); (X.S.); (L.G.); (X.B.); (Y.H.); (W.P.)
- Pulike Biological Engineering Inc., Luoyang 471000, China
| | - Suling Zhang
- National Research Center for Veterinary Medicine, Luoyang 471000, China; (Y.L.); (S.Z.); (S.W.); (C.Z.); (X.S.); (L.G.); (X.B.); (Y.H.); (W.P.)
- Pulike Biological Engineering Inc., Luoyang 471000, China
- College of Veterinary Medicine, Northwest A&F University, Yangling 712100, China
| | - Shuai Wang
- National Research Center for Veterinary Medicine, Luoyang 471000, China; (Y.L.); (S.Z.); (S.W.); (C.Z.); (X.S.); (L.G.); (X.B.); (Y.H.); (W.P.)
- Pulike Biological Engineering Inc., Luoyang 471000, China
| | - Chunhui Zhang
- National Research Center for Veterinary Medicine, Luoyang 471000, China; (Y.L.); (S.Z.); (S.W.); (C.Z.); (X.S.); (L.G.); (X.B.); (Y.H.); (W.P.)
- Pulike Biological Engineering Inc., Luoyang 471000, China
| | - Xiaorui Su
- National Research Center for Veterinary Medicine, Luoyang 471000, China; (Y.L.); (S.Z.); (S.W.); (C.Z.); (X.S.); (L.G.); (X.B.); (Y.H.); (W.P.)
- Pulike Biological Engineering Inc., Luoyang 471000, China
| | - Linghua Guo
- National Research Center for Veterinary Medicine, Luoyang 471000, China; (Y.L.); (S.Z.); (S.W.); (C.Z.); (X.S.); (L.G.); (X.B.); (Y.H.); (W.P.)
- Pulike Biological Engineering Inc., Luoyang 471000, China
| | - Xiaofei Bai
- National Research Center for Veterinary Medicine, Luoyang 471000, China; (Y.L.); (S.Z.); (S.W.); (C.Z.); (X.S.); (L.G.); (X.B.); (Y.H.); (W.P.)
- Pulike Biological Engineering Inc., Luoyang 471000, China
| | - Yuxin Huang
- National Research Center for Veterinary Medicine, Luoyang 471000, China; (Y.L.); (S.Z.); (S.W.); (C.Z.); (X.S.); (L.G.); (X.B.); (Y.H.); (W.P.)
- Pulike Biological Engineering Inc., Luoyang 471000, China
| | - Wenqiang Pang
- National Research Center for Veterinary Medicine, Luoyang 471000, China; (Y.L.); (S.Z.); (S.W.); (C.Z.); (X.S.); (L.G.); (X.B.); (Y.H.); (W.P.)
- Pulike Biological Engineering Inc., Luoyang 471000, China
| | - Feifei Tan
- National Research Center for Veterinary Medicine, Luoyang 471000, China; (Y.L.); (S.Z.); (S.W.); (C.Z.); (X.S.); (L.G.); (X.B.); (Y.H.); (W.P.)
- Pulike Biological Engineering Inc., Luoyang 471000, China
| | - Kegong Tian
- National Research Center for Veterinary Medicine, Luoyang 471000, China; (Y.L.); (S.Z.); (S.W.); (C.Z.); (X.S.); (L.G.); (X.B.); (Y.H.); (W.P.)
- Pulike Biological Engineering Inc., Luoyang 471000, China
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Optimization of Heat-Resistance Technology for a Duck Hepatitis Lyophilized Live Vaccine. Vaccines (Basel) 2022; 10:vaccines10020269. [PMID: 35214727 PMCID: PMC8880185 DOI: 10.3390/vaccines10020269] [Citation(s) in RCA: 4] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/28/2021] [Revised: 01/23/2022] [Accepted: 01/25/2022] [Indexed: 02/05/2023] Open
Abstract
In this study, to improve the quality of a live attenuated vaccine for duck viral hepatitis (DHV), the lyophilization of a heat-resistant duck hepatitis virus vaccine was optimized. The optimized heat protectors were made of 10% sucrose, 1.2% pullulan, 0.5% PVP, and 1% arginine, etc., with a titer freeze-drying loss of ≤0.50 Lg. The vaccine product’s valence measurements demonstrated the following: the vaccine could be stored at 2–8 °C for 18 months with a virus titer loss ≤0.91 Lg; at 37 °C for 10 days with a virus valence loss ≤0.89 Lg; and at 45 °C for 3 days with a virus titer loss ≤0.90 Lg. Regarding safety, no deaths occurred in two-day-old ducklings immunized with a 10 times dose vaccine; their energy, diet, and weight gain were all normal, demonstrating that the DHV heat-resistant vaccines were safe for ducklings and did not cause any immune side effects. Duck viral hepatitis freeze-dried vaccine began to produce antibodies at 7 d after immunization, reached above 5.0 on 14 d, and reached above 7.0 on 21 d, showing a continuous upward trend. This indicates that duck viral hepatitis vaccine has a good immunogen level. The optimization of the freeze-drying process saves costs and also improves the quality of the freeze-drying products, which provides important theoretical and technical support for the further study of vaccine products.
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Zuo XX, Zhao YH, Zhou MX, Deng BH, Hu LG, Lv F, Lu Y, Hou JB. Live vaccine preserved at room temperature: Preparation and characterization of a freeze-dried classical swine fever virus vaccine. Vaccine 2020; 38:8371-8378. [PMID: 33199076 DOI: 10.1016/j.vaccine.2020.10.093] [Citation(s) in RCA: 8] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/26/2020] [Revised: 10/19/2020] [Accepted: 10/31/2020] [Indexed: 11/29/2022]
Abstract
The heat-stable live-attenuated classical swine fever virus (CSFV) vaccine is an urgent need in many countries of Asia, Europe and Latin America. In this study, the thermostability of lyophilized live-attenuated CSFV vaccine formulations were investigated using accelerated stability at 37 °C for 10 days. The freeze-dried heat-stable formulation ST16, containing excipient combinations of trehalose, glycine, thiourea and phosphate buffer shows the superior thermostability. Moreover, the lyophilized vaccine with formula ST16 kept loss of viral activity less than 0.5 log10 during 24 months at storage temperatures of 2-8 °C. In thermal study, ST16 stabilized the vaccine within 1.0 log10 loss after storage at up to 25 °C for 6 months and room temperature for 7 months. Even under the harshest storage conditions of 37 °C for 25 days and 45 °C for 2 weeks, the virus titer dropped less than 1.0 log10 using ST16. Besides, it is notable that ST16 excluded gelatin and exogenous proteins, which might cause allergic reactions, thus avoiding immune side effects. The vaccine formulated ST16 proved to be safe and effective when immunized to piglets in vivo. The characteristics of dried vaccines were analyzed by X-ray powder diffraction, residual water measurements, differential scanning calorimetry and it was found that vaccine antigen were preserved in an amorphous matrix with high glass transition temperature above 60 °C and low residual water content below 2%, which made the vaccine more stable during storage.
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Affiliation(s)
- Xiao-Xin Zuo
- Institute of Veterinary Immunology & Engineering, National Research Center of Engineering and Technology for Veterinary Biologicals, Jiangsu Academy of Agricultural Sciences, Nanjing 210014, China
| | - Yan-Hong Zhao
- Institute of Veterinary Immunology & Engineering, National Research Center of Engineering and Technology for Veterinary Biologicals, Jiangsu Academy of Agricultural Sciences, Nanjing 210014, China
| | - Ming-Xu Zhou
- Institute of Veterinary Immunology & Engineering, National Research Center of Engineering and Technology for Veterinary Biologicals, Jiangsu Academy of Agricultural Sciences, Nanjing 210014, China
| | - Bi-Hua Deng
- Institute of Veterinary Immunology & Engineering, National Research Center of Engineering and Technology for Veterinary Biologicals, Jiangsu Academy of Agricultural Sciences, Nanjing 210014, China
| | - Lai-Gen Hu
- Institute of Veterinary Immunology & Engineering, National Research Center of Engineering and Technology for Veterinary Biologicals, Jiangsu Academy of Agricultural Sciences, Nanjing 210014, China
| | - Fang Lv
- Institute of Veterinary Immunology & Engineering, National Research Center of Engineering and Technology for Veterinary Biologicals, Jiangsu Academy of Agricultural Sciences, Nanjing 210014, China.
| | - Yu Lu
- Institute of Veterinary Immunology & Engineering, National Research Center of Engineering and Technology for Veterinary Biologicals, Jiangsu Academy of Agricultural Sciences, Nanjing 210014, China; Jiangsu Key Laboratory for Food Quality and Safety-State Key Laboratory Cultivation Base, Ministry of Science and Technology, Nanjing 210014, China; Jiangsu Co-Innovation Center for the Prevention and Control of Important Animal Infectious Disease and Zoonose, Yangzhou University, Yangzhou 225009, China; School of Pharmacy, Jiangsu University, Zhenjiang 212013, China.
| | - Ji-Bo Hou
- Institute of Veterinary Immunology & Engineering, National Research Center of Engineering and Technology for Veterinary Biologicals, Jiangsu Academy of Agricultural Sciences, Nanjing 210014, China; Jiangsu Key Laboratory for Food Quality and Safety-State Key Laboratory Cultivation Base, Ministry of Science and Technology, Nanjing 210014, China; Jiangsu Co-Innovation Center for the Prevention and Control of Important Animal Infectious Disease and Zoonose, Yangzhou University, Yangzhou 225009, China
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