1
|
Buckland B, Sanyal G, Ranheim T, Pollard D, Searles JA, Behrens S, Pluschkell S, Josefsberg J, Roberts CJ. Vaccine process technology-A decade of progress. Biotechnol Bioeng 2024; 121:2604-2635. [PMID: 38711222 DOI: 10.1002/bit.28703] [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: 12/22/2023] [Revised: 03/04/2024] [Accepted: 03/14/2024] [Indexed: 05/08/2024]
Abstract
In the past decade, new approaches to the discovery and development of vaccines have transformed the field. Advances during the COVID-19 pandemic allowed the production of billions of vaccine doses per year using novel platforms such as messenger RNA and viral vectors. Improvements in the analytical toolbox, equipment, and bioprocess technology have made it possible to achieve both unprecedented speed in vaccine development and scale of vaccine manufacturing. Macromolecular structure-function characterization technologies, combined with improved modeling and data analysis, enable quantitative evaluation of vaccine formulations at single-particle resolution and guided design of vaccine drug substances and drug products. These advances play a major role in precise assessment of critical quality attributes of vaccines delivered by newer platforms. Innovations in label-free and immunoassay technologies aid in the characterization of antigenic sites and the development of robust in vitro potency assays. These methods, along with molecular techniques such as next-generation sequencing, will accelerate characterization and release of vaccines delivered by all platforms. Process analytical technologies for real-time monitoring and optimization of process steps enable the implementation of quality-by-design principles and faster release of vaccine products. In the next decade, the field of vaccine discovery and development will continue to advance, bringing together new technologies, methods, and platforms to improve human health.
Collapse
Affiliation(s)
- Barry Buckland
- National Institute for Innovation in Manufacturing Biopharmaceuticals, University of Delaware, Newark, Delaware, USA
| | - Gautam Sanyal
- Vaccine Analytics, LLC, Kendall Park, New Jersey, USA
| | - Todd Ranheim
- Advanced Analytics Core, Resilience, Chapel Hill, North Carolina, USA
| | - David Pollard
- Sartorius, Corporate Research, Marlborough, Massachusetts, USA
| | | | - Sue Behrens
- Engineering and Biopharmaceutical Processing, Keck Graduate Institute, Claremont, California, USA
| | - Stefanie Pluschkell
- National Institute for Innovation in Manufacturing Biopharmaceuticals, University of Delaware, Newark, Delaware, USA
| | - Jessica Josefsberg
- Merck & Co., Inc., Process Research & Development, Rahway, New Jersey, USA
| | - Christopher J Roberts
- National Institute for Innovation in Manufacturing Biopharmaceuticals, University of Delaware, Newark, Delaware, USA
| |
Collapse
|
2
|
Zhao C, Huang J, Yang Z, Huang Z, Li C, Li H, Wu Z, Zhang X, Qin X, Yao S, Ruan M. An energy-efficient solution to sludge drying and combustion process through Camellia oleifera shells amended foaming. JOURNAL OF ENVIRONMENTAL MANAGEMENT 2024; 354:120400. [PMID: 38417358 DOI: 10.1016/j.jenvman.2024.120400] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Received: 11/27/2023] [Revised: 01/21/2024] [Accepted: 02/13/2024] [Indexed: 03/01/2024]
Abstract
Foaming pretreatment has been proven effective in promoting sludge drying, however, the variation in sludge properties significantly influences the foaming efficiency. Inspired by foam stabilizer of solid particles, Camellia oleifera shells (COS) was screened out from various biomasses as an additive incorporated with the CaO for promoting the sludge foaming. For the introduction of COS, this study analyzed the drying behaviors of foamed sludge, quantified the surface cracks information, characterized the combustion performance, and evaluated the energy consumption. The results indicated that 46.72-50.10% of time could be saved in foaming the sludge to 0.70 g/mL by addition of 3.0 wt% COS. Compared with the original sludge (OS), the 0.70 g/mL foamed sludge saved 47.43% of time for sludge drying at 80 °C, and this value further increased to 53.14% with 3.0 wt% COS addition. Combining the multifractal spectra and drying kinetics analysis, the foaming promoted the formation of complex surface cracks in the warm-up period, while COS further improved the complexity of cracks in the constant rate period, and the shrinkage of isolated sludge blocks in the falling rate period, thus enhanced the moisture diffusion and heat transfer. Furthermore, the appropriate porous structure and additional volatile matters promoted the combustion performance. The 0.90 g/mL foamed sludge with COS presented the lowest activation energy of 180.362 kJ/mol in combustion. Overall, compared with OS, the 0.70 g/mL foamed sludge with COS saved 40.65% energy consumption during the foaming, drying and combustion processes, providing an energy-efficient solution for the sludge treatment and disposal.
Collapse
Affiliation(s)
- Cheng Zhao
- School of Energy and Power Engineering, Changsha University of Science & Technology, Changsha, 410076, PR China; State Key Laboratory of Utilization of Woody Oil Resource, Hunan Academy of Forestry, Changsha, Hunan, 410004, PR China
| | - Jing Huang
- State Key Laboratory of Utilization of Woody Oil Resource, Hunan Academy of Forestry, Changsha, Hunan, 410004, PR China
| | - Zhaohui Yang
- College of Environmental Science and Engineering, Hunan University, Changsha, 410082, PR China
| | - Zhongliang Huang
- State Key Laboratory of Utilization of Woody Oil Resource, Hunan Academy of Forestry, Changsha, Hunan, 410004, PR China
| | - Changzhu Li
- State Key Laboratory of Utilization of Woody Oil Resource, Hunan Academy of Forestry, Changsha, Hunan, 410004, PR China
| | - Hui Li
- State Key Laboratory of Utilization of Woody Oil Resource, Hunan Academy of Forestry, Changsha, Hunan, 410004, PR China
| | - Zijian Wu
- State Key Laboratory of Utilization of Woody Oil Resource, Hunan Academy of Forestry, Changsha, Hunan, 410004, PR China
| | - Xuan Zhang
- State Key Laboratory of Utilization of Woody Oil Resource, Hunan Academy of Forestry, Changsha, Hunan, 410004, PR China
| | - Xiaoli Qin
- State Key Laboratory of Utilization of Woody Oil Resource, Hunan Academy of Forestry, Changsha, Hunan, 410004, PR China
| | - Shirong Yao
- School of Energy and Power Engineering, Changsha University of Science & Technology, Changsha, 410076, PR China; State Key Laboratory of Utilization of Woody Oil Resource, Hunan Academy of Forestry, Changsha, Hunan, 410004, PR China
| | - Min Ruan
- School of Energy and Power Engineering, Changsha University of Science & Technology, Changsha, 410076, PR China.
| |
Collapse
|
3
|
Dumpler J, Moraru CI. Microwave vacuum drying of dairy cream: Processing, reconstitution, and whipping properties of a novel dairy product. J Dairy Sci 2024; 107:774-789. [PMID: 37769946 DOI: 10.3168/jds.2023-23657] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/24/2023] [Accepted: 09/02/2023] [Indexed: 10/03/2023]
Abstract
Traditional ways to preserve cream involve processing it into butter, butter oil, or frozen storage. These technologies do not preserve the unique functionality of cream with respect to whipping or processing into butter. In this work, microwave vacuum drying (MVD) was investigated as a method to manufacture dehydrated cream. Dehydrated cream microstructure, color, and free fat were evaluated using scanning electron microscopy, colorimetry, and solvent extraction, respectively. Effects of homogenization on reconstituted cream microstructure and functionality were investigated using confocal laser scanning microscopy, color, particle sizing, and texture analysis of whipped cream. Reconstituted MVD cream whipped faster, and the whipped cream was more cohesive and firmer when 2-step homogenization at 3.5/7 MPa was used. Fat globules in reconstituted MVD cream were covered by phospholipids, explaining MVD cream's similar functionality compared with pasteurized cream. These results may foster the development of novel shelf stable and highly functional dairy products using MVD.
Collapse
Affiliation(s)
- Joseph Dumpler
- Department of Food Science, Cornell University, Ithaca, NY 14853; ETH Zurich, Department of Health Science and Technology, Institute of Food, Nutrition and Health, Sustainable Food Processing Laboratory, 8092 Zurich, Switzerland.
| | - Carmen I Moraru
- Department of Food Science, Cornell University, Ithaca, NY 14853.
| |
Collapse
|
4
|
Irreversible thermochromic ink in the identification of over- and under-processed product segments in microwave-assisted freeze drying. J FOOD ENG 2023. [DOI: 10.1016/j.jfoodeng.2023.111470] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/16/2023]
|
5
|
Dumpler J, Moraru CI. A process optimization approach for microwave vacuum drying of concentrated skim milk. J Dairy Sci 2022; 105:8765-8781. [PMID: 36175231 DOI: 10.3168/jds.2021-21459] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/20/2021] [Accepted: 06/27/2022] [Indexed: 11/19/2022]
Abstract
Microwave vacuum drying (MVD) of concentrated skim milk and its resulting powder properties have been studied to a very limited extent. To explore the potential of this technology for the manufacture of milk powder, MVD of concentrated skim milk (37.5% total solids) was evaluated with respect to product properties and drying efficiency. A custom factorial design was used to optimize drying parameters, which enabled us to find optimal drying conditions with a minimal number of drying experiments (16). Vacuum level (3.3-13.3 kPa), specific power input (0.86-1.72 W·g-1), and product layer thickness (1-4 mm) were studied as factors. Total drying time, product foaming at the beginning of the process, product temperature in the last drying interval, browning, insolubility index, and calculated product yield were used as responses to identify optimal MVD processing parameters. Optimal drying of concentrated skim milk that maximized yield and minimized drying time while maintaining good product quality was achieved at a layer thickness of 2 mm, pressure of 6.0 kPa, and a specific power input of 1.29 W·g-1. Under constant power output, layer thickness was found to be the most important processing parameter to control product temperature during the final drying stage. Maximum product temperatures below 55°C yielded powder with good solubility. The findings of this exploratory study for MVD of concentrated skim milk yield important information and guidelines for production of good quality milk powders or preservation of starter cultures in a dairy matrix such as infant formula.
Collapse
Affiliation(s)
- Joseph Dumpler
- Department of Food Science, Cornell University, Ithaca, NY 14853.
| | - Carmen I Moraru
- Department of Food Science, Cornell University, Ithaca, NY 14853.
| |
Collapse
|
6
|
Kumar G, Kumar N, Prabhakar PK, Kishore A. Foam mat drying: Recent advances on foam dynamics, mechanistic modeling and hybrid drying approach. Crit Rev Food Sci Nutr 2022; 63:8275-8291. [PMID: 35380483 DOI: 10.1080/10408398.2022.2053061] [Citation(s) in RCA: 4] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/03/2022]
Abstract
Drying is one of the oldest and most widely used methods for food preservation. It reduces the availability of moisture and inhibits microbial and enzymatic spoilage in food products. Foam mat drying is a mild drying technique used for semiliquid and liquid foodstuff. It is useful for heat-sensitive and sticky liquid food products. In this process, liquid food is converted into foam using surfactant additives, which can be a foaming agent or foam stabilizer. These additives are surface-active compounds of vegetative and animal origins. The foamed material is then convectively dried using hot air. The foam mat drying is an efficient and economical technique. With the emergence of different hybrid techniques such as foam mat freeze drying, foamed spray drying, foamed vacuum drying, and microwave assisted foam mat drying, the powders' physical, chemical, and functional properties have enhanced many folds. These strategies have shown very promising results in terms of cost and time efficiency in almost all the cases barring a few exceptions. This review article attempts to comprehensively summarize the mechanisms dictating the foam mat drying process, novel technological tools for modeling, mathematical and computational modeling, effects of various foaming additives, and various hybrid techniques employed to foam mat drying.
Collapse
Affiliation(s)
- Gaurav Kumar
- Department of Food Engineering, National Institute of Food Technology Entrepreneurship and Management, Sonepat, Haryana, India
| | - Nitin Kumar
- Department of Food Engineering, National Institute of Food Technology Entrepreneurship and Management, Sonepat, Haryana, India
| | - Pramod K Prabhakar
- Department of Food Science and Technology, National Institute of Food Technology Entrepreneurship and Management, Sonepat, Haryana, India
| | - Anand Kishore
- Department of Food Engineering, National Institute of Food Technology Entrepreneurship and Management, Sonepat, Haryana, India
| |
Collapse
|
7
|
Kalinke I, Kubbutat P, Taghian Dinani S, Ambros S, Ozcelik M, Kulozik U. Critical assessment of methods for measurement of temperature profiles and heat load history in microwave heating processes-A review. Compr Rev Food Sci Food Saf 2022; 21:2118-2148. [PMID: 35338578 DOI: 10.1111/1541-4337.12940] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/08/2021] [Revised: 02/11/2022] [Accepted: 02/24/2022] [Indexed: 12/23/2022]
Abstract
Limitations of microwave processing due to inhomogeneities of power input and energy absorption have been widely described. Over- and underheated product areas influence reproducibility, product quality, and possibly safety. Although a broad range of methods is available for temperature measurement and evaluation of time/temperature effects, none of them is sufficiently able to detect temperature differences and thermally induced effects within the product caused by inhomogeneous heating. The purpose of this review is to critically assess different methods of temperature measurement for their suitability for different microwave applications, namely metallic temperature sensors, thermal imaging, pyrometer measurement, fiber optic sensors, microwave radiometry, magnetic resonance imaging, liquid crystal thermography, thermal paper, and biological and chemical time-temperature indicators. These methods are evaluated according to their advantages and limitations, method characteristics, and potential interference with the electric field. Special attention is given to spatial resolution, accuracy, handling, and purpose of measurement, that is, development work or online production control. Differences of methods and examples of practical application and failure in microwave-assisted food processing are discussed with a special focus on microwave pasteurization and microwave-assisted drying. Based on this assessment, it is suggested that infrared cameras for measuring temperature distribution at the product surface and partially inside the product in combination with a chemical time/temperature indicator (e.g., Maillard reaction, generating heat-induced color variations, depending on local energy absorption) appear to be the most appropriate system for future practical application in microwave food process control, microwave system development, and product design. Reliable detection of inhomogeneous heating is a prerequisite to counteracte inhomogeneity by a targeted adjustment of process and product parameters in microwave applications.
Collapse
Affiliation(s)
- Isabel Kalinke
- Food and Bioprocess Engineering, TUM School of Life Sciences, Technical University Munich, Freising, Germany
| | - Peter Kubbutat
- Food and Bioprocess Engineering, TUM School of Life Sciences, Technical University Munich, Freising, Germany
| | - Somayeh Taghian Dinani
- Food and Bioprocess Engineering, TUM School of Life Sciences, Technical University Munich, Freising, Germany
| | - Sabine Ambros
- Food and Bioprocess Engineering, TUM School of Life Sciences, Technical University Munich, Freising, Germany
| | - Mine Ozcelik
- Food and Bioprocess Engineering, TUM School of Life Sciences, Technical University Munich, Freising, Germany
| | - Ulrich Kulozik
- Food and Bioprocess Engineering, TUM School of Life Sciences, Technical University Munich, Freising, Germany
| |
Collapse
|
8
|
Dielectric determination of glucose solutions under microwave fields via a novel molecular dynamics simulation approach. J FOOD ENG 2022. [DOI: 10.1016/j.jfoodeng.2021.110844] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/20/2022]
|
9
|
Kubbutat P, Kulozik U, Dombrowski J. Influence of interfacial characteristics and dielectric properties on foam structure preservation during microwave-assisted vacuum drying of whey protein isolate-maltodextrin dispersions. J FOOD ENG 2021. [DOI: 10.1016/j.jfoodeng.2021.110691] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/21/2022]
|
10
|
Tramis O, Fujioka A, Imanaka H, Ishida N, Imamura K. Foaming characteristics of sugar- and polyvinylpyrrolidone-alcohol solutions during vacuum foam drying: A rheological approach. Colloids Surf A Physicochem Eng Asp 2021. [DOI: 10.1016/j.colsurfa.2021.127174] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022]
|
11
|
Kubbutat P, Leitão L, Kulozik U. Stability of Foams in Vacuum Drying Processes. Effects of Interactions between Sugars, Proteins, and Surfactants on Foam Stability and Dried Foam Properties. Foods 2021; 10:foods10081876. [PMID: 34441652 PMCID: PMC8392398 DOI: 10.3390/foods10081876] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/07/2021] [Revised: 08/05/2021] [Accepted: 08/11/2021] [Indexed: 01/16/2023] Open
Abstract
The hypothesis was that saccharides mediate interactions between surface-active components and that this will have an impact on foam decay during the drying process. Static light scattering was performed to determine changes in interactions between the foam stabilizer on a molecular level. Furthermore, pendant drop and oscillating drop measurements were performed to examine the surface tension and surface rheology. Foams were dried in conventional dryers as well as microwave-supported vacuum dryers. Final foam properties were determined. It was shown that the addition of sugars, often added as protective substances for sensitive organic molecules, resulted in lower repulsion between different types of surface-active components, namely polysorbate 80 and β-lactoglobulin (β-lg). Differences in impact of the types of sugars and between different types of surfactant, protein, and small molecules were observed influencing the foam decay behavior. The interfacial properties of polysorbate 80 and β-lg were influenced by the type of the used sugars. The surface elasticity of protein stabilized surfaces was higher compared to that of polysorbate stabilized systems. Protein stabilized systems remained more stable compared to polysorbate systems, which was also affected by the used saccharide. Overall, a correlation between molecular interactions and foam decay behavior was found.
Collapse
|
12
|
Microwave-vacuum-assisted drying of pretreated cranberries: Drying kinetics, bioactive compounds and antioxidant activity. Lebensm Wiss Technol 2021. [DOI: 10.1016/j.lwt.2021.111464] [Citation(s) in RCA: 7] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/28/2023]
|
13
|
Kubbutat P, Kulozik U, Dombrowski J. Foam Structure Preservation during Microwave-Assisted Vacuum Drying: Significance of Interfacial and Dielectric Properties of the Bulk Phase of Foams from Polysorbate 80-Maltodextrin Dispersions. Foods 2021; 10:foods10061163. [PMID: 34067254 PMCID: PMC8224648 DOI: 10.3390/foods10061163] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/24/2021] [Revised: 05/03/2021] [Accepted: 05/20/2021] [Indexed: 11/23/2022] Open
Abstract
This study aimed at examining the cause of differences in the structure preservation of polysorbate 80–maltodextrin foams during microwave-assisted vacuum drying (MWVD) versus conventional vacuum drying (CVD). Aqueous dispersions of 3% polysorbate 80 and 0–40% maltodextrin were characterized for their dielectric and interfacial properties, and results were related to their drying performance in a foamed state. Surface tension and surface dilatational properties as well as dielectric properties clearly responded to the variation in the maltodextrin content. Likewise, the foam structure preservation during CVD was linked to the maltodextrin concentration. Regarding MWVD, however, foams collapsed at all conditions tested. Nevertheless, if the structure during MWVD remained stable, the drying time was significantly reduced. Eventually, this finding could be linked to the dielectric properties of polysorbate 80 rather than its adsorption kinetics and surface film viscoelasticity as its resonant frequency fell within the working frequency of the microwave drying plant.
Collapse
Affiliation(s)
- Peter Kubbutat
- Chair of Food and Bioprocess Engineering, TUM School of Life Science, Technical University of Munich, Weihenstephaner Berg 1, 85354 Freising, Germany; (U.K.); (J.D.)
- Correspondence:
| | - Ulrich Kulozik
- Chair of Food and Bioprocess Engineering, TUM School of Life Science, Technical University of Munich, Weihenstephaner Berg 1, 85354 Freising, Germany; (U.K.); (J.D.)
| | - Jannika Dombrowski
- Chair of Food and Bioprocess Engineering, TUM School of Life Science, Technical University of Munich, Weihenstephaner Berg 1, 85354 Freising, Germany; (U.K.); (J.D.)
- Nestlé Research, Société des Produits Nestlé SA, Route du Jorat 57, 1000 Lausanne, Switzerland
| |
Collapse
|
14
|
Water Vapor Pathways during Freeze-Drying of Foamed Product Matrices Stabilized by Maltodextrin at Different Concentrations. Processes (Basel) 2020. [DOI: 10.3390/pr8111463] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022] Open
Abstract
This study aimed to identify the water-vapor transport mechanisms through an aerated matrix during microwave freeze-drying. Due to the larger surface area and lower water vapor transport resistance of an aerated product compared to the solution, foam structures dry faster. Different foam structures were produced with different maltodextrin (MD) concentrations (10–40%) as a foam-stabilizing agent. Depending on the initial viscosity of the solution prior to foaming, the samples differed in overrun (41–1671%) and pore size (d50 = 58–553 µm). Experiments were partially performed in a freeze-drying chamber of a light microscope to visualize structural changes in-situ. Different mechanisms were identified explaining the accelerated drying of foams, depending on the MD concentration, above or below 30%. At lower MD concentration, high overruns could be produced prior to freezing with big bubbles and thin lamellae with short diffusion pathway length. At 40% MD concentration, the viscosity was too high to integrate much air into the product. Therefore, the foam overrun was low and the bubble size small. Under these conditions, the water vapor generates high pressure, resulting in the formation of channels between bubbles, thus creating the pathways with low resistance for a very fast water vapor mass transfer. In addition, microwave freeze-drying experiments using a pilot plant unit were conducted to validate the findings of the freeze-drying microscope. A reduction of the drying time from 150 min (10% MD) to 78 min (40% MD) was achieved.
Collapse
|
15
|
Ambros S, Dombrowski J, Boettger D, Kulozik U. Structure-Function-Process Relationship for Microwave Vacuum Drying of Lactic Acid Bacteria in Aerated Matrices. FOOD BIOPROCESS TECH 2018. [DOI: 10.1007/s11947-018-2218-y] [Citation(s) in RCA: 8] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/24/2022]
|