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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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Li M, Jia L, Xie Y, Ma W, Yan Z, Liu F, Deng J, Zhu A, Siwei X, Su W, Liu X, Li S, Wang H, Yu P, Zhu T. Lyophilization process optimization and molecular dynamics simulation of mRNA-LNPs for SARS-CoV-2 vaccine. NPJ Vaccines 2023; 8:153. [PMID: 37813912 PMCID: PMC10562438 DOI: 10.1038/s41541-023-00732-9] [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: 02/08/2023] [Accepted: 09/12/2023] [Indexed: 10/11/2023] Open
Abstract
Some studies have shown that lyophilization significantly improves the stability of mRNA-LNPs and enables long-term storage at 2-8 °C. However, there is little research on the lyophilization process of mRNA-lipid nanoparticles (LNPs). Most previous studies have used empirical lyophilization with only a single lyoprotectant, resulting in low lyophilization efficiency, often requiring 40-100 h. In the present study, an efficient lyophilization method suitable for mRNA-LNPs was designed and optimized, shortening the total length of the lyophilization process to 8-18 h, which significantly reduced energy consumption and production costs. When the mixed lyoprotectant composed of sucrose, trehalose, and mannitol was added to mRNA-LNPs, the eutectic point and collapse temperature of the system were increased. The lyophilized product had a ginger root-shaped rigid structure with large porosity, which tolerated rapid temperature increases and efficiently removed water. In addition, the lyophilized mRNA-LNPs rapidly rehydrated and had good particle size distribution, encapsulation rate, and mRNA integrity. The lyophilized mRNA-LNPs were stable at 2-8 °C, and they did not reduce immunogenicity in vivo or in vitro. Molecular dynamics simulation was used to compare the phospholipid molecular layer with the lyoprotectant in aqueous and anhydrous environments to elucidate the mechanism of lyophilization to improve the stability of mRNA-LNPs. This efficient lyophilization platform significantly improves the accessibility of mRNA-LNPs.
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Affiliation(s)
- Mingyuan Li
- China International Science and Technology Cooperation Base of Food Nutrition/Safety and Medicinal Chemistry, Tianjin International Cooperation Research Centre of Food Nutrition/Safety and Medicinal Chemistry, College of Biotechnology, Tianjin University of Science & Technology, Tianjin, 300457, China
| | - Lin Jia
- China International Science and Technology Cooperation Base of Food Nutrition/Safety and Medicinal Chemistry, Tianjin International Cooperation Research Centre of Food Nutrition/Safety and Medicinal Chemistry, College of Biotechnology, Tianjin University of Science & Technology, Tianjin, 300457, China
| | - Yanbo Xie
- China International Science and Technology Cooperation Base of Food Nutrition/Safety and Medicinal Chemistry, Tianjin International Cooperation Research Centre of Food Nutrition/Safety and Medicinal Chemistry, College of Biotechnology, Tianjin University of Science & Technology, Tianjin, 300457, China
| | - Wenlin Ma
- China International Science and Technology Cooperation Base of Food Nutrition/Safety and Medicinal Chemistry, Tianjin International Cooperation Research Centre of Food Nutrition/Safety and Medicinal Chemistry, College of Biotechnology, Tianjin University of Science & Technology, Tianjin, 300457, China
| | - Zhihong Yan
- CanSino Biologics Inc., Tianjin, 300301, China
- CanSino (Shanghai) Biotechnologies Co., Ltd, Shanghai, 201208, China
- CanSino (Shanghai) Biological Research Co., Ltd, Shanghai, 201208, China
| | - Fufeng Liu
- China International Science and Technology Cooperation Base of Food Nutrition/Safety and Medicinal Chemistry, Tianjin International Cooperation Research Centre of Food Nutrition/Safety and Medicinal Chemistry, College of Biotechnology, Tianjin University of Science & Technology, Tianjin, 300457, China
| | - Jie Deng
- CanSino Biologics Inc., Tianjin, 300301, China
| | - Ali Zhu
- CanSino Biologics Inc., Tianjin, 300301, China
| | - Xue Siwei
- CanSino Biologics Inc., Tianjin, 300301, China
| | - Wen Su
- China International Science and Technology Cooperation Base of Food Nutrition/Safety and Medicinal Chemistry, Tianjin International Cooperation Research Centre of Food Nutrition/Safety and Medicinal Chemistry, College of Biotechnology, Tianjin University of Science & Technology, Tianjin, 300457, China
| | - Xiaofeng Liu
- China International Science and Technology Cooperation Base of Food Nutrition/Safety and Medicinal Chemistry, Tianjin International Cooperation Research Centre of Food Nutrition/Safety and Medicinal Chemistry, College of Biotechnology, Tianjin University of Science & Technology, Tianjin, 300457, China
| | - Shiqin Li
- China International Science and Technology Cooperation Base of Food Nutrition/Safety and Medicinal Chemistry, Tianjin International Cooperation Research Centre of Food Nutrition/Safety and Medicinal Chemistry, College of Biotechnology, Tianjin University of Science & Technology, Tianjin, 300457, China
| | - Haomeng Wang
- CanSino Biologics Inc., Tianjin, 300301, China.
- CanSino (Shanghai) Biotechnologies Co., Ltd, Shanghai, 201208, China.
- CanSino (Shanghai) Biological Research Co., Ltd, Shanghai, 201208, China.
| | - Peng Yu
- China International Science and Technology Cooperation Base of Food Nutrition/Safety and Medicinal Chemistry, Tianjin International Cooperation Research Centre of Food Nutrition/Safety and Medicinal Chemistry, College of Biotechnology, Tianjin University of Science & Technology, Tianjin, 300457, China.
| | - Tao Zhu
- China International Science and Technology Cooperation Base of Food Nutrition/Safety and Medicinal Chemistry, Tianjin International Cooperation Research Centre of Food Nutrition/Safety and Medicinal Chemistry, College of Biotechnology, Tianjin University of Science & Technology, Tianjin, 300457, China.
- CanSino Biologics Inc., Tianjin, 300301, China.
- CanSino (Shanghai) Biotechnologies Co., Ltd, Shanghai, 201208, China.
- CanSino (Shanghai) Biological Research Co., Ltd, Shanghai, 201208, China.
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Zhang Y, Wu S, Liu W, Hu Z. Current status and future direction of duck hepatitis A virus vaccines. Avian Pathol 2023; 52:89-99. [PMID: 36571394 DOI: 10.1080/03079457.2022.2162367] [Citation(s) in RCA: 2] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/27/2022]
Abstract
Duck viral hepatitis (DVH), mainly caused by duck hepatitis A virus (DHAV), is a highly fatal and rapidly spreading infectious disease of young ducklings that seriously jeopardizes the duck industry worldwide. DHAV type 1 (DHAV-1) is the main genotype responsible for disease outbreaks since 1945, and the disease situation is complicated by the emergence and dissemination of a novel genotype (DHAV-3) in some countries in Asia and Africa. Live attenuated DHAV vaccines are widely used to induce a considerable degree of protection in ducklings. Breeder ducks are immunized with inactivated or/and live DHAV vaccines to achieve satisfactory levels of passive immunity in progeny. In addition, novel characteristics of virus transmission, pathogenicity and pathogenesis of DHAV were recently characterized, necessitating the development of new vaccines and effective vaccination programmes against DVH. Therefore, a systematic dissection of the profiles, strengths and shortcomings of the available DHAV vaccines is essential. Moreover, to further increase the efficiency of vaccine production and administration, the development of next-generation DHAV vaccines using cutting-edge technologies is also required. In this review, based on a comprehensive summary of the research advances in the epidemiology, pathogenicity, and genomic features of DHAV, we focus on reviewing and analysing the features of the commercial and experimental DHAV vaccines. We also propose perspectives for disease control based on the specific disease situations in different countries. This review provides essential information for vaccine development and disease control of DVH.
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Affiliation(s)
- Yanyan Zhang
- Joint International Research Laboratory of Agriculture and Agri-Product Safety, The Ministry of Education of China, Yangzhou University, Yangzhou, People's Republic of China.,Key Laboratory of Animal Infectious Diseases, School of Veterinary Medicine, Yangzhou University, Yangzhou, People's Republic of China
| | - Shuang Wu
- Jiangsu Agri-animal Husbandry Vocational College, Jiangsu Key Laboratory for High-Tech Research and Development of Veterinary Biopharmaceuticals, Taizhou, People's Republic of China
| | - Wenbo Liu
- Key Laboratory of Animal Infectious Diseases, School of Veterinary Medicine, Yangzhou University, Yangzhou, People's Republic of China.,Jiangsu Co-innovation Center for Prevention and Control of Important Animal Infectious Diseases and Zoonosis, Yangzhou University, Yangzhou, People's Republic of China
| | - Zenglei Hu
- Joint International Research Laboratory of Agriculture and Agri-Product Safety, The Ministry of Education of China, Yangzhou University, Yangzhou, People's Republic of China.,Key Laboratory of Animal Infectious Diseases, School of Veterinary Medicine, Yangzhou University, Yangzhou, People's Republic of China.,Jiangsu Co-innovation Center for Prevention and Control of Important Animal Infectious Diseases and Zoonosis, Yangzhou University, Yangzhou, People's Republic of China
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Lyu F, Zhao YH, Lu Y, Zuo XX, Deng BH, Zeng MQ, Wang JN, Olaniran A, Hou J, Khoza T. Vacuum Foam Drying Method Improved the Thermal Stability and Long-Term Shelf Life of a Live Attenuated Newcastle Disease Virus Vaccine. AAPS PharmSciTech 2022; 23:291. [DOI: 10.1208/s12249-022-02440-4] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/17/2022] [Accepted: 10/06/2022] [Indexed: 11/30/2022] Open
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