Spray drying of an attenuated live Newcastle disease vaccine virus intended for respiratory mass vaccination of poultry

Abstract

A powder vaccine intended for aerosol vaccination of poultry was formulated by spray drying a live attenuated Newcastle disease virus with potential stabilizers (mannitol, trehalose, polyvinylpyrrollidone (PVP), bovine serum albumin (BSA)). Thermodynamic properties, water sorption, particle size distribution, nebulization properties, density and morphology of the powders were evaluated and the virus survival during spray drying and storage was determined by incubation in embryonated eggs and subsequent haemagglutination assay. All powders had a narrow size distribution with a median volume diameter of ±30 m (suitable for primary respiratory vaccination of chickens) and good aerosolization characteristics. Four amorphous, hygroscopic formulations were produced (trehalose, trehalose-PVP, trehalose-BSA, trehalose-PVP-BSA), where addition of BSA was beneficial for virus survival during production and storage at 6 and 25 • C. A crystalline, non-hygroscopic powder (mannitol) had a lower stabilizing capacity during production but maintained the remaining virus titre during storage. In conclusion, the study demonstrates that it is possible to produce a dry powder formulation of an attenuated live vaccine for mass vaccination of poultry in a one-step spray drying process.

Effects of Temperature, Relative Humidity, Absolute Humidity, and Evaporation Potential on Survival of Airborne Gumboro Vaccine Virus

“…Other vaccination methods should be investigated, e.g., the dry aerosolization of vaccine virus (5,6).…”

Trehalose: Current Use and Future Applications

“…The activity of the trehalose-stabilized vaccine was maintained above 90% following 35 weeks storage at 45 • C, whereas the control vaccine (without trehalose) demonstrated less than 5% activity following 2.5 weeks of storage at the same temperature. Furthermore, analysis of aluminum hydroxide sedimentation revealed that trehalose-stabilized vaccine maintained 90% of the values of the fresh suspension control, whereas those stabilized in sucrose demonstrated only 50%, following 4 weeks of storage at 45 • C. Trehalose was also utilized to stabilize 17D Yellow Fever virus, 174 Newcastle disease virus, 175 and Rinderpest and Peste des Petits ruminants viruses. 176 All of the viruses were dried by different techniques, including freeze drying, spray drying, and foam drying; however, they all demonstrated the efficacy of trehalose in conferring stability to a wide variety of stresses.…”

Comparison of Newcastle disease vaccine administered as powder or liquid in relation to the serum antibody response and adverse vaccinal reactions in broilers

“…It has been suggested (Huyge et al, 2012) that the ideal powder vaccine should meet the following requirements: (1) show no or only limited virus loss during production and storage; (2) be monodisperse; (3) consist of particles with a size that will enable exclusive targeting of the upper respiratory tract for primary vaccinations or the lower respiratory airways for secondary, booster vaccinations; (4) be easy to disperse into their primary particle size; (5) be non-hygroscopic to prevent hygroscopic growth of the vaccine virus-loaded particles in the airways during respiration (Morrow, 1986); and (6) be non-toxic for man, animals and the environment. In previous research Newcastle disease virus (NDV) powder vaccines based on mannitol and bovine serum albumin (BSA), which approximated to the requirements mentioned above, were prepared in a onestep spray-drying process (Corbanie et al, 2007;Huyge et al, 2012). A preliminary proof of principle experiment showed that the powder vaccine formulations induced high haemagglutination inhibiting (HI) antibody titres in 4-weekold broilers (Corbanie et al, 2008).…”