Method for vacuum-assisted preservation of biologics including vaccines

1. A process for vitrifying biological material comprising the steps of:

(a) formulating a liquid biological preparation, wherein the liquid biological preparation comprises at least one active biologic ingredient selected from RNA and DNA viruses; and at least one stabilizer, wherein the at least one stabilizer comprises: 1) a bulking agent consisting of dextran, present in an amount of about 6% to about 10% w/v of the stabilizer: 2) one of the following combinations of sugars: glucose+raffinose; glucose+fructose; glucose+galactose; or glucose+sucrose, wherein the glucose is present in an amount of about 1% to about 5% w/v of the stabilizer and 3) optionally aspartic acid: wherein the stabilizer is capable of reducing or eliminating cryogenic damage to the biologic ingredient;

(b) adding a portion of the liquid biological preparation of step (a) to at least one vial;

(c) loading the at least one vial into a temperature-controlled container, wherein the temperature of the temperature-controlled container is between −15° C. and 10° C.; and

(d) reducing the moisture content of the biological preparation to less than about 5% by weight by controlled changes in pressure and temperature, comprising the following steps in the following order:

1) reducing pressure from about 10-30 mbar to about 5 mbar, over about 5-15 minutes, then holding the pressure at about 5 mbar for about 40-50 minutes;

2) reducing pressure from about 5 mbar to about 3 mbar, over about 5-10 minutes, then holding the pressure at about 3 mbar for about 10-40 minutes; and

3) reducing pressure from about 3 mbar to about 1.5-2 mbar, over about 5-10 minutes, then holding the pressure at about 1.5-2 mbar for about 5-160 minutes;

thereby reducing the moisture content of the biological preparation to less than about 5% by weight, and thereby vitrifying the biological material, and wherein the one or more biologic ingredients remains at least 85% viable for at least a year after vitrification, thereby the one or more biologic ingredients is stabilized.

2. The process of claim 1 , wherein reducing the moisture content of the biological preparation further comprises the steps of:

(e) reducing the pressure of the temperature-controlled container to between about 0.5 and about 2.0 mbars, and maintaining a constant pressure until foaming has completed;

(f) reducing the pressure of the temperature-controlled container to between about 5 μbar and about 100 μbar while maintaining the temperature of the temperature-controlled container at about 30° C. for about 400 to about 2400 or more minutes, until a moisture content of between about 0.5% to about 15% is obtained; and

(g) completing the vitrification process by stoppering the at least one vial while it is within the temperature-controlled container and

wherein the at least one active biologic ingredient comprises a live attenuated virus.

3. The process of claim 2 , wherein the live virus is selected from canine distemper virus (CDV), canine parainfluenza virus type 2 (PI2), and a combination thereof.

4. The process of claim 2 , wherein the live attenuated virus is selected from canarypox, Marek's disease virus, infectious bronchitis, west nile virus (WNV) and feline leukemia virus (FeLV).

5. The process of claim 1 , wherein the biological preparation comprises at least one adjuvant.

6. The process of claim 1 , wherein the vitrified biological material is stable at 4° C. for at least one year.

7. The process of claim 1 , wherein the vitrified biological material is stable at −20° C. and −80° C. for at least one year.

8. A process for preparing a vitrified biological preparation comprising the steps of:

(a) adding to an active biologic ingredient, which is selected from RNA viruses and DNA viruses, stabilizers, which reduce or eliminate damage induced by subjecting the biologic ingredient to cryogenic preservation means, and optionally adding one or more adjuvants; and wherein the stabilizer comprises dextran, present in an amount of about 6% to about 10% w/v of the stabilizer, and one or more of the following combinations of sugars: glucose+raffinose; glucose+fructose; glucose+galactose; or glucose+sucrose, wherein the glucose is present in an amount of about 1% to about 5% w/v of the stabilizer: thereby preparing a biological preparation;

(b) filling vials with the biological preparation of step (a);

(c) loading of vials into temperature-controlled container, wherein the temperature is between −15° C. and 10° C.;

(d) reducing the air pressure of the temperature-controlled container until a pressure within the range of 15-30 mbars is obtained;

(e) maintaining the pressure obtained during step (d) for between 5 and 20 minutes, to allow the temperature of the preparation to stabilize and to allow volatile gases to be released from the biological preparation, wherein the container temperature remains at about 4° C. to about 6° C. during this step;

(f) decreasing the container air pressure to about 1.5 to about 2.5 mbars using the following steps, in the following order;

1) reducing pressure from about 15-30 mbar to about 5 mbar, over about 5-15 minutes, then holding pressure at about 5 mbar for about 40-50 minutes;

2) reducing pressure from about 5 mbar to about 3 mbar, over about 5-10 minutes, then holding pressure at about 3 mbar for about 10-40 minutes;

3) reducing pressure from about 3 mbar to about 1.5-2.5 mbar, over about 5-10 minutes;

(g) maintaining the pressure of step (f)(3) for about 5 to about 160 minutes, which allows the biological preparation to become more concentrated;

(h) increasing the temperature of the container from negative to positive temperature over the course of between 45 and 85 minutes, and holding the pressure constant until reaching about 10° C. to about 20° C.;

(i) reducing container air pressure to accelerate the concentration, and until the container temperature reaches and maintains about 30° C. for about 30 minutes to about 90 minutes;

(j) further reducing pressure to between about 0.5 and about 4.0 mbars, or about 1 mbar, and then maintaining constant pressure until foaming has completed;

(k) further reducing pressure to between about 5 μbar and about 100 μbar, while maintaining the temperature at about 30° C. for about 400 to about 2400 or more minutes, until the desired moisture of between about 0.5% to about 15% is obtained;

(l) stoppering the vials while in the freeze-dryer container, thereby completing the vitrification process.

9. The process of claim 8 , wherein the active biologic ingredient is a live virus.

10. The process of claim 9 , wherein active biologic ingredient is a live attenuated virus.

11. The process of claim 9 , wherein the virus is canine distemper virus (CDV), canine parainfluenza virus type 2 (PI2), or combinations thereof.

12. The process of claim 9 , wherein the attenuated virus is canarypox, Marek's disease virus, infectious bursal disease virus, west nile virus (WNV) or feline leukemia virus (FeLV).

13. The process of claim 1 , wherein the aspartic acid is present, and is present in an amount of about 0.20% to about 0.50% w/v of the stabilizer.

14. The process of claim 13 , wherein the aspartic acid is present in an amount of about 0.20% w/v of the stabilizer.

15. The process of claim 13 , wherein the aspartic acid is present in an amount of about 0.40% w/v of the stabilizer.

16. The process of claim 13 , wherein the aspartic acid is present in an amount of about 0.50% w/v of the stabilizer.

17. The process of claim 2 , wherein the aspartic acid is present, and is present in an amount of about 0.20% to about 0.50% w/v of the stabilizer.

18. The process of claim 17 , wherein the aspartic acid is present, and is present in an amount of about 0.20% w/v of the stabilizer.

19. The process of claim 17 , wherein the aspartic acid is present, and is present in an amount of about 0.40% w/v of the stabilizer.

20. The process of claim 17 , wherein the aspartic acid is present, and is present in an amount of about 0.50% w/v of the stabilizer.