Methods for producing vaccine adjuvants

1. A method for manufacture of an oil-in-water emulsion vaccine adjuvant comprising squalene and a surfactant, said method comprising steps of:

(i) mixing emulsion components to form a first emulsion comprising squalene and a surfactant and having an average oil droplet size of 5000 nm or less;

(ii) microfluidizing the first emulsion to form a second emulsion having an average oil droplet size which is 500 nm or less; and

(iii) filtering the second emulsion using a hydrophilic polyethersulfone asymmetric membrane, thereby providing a vaccine adjuvant.

2. The method of claim 1 , further comprising prefiltering the second emulsion through a polyethersulfone membrane prior to step (iii).

3. The method of claim 2 , wherein the prefiltration membrane is porous.

4. The method of claim 2 , wherein the prefiltering step[s ] are carried out using a double-layer filter comprising first and second layers.

5. The method of claim 4 , wherein (a) the first layer has a pore size ≧0.3 μm, and/or (b) the second layer has a pore size <0.3 μm.

6. The method according to claim 1 , wherein the number of oil droplets having a size of >1.2 μm in the first emulsion is 5×10 11 /ml or less.

7. The method according to claim 1 , wherein the second average oil droplet size is 500 nm or less.

8. The method according to claim 1 , wherein the number of oil droplets having a size of >1.2 μm in the second emulsion is 5×10 10 /ml or less.

9. The method according to claim 1 , wherein the average oil droplet size after filtration is less than 220 nm.

10. The method according to claim 1 , wherein the number of oil droplets having a size of >1.2 μm after filtration is 5×10 8 /ml or less.

11. A method for preparing a vaccine composition, comprising preparing an emulsion adjuvant according to claim 1 and combining the emulsion adjuvant with an antigen.

12. The method of claim 11 , wherein the emulsion adjuvant is a bulk adjuvant and the method comprises extracting unit doses from the bulk adjuvant for packaging as kit components.

13. The method of claim 11 , wherein the antigen is an influenza virus antigen.

14. The method of claim 13 , wherein the combination of the emulsion and the antigen forms a vaccine composition, said composition comprising about 15 μg, about 10 μg, about 7.5 μg, about 5 μg, about 3.8 μg, about 3.75 μg, about 1.9 μg, or about 1.5 μg of hemagglutinin per influenza virus strain.

15. The method of claim 13 , wherein the combination of the emulsion and the antigen forms a vaccine composition, wherein the vaccine composition comprises thiomersal or 2-phenoxyethanol preservative.

16. A method for preparing a vaccine kit comprising preparing an emulsion adjuvant according to claim 1 and packaging the emulsion adjuvant into a kit as a kit component together with an antigen component.

17. The method of claim 16 , wherein the kit components are in separate vials.

18. The method of claim 17 , wherein the vials are made from borosilicate glass.

19. A method for manufacture of an oil-in-water emulsion vaccine adjuvant comprising squalene and a surfactant, said method comprising steps of:

(i) mixing emulsion components to form an emulsion comprising squalene and a surfactant and having an average oil droplet size of 500 nm or less;

(ii) filtering the emulsion using a hydrophilic polyethersulfone double-layer filter which has a first membrane layer with larger pores and a second membrane layer with smaller pores, thereby providing a vaccine adjuvant.

20. A method for manufacturing a pharmaceutically acceptable composition comprising an oil-in-water emulsion, said method comprising:

(a) mixing emulsion components to form an oil-in-water emulsion having an average oil droplet size below 1 μm;

(b) prefiltering the oil-in-water emulsion using a hydrophilic polyethersulfone filtration membrane; and

(c) filtering the prefiltered oil-in-water emulsion obtained in step (b) using a hydrophilic polyethersulfone filtration membrane.