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Conventional methods of
animal vaccine production


       Submitted by:
        Dr. Vijayata
       (dr.viz.vet@gmail.com)
                                1
Pathogen

                                            Inactivation                               Culture
                                                                                                   Attenuation
                                                                                        Ag
                                                                                    Purification
                                                                                                    Seed (Live
        VACCINE                             Purification                                            attenuated)
                                                                                    Inactivation
           wP,
           HAV                                                                                       Culture
                                                                                     VACCINE
                                             VACCINE
                                                                                aP
                                                                                                     VACCINE
                                              Rab,Flu
                                                                                                    MMR,OPV




Ada G. The immunology of vaccination. In: Plotkin SA, Orenstein WA. Vaccines. 4th
ed. Philadelphia, PA: Saunders, 2003:31-45. Principles of Vaccination

Veterinary Immunology by Tizard
Types of Vaccine Manufacturing Methods



      Egg Based Vaccine
        Production




                             Cell Culture Based
                                Vaccine Production

                                                                       3
Recommendations for production and control of influenza vaccine ,WHO
Vaccine production methods
     Bacterial Vaccine:

             Diseases                                          Vaccines                                Methods of Production
 Dipthera                                   DTaP, DTaP/Hib, Tdap                                                    Cell based
 Hemophilus infl uenza                      Hib, DTaP/Hib, Hib/Hepatitis                                            Cell based
 type B (Hib)
 Pertussis (whooping                        DTaP, DTaP/Hib, Tdap                                                    Cell based
 cough)
 Pneumococcal                               Pneumococcal conjugate                                                  Cell based
                                            (Heptavalent)
 Tetanus                                    DTaP, DTaP/Hib, Tdap                                                    Cell based
 Meningococcal                              Meningococcal conjugate                                                 Cell based
                                            (quadravalent)

 Meningococcal                              Meningococcal polysaccharide                                            Egg based
                                            (quadravalent)
                                                                                                                                             4
Source : Center for Disease Control and Prevention. VFC: Approved Vaccines and Biologicals. www.cdc.gov/vaccines/programs/vfc/parents/apprvd -
vaccs.htm [accessed September 8, 2007].
Viral Vaccine:

               Diseases                                              Vaccines                                 Methods of Production
 Hepatitis A                                  Hepatitis A (pediatric)                                                    Cell based
 Hepatitis B                                  Hepatitis B (pediatric/adolescent)                                         Cell based

 Hepatitis B                                  Hib/Hepatitis B                                                            Cell based

 Poliomyelitis (polio)                        IPV (Inactivated poliovirus vaccine)                                       Cell based
                                              OPV (Oral polio vaccine)
 Rotavirus                                    Rotavirus                                                                  Cell based
 Influenza (Flu)                              Influenza                                                                  Egg based
 Measles                                      MMR, measles                                                               Egg based
 Mumps                                        MMR, Mumps                                                                 Egg based
 Rubella (German measles)                     MMR, rubella                                                               Egg based

 Varicella (chicken pox)                      Varicella                                                                  Egg based
                                                                                                                                             5
Source : Center for Disease Control and Prevention. VFC: Approved Vaccines and Biologicals. www.cdc.gov/vaccines/programs/vfc/parents/apprvd -
vaccs.htm [accessed September 8, 2007].
Steps in vaccine production

              Upstream                                                                           Downstream
             processing                                                                           processing


Selecting
                                                           Harvesti
   the                        Growing                                                  Inactivati
                                                             ng &                                                                                  Quality
 strains                         the                                                     on and                     Formulat
                                                           purificati                                                                              control
   for                         micro-                                                   splitting                     ion of
                                                             on of                                                                                 and lot
 vaccine                      organism                                                     of                        vaccine
                                                           microorg                                                                                release
productio                         s                                                    organism
                                                            anisms
    n




                                                                                                                                                           6
Novel Techniques in the Production of Industrially Imperative Products, Sameera V* Biotechnology Department, REVA Institute of Science and Technology, Bangalore
SELECTING THE STRAINS FOR VACCINE
                             PRODUCTION



    • Manufacturing begins with small amounts of a specific
      Virus/Bacteria (seed).
    • Viruses/Bacteria used in manufacture shall be derived
      from a Seed Lot System.
    • The virus/Bacteria must be free of impurities, including
          other similar viruses/ bacteria and even variations of the
      same type of virus/Bacteria.
    • The seed shall pass the tests for sterility and freedom
          from mycoplasma.
                                                                                                                                                                 7
Eurropean medical agency guide line for General requirements for the production and control of live mammalian bacterial and viral vaccines for veterinary use (7BIm1a)
• A record of the origin, passage history (including purification
  and characterisation procedures) and storage conditions should
  be maintained for each Seed Lot.
• The seed must be kept under "ideal" conditions, usually frozen,
  that prevent the virus from becoming either stronger or weaker
  than desired.

Selecting the seed (Strain) used for vaccine production

• The choice of strain depends on a number of factors including
  the efficacy of the resulting vaccine, and its secondary effects.
• If possible, the bacterial strain or cell line should be obtained
  from a recognized culture collection with an established and
  documented provenance.
                                                                                                      8
     The annual production cycle for influenza vaccine:Catherine Gerdil∗Vaccine 21 (2003) 1776–1779
• Alternatively, if the chosen vaccine strain is an “in house”
  clinical isolate, it will be necessary to compile a complete history
  of the strain, including details of its isolation, identification, and
  maintenance for product registration.


Standardizing the seed strains for vaccine production

• Once the candidate seed strains for vaccine production have been
  prepared, their antigens undergo identity testings and to evaluate
  their suitability for vaccine production.
• This includes satisfactory yields when grown in embryonated
  eggs/ cell culture and antigenic stability throughout serial
  passage in eggs as well as the inactivation and purification
  processes.                                                       9
  The annual production cycle for influenza vaccine: Catherine Gerdil∗Vaccine 21 (2003) 1776–1779
GROWING THE MICROORGANISMS

   • Once the production strain for each vaccine component has been
     selected, bulk vaccine production can begin.
   • Bulk production begins with the cultivation of the virus or Bacteria
     in a fermenter equipped with numerous process parameters to
     control temperature, pH, dissolved oxygen, and other factors.

                                    Growing    • Batch culture
    Growing the                     Bacteria   • Continuous culture
    microorganisms
    in maximum
    titre are mainly
    classified in
    two category :                  Growing    • Cell (tissue) cultures
The BRIDGE,Cell-Culture-Based       Viruses    • Embryonated Eggs         10
Vaccine Production: Rino Rappuoli
p 26-27,
• Bacteria are grown in
                                                             bioreactors e.g. Haemophilus
                                                             influenza type b.
               Growing
               Bacteria                                       • Batch culture
                                                              • Continuous culture




Production of Freeze-dried Brucella abortus Strain 19 Vaccine using Cells produced by Continuous Culture† K. J. Boyce, A. W. Edgar, Journal of
Applied Microbiology, Volume 29, Issue 2, pages 401–408, August 1966
                                                                                                                                    11
                  VACCINE PRODUCTION AS A UNIT PROCESS,PROF.DR.T.O. WIKE'N,1971 Chapter 3.3,pp65-71
Batch culture


   • The micro-organism are grown in a closed
     vessel.
   • All the raw materials are put in the fermenter at
     the start and then the micro-organism is added.
   • The system is then left for a long time –
     possibly a week – until all the raw materials
     have been used up and there is loads of the
     product.
   • The fermenter is then emptied and other
     processes are used to separate the product from
     the micro-organism.

                                                                                                                        12
                                                                                                VACCINE PRODUCTION AS A UNIT
                                                                                                PROCESS,PROF.DR.T.O.
The tularaemia vaccine: review. Sandstrom, G. Journal of Chemical Technology & Biotechnology.
                                                                                                WIKE'N,1971 Chapter 3.3,pp65-71
Vol. 59, no. 4, pp. 315-20. Apr. 1994
Continuous culture


       • The micro-organism are grown in an open system.
       • Continuous culture aims to keep a culture growing
            indefinitely. This can be done if:
              • fresh nutrients are continually supplied
              • Accumulated cells and waste products are removed at the
                  same rate
              • Conditions such as temperature and pH are kept at their
                  optimum values.
The tularaemia vaccine: review. Sandstrom, G. Journal of Chemical Technology & Biotechnology. Vol. 59, no. 4, pp. 315-20. Apr. 199413
                 VACCINE PRODUCTION AS A UNIT PROCESS,PROF.DR.T.O. WIKE'N,1971 Chapter 3.3,pp65-71
Here the raw materials are
  trickled in at the top of a
  column in which there are
  immobilised micro-
  organisms.
• The product flows out the
  bottom in a pure state.
• However this process can
  only be used for reactions
  that are fast – possibly taking
  10 minutes.
• E.g. - in the cultivation of
  Corynebacterium diphtheriae


                                                                                           14
       VACCINE PRODUCTION AS A UNIT PROCESS,PROF.DR.T.O. WIKE'N,1971 Chapter 3.3,pp65-71
• Viruses are grown either on
                                                               primary cells e.g.for influenza, or
              Growing                                          on continuous cell lines,e.g.
                                                               for hepatitis A.
              Viruses                                        • Cell culture
                                                             • Embryonated Eggs




                                                                                                                                    15
Recommendations for production and control of influenza vaccine ,WHO   OIE Terrestrial Manual 2010 C H A P T E R 2 . 8 . 8 . SWINE INFLUENZA,
Cell culture


• Cell culture is the complex process by which cells are grown
  under controlled conditions, generally outside of their natural
  environment.

• Cell cultures are separated into 3 types:-
   - Primary cell culture
   - Secondary cell culture
   - Continuous cell line


                                                                                                            16
                   Mammalian Cell Culture Technology: An Emerging Field ,D. Eibl, R. Eibl, and R. Pörtner
Primary cell culture-
•   Cells that are cultured directly from animal or human tissues and
    can be subcultured only once or twice . e.g. Primary monkey
    kidney cell
• For most of the mammalian vaccines the use of primary cells is
  not acceptable for the manufacture of vaccines.
• If a vaccine has to be produced on primary cells, they should be
  obtained from a SPF herd or flock with complete protection
  from introduction of diseases.


Secondary cell culture-
•   are derived from human fetal tissue and can be subcultured 20 to
    50 times e.g. Human diploid fibroblasts such as MRC-5

                                                                                                              17
                     Mammalian Cell Culture Technology: An Emerging Field ,D. Eibl, R. Eibl, and R. Pörtner
Continuous cell lines –
• a single cell type that can propagated indefinitely in culture.
• e.g. Vero cells, Hep2

Cell Line Selection :
• If a cell line is used for the manufacture of vaccines it shall
  normally be produced according to a Seed Lot System.
• The history of the cell line must be known in detail (e.g. origin,
  number of passages and media used for their multiplication,
  storage conditions).
• The cell line used to cultivate the virus must be able to propagate
  the virus in large quantities , rapid, efficient in expressing the
  desired virus, and suitable for a wide variety of virus strains.
• The cells must be checked for their appearance , rate of growth
  and for contamination with bacteria, virus, fungi, mycoplasma.
                                                                                                  18
                       The BRIDGE,Cell-Culture-Based Vaccine Production: Rino Rappuoli p 26-27,
• Preparation of a cell line for propagation begins with the
  thawing of the cell line seed lot (e.g., EBx™, VERO, or
  MDCK).
• Cell line propagation begins with the small scale pre-culture
  propagation of seed cells after thawing.
• The cells are then introduced to the fermenter vessel with the
  selected nutrient medium.
• When the cell line reaches a predetermined cell density, the
  virus is introduced and begins to propagate in the cell line.
• Two methods of mass cultivation of cells are recognized in the
  industry today, microcarrier cultures and free-cell
  suspension cultures.
• Both systems begin cultivation of the cell line in a fermenter,
  which can be scaled up to thousands of liters.
                                                                                                19
                     The BRIDGE,Cell-Culture-Based Vaccine Production: Rino Rappuoli p 26-27,
In microcarrier systems-
• Cells are anchorage dependent and grow on solid or macroporous
   microcarriers. (microbeads.)
• Cell expansion often occurs in roller-flasks.
• In the presence of nutrient media, the cells grow and proliferate
   covering the beads uniformly.
• Microbeads provide a high surface-area-to-volume ratio, which
   can lead to high cell densities.
• Once a bead is covered, the cells are dislodged, dispersed, and
   allowed to reattach to achieve another round of cell growth on
                       the surface of the bead.




                                                                                            20
                           The BRIDGE,Cell-Culture-Based Vaccine Production: Rino Rappuoli p 26-27,
Suspension culture -
• Suspension cultures are derived from cells that can survive and
  proliferate without attachment (on-adherent)
• These cells are maintained by continuous stirring with a magnet
  and can multiply while suspended in a suitable medium.
• Larger volumes of media are required because the cell line
  proliferates while growing freely suspended in the nutrient
  medium.
• However, the scaling up of the system is easier, and there is no
  limit to the volume.




                                                                                        21
                        The BRIDGE,Cell-Culture-Based Vaccine Production: Rino Rappuoli p 26-27,
Embryonated Eggs

     • If the vaccine is to be produced in embryonated eggs, the eggs to
       be used should be from closed, specific-pathogen-free, healthy
       flocks.
     • This flock shall be monitored at regular intervals for Bacteria,
       Virus and Mycoplasma.
     • Many viruses can be propagated in embryonated chicken eggs
       but the method is now only used for Influenza viruses.
     • At 5 to 14 days after fertilization, a hole is drilled in the shell
       and virus injected into the site appropriate for its replication
       (yolk sac, chorioallantoic membrane, amniotic cavity, allantoic
       cavity).
     • The eggs are incubated at about 33 C for 2 to 3 days, candled
       for viability and lack of contamination from the inoculation, and
       then the allantoic fluid is harvested.
                                                                                                           22
RECOMMENDATIONS FOR PRODUCTION AND CONTROL OF INFLUENZA VACCINE (INACTIVATED) WORLD HEALTH ORGANIZATION)
Herpes simplex
                                                                              virus
                                                                              Pox virus
                                                                              Rous sarcoma
                                                                              virus


                                                                            Influenza virus
                                                                            Mumps virus


                                                                          Influenza virus
                                                                          Mumps virus
                                                                          New castle disease
                                                                          virus
                                                                          Avian adenovirus



                                                              Herpes simplex virus
          GROWTH OF VIRUSES IN EMBRYONATED EGG –
An embryonated chicken egg showing the different compartments in which viruses
  may grow. The different routes by which viruses are inoculated into eggs are
                                   indicated.                                23
                                       http://www.virology.ws/2009/12/10/influenza-virus-growth-in-eggs/
Harvesting & Purification of
                            microorganism
       • After propagation, the virus is harvested.
       • Harvesting of virus is largely a manual process that requires
         extracting infected cells, breaking down cell walls, and then
         collecting the virus.
       • After treatment of the infected cell line, the virus is released
         into the supernatant, and the cellular debris is centrifuged
         away by use of appropriate Centrifugation method.

       • Purification selectively separates and retains the desired
         product at the highest purity per its pre-determined
         specification. (Remove unwanted compounds)
                                                                                                                                     24
An international technology platform for influenza vaccines: Jan Hendriksa,∗, Marit Hollemanb, Otto de Boerb, Patrick de Jongc, Willem Luytjesb
Centrifugation:
    • Centrifugation is a process by which solid particles are
      sedimented and separated from a liquid using
      centrifugal force as a driving force.
    • Centrifugation is used to separation and purification of
      pathogenic virus antigens and other agents used in the
      production of vaccine.
    • Centrifugation is also used to remove dead cells, cell
      debris etc.
    Example : Influenza vaccine, rabies vaccine , Hepatitis B
      vaccine, and Japanese encephalitis vaccine production.



                                                                                                  25
An international technology platform for influenza vaccines                          Filtration Technique in
Jan Hendriksa,∗, Marit Hollemanb, Otto de Boerb, Patrick de Jongc, Willem Luytjesb   Vaccine Manufacturing
Chromatography
  • A group of physical separation techniques, which are
    characterized by the separation of mixtures due to differences
    in the distribution coefficient of sample components between
    two phases, one stationary and the other mobile phase.
  • Example : Modified Vaccinia Ankara virus (Small pox
    vaccine)
  Filtration
  • Filtration is a process for separating two substances of two
     different physical states. It is used for separating solids from
     turbid liquids (filtrate), pure gases or solids.
  • Separation of particles from liquid by applying a pressure to the
    solution to force the solution through a filter.        Filtration Technique in
                                                                                     Vaccine Manufacturing
                                                                                                 26
An international technology platform for influenza vaccines
Jan Hendriksa,∗, Marit Hollemanb, Otto de Boerb, Patrick de Jongc, Willem Luytjesb
Inactivation And splitting of
                microorganism

• Following purification, the virus is inactivated through a
  chemical process.
• After inactivation, the whole virus can be purified, split, and ultra
  purified as a “subunit.”
• Virus splitting follows because only fractions of specific viral
  surface proteins are required for the subsequent vaccine.
  (influenza )
• Further purification procedures are then performed.
• At this point, the development phase of vaccine is complete.

                                                                                         27
                         The BRIDGE,Cell-Culture-Based Vaccine Production: Rino Rappuoli p 26-27,
KILLED / INACTIVATED VACCINE


• The term killed generally refers to bacterial vaccines, whereas
  inactivated relates to viral vaccines (Levine et al., 1997).
• For viruses, the outer virion coat should be left intact but the
  replicative function should be destroyed.
• Virus inactivation works by one of the following two
  mechanisms:
   - By attacking the viral envelope or capsid and destroying
      its ability to infect or interact with cells.
   - By disrupting the viral DNA or RNA and preventing
      replication.
• Killed vaccines may take the route of heat or chemicals (Turner
  et al., 1970).
                                                                                                                                       28
 The Biomedical Engineering Handbook: Second Edition. Ed. Joseph D. Bronzino ,Aunins, J. G., Lee. A. L.,Volkin, D. B. “Vaccine Production.”
Chemical treatment -
       • The chemicals used for killed vaccines include formaldehyde
         or beta-propiolactone (Lo Grippo, 1960; Gard, 1960).
       • The traditional agent for inactivation of the virus is formalin
         (Weil & Gall, 1940; Kim & Sharp, 1967).
       • The agent is chosen for effectiveness without destruction of
         antigenicity.
       • For whole organisms, the inactivation abolishes infectivity.
       • For antigens such as the diphtheria and tetanus toxins,
         formaldehyde treatment removes the toxicity of the antigen
         itself as well as killing the organism.
       • Such detoxified antigen, called toxoids, are safe for use in
         vaccines.
                                                                                                                                          29
Recombination and Point Mutations in Type G Rotavirus Strains: The Challenges of Vaccine Development, Abid Nabil Ben Salem1, Rouis Zyed1, Buesa
Javier2 and Aouni Mahjoub1
Solvent/detergent (S/D) inactivation –

      • Effective with lipid-coated viruses.

      • The detergents used in this method, Disrupts the interactions
           between molecules in the lipid coat , rendering the coat
           dysfunctional and impeding replication.

      • Most enveloped viruses cannot live without their lipid coating,
           so they die when exposed to these detergents. Other viruses
           may still live, but they are unable to reproduce, rendering them
           non-infective.

      • The detergent typically used is Triton-X 100.
                                                                                                                                   30
The Biomedical Engineering Handbook: Second Edition. Ed. Joseph D. Bronzino ,Aunins, J. G., Lee. A. L.,Volkin, D. B. “Vaccine Production.”
By Heat -
       A physical inactivation method that leaves intact virus, bacteria.
       The heat inactivates the infectious agents, by destroying there
      surface antigen.
       Heat inactivation usually done at 56 C for 30 minutes.
      e.g. A normal suspension of pertussis cells contains a thermolabile
         toxin that is inactivated by heating at 56 C for 10 minutes.
       Ultraviolet (UV) inactivation -
      • UV rays can be used to inactivate viruses since virus particles
        are small and the UV rays can reach the genetic material,
        inducing the dimerisation of nucleic acids.
      •     Once the DNA dimerised, the virus particles cannot replicate
           their genetic material.                                       31
The Biomedical Engineering Handbook: Second Edition. Ed. Joseph D. Bronzino ,Aunins, J. G., Lee. A. L.,Volkin, D. B. “Vaccine Production.”
LIVE WHOLE VACCINES:


      Several methods have been used to attenuate viruses for vaccine
          production.
     a) Use of a related microorganism from another animal -
     The earliest example was the use of cowpox to prevent smallpox.


     b) Administration of pathogenic or partially attenuated
            microorganism by an unnatural route -
     The virulence of the virus is often reduced when administered by an
      unnatural route.
                                                                                                                                          32
Recombination and Point Mutations in Type G Rotavirus Strains: The Challenges of Vaccine Development, Abid Nabil Ben Salem1, Rouis Zyed1, Buesa
Javier2 and Aouni Mahjoub1
c) Passage of the microorganism in an "unnatural host" or
        host cell

     • The major vaccines used in man and animals have all been
       derived this way.
     • Example :
       - the 17D strain of yellow fever was developed by passage in
          mice and then in chick embryos
                                          (Norrby, 2007).
       - Polioviruses were passaged in monkey kidney cells
                                         (Chezzi et al., 1998).
       - Measles in chick embryo fibroblasts
                                               (Katz, 1958).
                                                                                                                                          33
Recombination and Point Mutations in Type G Rotavirus Strains: The Challenges of Vaccine Development, Abid Nabil Ben Salem1, Rouis Zyed1, Buesa
Javier2 and Aouni Mahjoub1
Formulation of vaccine
Finally, the vaccine is formulated by adding adjuvant, stabilizers, and preservatives as
needed.Other than microorganism or its part (antigen), a vaccine contain the following
components:

Component             Purpose              Example             Example of Vaccines

Adjuvants      Enhance the immune       Aluminium salts   Diphtheria-pertussis-tetanus
               response to a vaccine    (Alum)            Diphtheria tetanus(DT)
                                                          DT combined with Hepatitis B
                                                          (HBV)
                                                          Haemophilus influenza B
                                                          Inactivated polio virus(IPV)
                                                          Hepatitis A (HAV)

Preservatives Prevent bacterial or      Thimerosal        Diphtheria-tetanus-acellular
              fungal contamination of                     pertussis (DTaP)
              vaccine                                     Hepatitis B,
                                                          Haemophilus influenza type B
                                                          (Hib).                       34
Compone                                                                 Example of
                         Purpose                        Example
   nt                                                                    Vaccines
Stabilizers   Protects vaccines from adverse      Gelatine,         17D Yellow Fever
              conditions such as freeze-drying    Monosodium        virus vaccine,
              or heat, thereby maintaining a      glutamate (MSG)   Rabies,Varicella
              vaccine’s potency
              Inactivating agents - used to       Formaldehyde      Influenza virus,
              inactivate bacterial products for                     Poliovirus, Diphtheria
              toxoid vaccines, to kill                              and Tetanus toxins.
              unwanted viruses and bacteria       β-propiolactone
                                                                    Rabies virus
              that might contaminate the
                                                  Glutaraldehyde
Residuals     vaccine during production                             Acellular pertussis
from        Antibiotics - prevent bacterial                         DTaP-IPV/Hib
                                                  Neomycin,
manufactur contamination during
                                                  Streptomycin,     Influenza, MMR
ing process manufacturing process
                                                  Polymyxin B

                                                                    Influenza and yellow
              Suspending fluids –                 Egg proteins
                                                                    fever vaccines
              kill or weaken the organism for
                                                                    Hepatitis B vaccines
              use in vaccines.
                                                  Yeast proteins
QUALITY CONTROL AND LOT RELEASE
                      Schedule of final product testing for a veterinary vaccine

           Test                                            Purpose of Test
Sterility                     Demonstrates that no live microorganisms are present in product
Safety                        Demonstrates that overdose of the product causes no harm
Residual toxicity             Demonstrates that the product contains no material that can cause harm

Efficacy                      Demonstrates that each antigen in the product meets the recommended
                              guideline level in internationally recognised tests.
Increase in                   With live vaccines, there is concern that the organism might be shed from
virulence tests               the host and transmitted to contact animals, causing disease if it retains
                              residual virulence or reverts to virulence.
                              All live vaccines should be tested for virulence by means of passage
                              studies.
Interference tests            For products with two or more antigenic components, tests must confirm
                              that there is no interference between individual components, that is, one
PRINCIPLES OF
VETERINARY VACCINE            component causing a decrease in the protective immunological response
PRODUCTION, OIE Terrestrial                                                                             36
Manual 2008
                              to another component.
Lot release
BATCH/SERIAL RELEASE FOR DISTRIBUTION :

Prior to release, the manufacturer must test each
batch/serial for purity, safety, and potency.



                                      1. Batch purity test –
                                      Purity is determined by testing for a
                                      variety of contaminants.
                                      Tests to detect contaminants are
                                      performed on: master seeds, primary
                                      cells, MCSs(Master cell stock), and
                                      each batch of final product prior to
                                      release.                          37
                      PRINCIPLES OF VETERINARY VACCINE PRODUCTION, OIE Terrestrial Manual 2008
2. Batch safety test -
Batches are considered satisfactory if local and
systemic reactions to vaccination with the batch to
be released are in line with those described in the
registration dossier and product literature.




                                   3. Batch potency test -
                                   Batch/serial potency tests, required for
                                   each batch prior to release, are
                                   designed to correlate with the host
                                   animal vaccination–challenge efficacy
                                   studies.                            38
                      PRINCIPLES OF VETERINARY VACCINE PRODUCTION, OIE Terrestrial Manual 2008
Sampling :
  Samples should be selected from each batch/serial
  of product.
  The selector should pick representative sample.

Filling , Packaging and Labelling
Once all procedures of vaccine production are completed, the
vaccine is blended, filled the doses into vials and packaged.
Which are then sealed and carefully inspected before labels are
applied to show the vaccine batch,lot numbers, and expiration
date.
Standards for labelling products will vary from country to
   country.
                Field tests (safety and efficacy)

               Performance monitoring                                                 39
                     PRINCIPLES OF VETERINARY VACCINE PRODUCTION, OIE Terrestrial Manual 2008
Processes of Egg-Based Vaccine Production

   Embryonated
   chicken eggs                             Inoculation                                 Incubation

    The upstream                         A seed ampoule                          This is followed by a 3
   process, begins                           is used to                          day incubation period
  with embryonated                        inoculate the                          during which the virus
   eggs brought in                          chick eggs                            grows to ensure that
   on a daily basis                          during the                            sufficient quantities
   from biosecure                           inoculation                            can support further
        flocks.                                phase.                                manufacturing.



                                Harvest (pool                                            Candling
                                allantoic fluid)
                                                                             After 3 days, all of the eggs are
                               The allantoic fluid is                      candled to make sure there are no
                             then harvested; a low-                        cracks or contamination; the eggs
Clarification                   speed clarification                           are then chilled to 2° to 8°C to
                                  process follows.                             constrict vessels and make
                                                                                    harvesting easier.         40
The BRIDGE, Egg-Based Production ofInfluenza Vaccine:James T. Matthews page 21
1st inactivation                Filtration                 Concentration

 The first step in the
                                                                                 Zonal centrifugation
     downstream                  Extensive filtration and concentration
       process is                 steps yield a concentrate, which is
 inactivation, which             then loaded onto zonal centrifugation
     involves the                              equipment.
 addition of formalin
   to inactivate the
         virus.
                                                                                Triton fragmentation
                  2nd   inactivation              Centrifugation


Ultrafiltration                          The material is then                      The first purified
                                               clarified by                     bulk virus, which is
An ultrafiltration                        centrifugation to                     recovered from the
(UF) step is                                remove large                            centrifugation
followed by terminal                      particulates and                       process, is split in
sterile filtration to Sterile filtration      treated with                         a fragmentation
generate one                                 formalin in a                       step by treatment
monovalent bulk                          second inactivation                           with Triton
concentrate.                                      step.                                detergent. 41
                      Final product        The BRIDGE, Egg-Based Production of Influenza Vaccine:James T.
Cell Culture Based Vaccine Production

                                                                                                                                             centrifugation

                                                                     virus
                                  cell                             (production
                                                                      seed)

                                                                                                                                         filtering


             Cell culture                         Inoculation                             Harvest                          Bulk            Purification




                                                                                                                                                   
                                                                                                                                       Add

                                                                                                                               Adjuvant         Stabilizer
                                                                                                                    
                                                                                                                                         Preservative

                 Packaging                    Labeling               Inspection                        Filling                        Formulation

                                                                                                                                                         42
ccines / [edited by] Stanley A. Plotkin, Edward A. Mortimer, Jr.     Influenza Vaccines (Tina Kröber, Thomas Jarosch, and Laura Fischer) Max-Planck-Gesellschaft, Münche
Thank
 you
        43
44
• Production of Freeze-dried Brucella abortus Strain 19 Vaccine
  using Cells produced by Continuous Culture† K. J. Boyce, A. W.
  Edgar ,Journal of Applied Microbiology, Volume 29, Issue 2, pages
  401–408, August 1966
• The tularaemia vaccine: review. Sandstrom, G.
  Journal of Chemical Technology & Biotechnology. Vol. 59, no.
  4, pp. 315-20. Apr. 1994
  The live vaccine can be produced in fermenter cultures and the
  bacteria have to undergo quality controls for each batch of vaccine.
  It is important to estimate the amount of non-immunogenic bacteria
  in each batch and to disclose the immunogenicity of the vaccine in
  man.




                                                                45

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Conventional methods of animal vaccine production

  • 1. Conventional methods of animal vaccine production Submitted by: Dr. Vijayata (dr.viz.vet@gmail.com) 1
  • 2. Pathogen Inactivation Culture Attenuation Ag Purification Seed (Live VACCINE Purification attenuated) Inactivation wP, HAV Culture VACCINE VACCINE aP VACCINE Rab,Flu MMR,OPV Ada G. The immunology of vaccination. In: Plotkin SA, Orenstein WA. Vaccines. 4th ed. Philadelphia, PA: Saunders, 2003:31-45. Principles of Vaccination Veterinary Immunology by Tizard
  • 3. Types of Vaccine Manufacturing Methods Egg Based Vaccine Production Cell Culture Based Vaccine Production 3 Recommendations for production and control of influenza vaccine ,WHO
  • 4. Vaccine production methods Bacterial Vaccine: Diseases Vaccines Methods of Production Dipthera DTaP, DTaP/Hib, Tdap Cell based Hemophilus infl uenza Hib, DTaP/Hib, Hib/Hepatitis Cell based type B (Hib) Pertussis (whooping DTaP, DTaP/Hib, Tdap Cell based cough) Pneumococcal Pneumococcal conjugate Cell based (Heptavalent) Tetanus DTaP, DTaP/Hib, Tdap Cell based Meningococcal Meningococcal conjugate Cell based (quadravalent) Meningococcal Meningococcal polysaccharide Egg based (quadravalent) 4 Source : Center for Disease Control and Prevention. VFC: Approved Vaccines and Biologicals. www.cdc.gov/vaccines/programs/vfc/parents/apprvd - vaccs.htm [accessed September 8, 2007].
  • 5. Viral Vaccine: Diseases Vaccines Methods of Production Hepatitis A Hepatitis A (pediatric) Cell based Hepatitis B Hepatitis B (pediatric/adolescent) Cell based Hepatitis B Hib/Hepatitis B Cell based Poliomyelitis (polio) IPV (Inactivated poliovirus vaccine) Cell based OPV (Oral polio vaccine) Rotavirus Rotavirus Cell based Influenza (Flu) Influenza Egg based Measles MMR, measles Egg based Mumps MMR, Mumps Egg based Rubella (German measles) MMR, rubella Egg based Varicella (chicken pox) Varicella Egg based 5 Source : Center for Disease Control and Prevention. VFC: Approved Vaccines and Biologicals. www.cdc.gov/vaccines/programs/vfc/parents/apprvd - vaccs.htm [accessed September 8, 2007].
  • 6. Steps in vaccine production Upstream Downstream processing processing Selecting Harvesti the Growing Inactivati ng & Quality strains the on and Formulat purificati control for micro- splitting ion of on of and lot vaccine organism of vaccine microorg release productio s organism anisms n 6 Novel Techniques in the Production of Industrially Imperative Products, Sameera V* Biotechnology Department, REVA Institute of Science and Technology, Bangalore
  • 7. SELECTING THE STRAINS FOR VACCINE PRODUCTION • Manufacturing begins with small amounts of a specific Virus/Bacteria (seed). • Viruses/Bacteria used in manufacture shall be derived from a Seed Lot System. • The virus/Bacteria must be free of impurities, including other similar viruses/ bacteria and even variations of the same type of virus/Bacteria. • The seed shall pass the tests for sterility and freedom from mycoplasma. 7 Eurropean medical agency guide line for General requirements for the production and control of live mammalian bacterial and viral vaccines for veterinary use (7BIm1a)
  • 8. • A record of the origin, passage history (including purification and characterisation procedures) and storage conditions should be maintained for each Seed Lot. • The seed must be kept under "ideal" conditions, usually frozen, that prevent the virus from becoming either stronger or weaker than desired. Selecting the seed (Strain) used for vaccine production • The choice of strain depends on a number of factors including the efficacy of the resulting vaccine, and its secondary effects. • If possible, the bacterial strain or cell line should be obtained from a recognized culture collection with an established and documented provenance. 8 The annual production cycle for influenza vaccine:Catherine Gerdil∗Vaccine 21 (2003) 1776–1779
  • 9. • Alternatively, if the chosen vaccine strain is an “in house” clinical isolate, it will be necessary to compile a complete history of the strain, including details of its isolation, identification, and maintenance for product registration. Standardizing the seed strains for vaccine production • Once the candidate seed strains for vaccine production have been prepared, their antigens undergo identity testings and to evaluate their suitability for vaccine production. • This includes satisfactory yields when grown in embryonated eggs/ cell culture and antigenic stability throughout serial passage in eggs as well as the inactivation and purification processes. 9 The annual production cycle for influenza vaccine: Catherine Gerdil∗Vaccine 21 (2003) 1776–1779
  • 10. GROWING THE MICROORGANISMS • Once the production strain for each vaccine component has been selected, bulk vaccine production can begin. • Bulk production begins with the cultivation of the virus or Bacteria in a fermenter equipped with numerous process parameters to control temperature, pH, dissolved oxygen, and other factors. Growing • Batch culture Growing the Bacteria • Continuous culture microorganisms in maximum titre are mainly classified in two category : Growing • Cell (tissue) cultures The BRIDGE,Cell-Culture-Based Viruses • Embryonated Eggs 10 Vaccine Production: Rino Rappuoli p 26-27,
  • 11. • Bacteria are grown in bioreactors e.g. Haemophilus influenza type b. Growing Bacteria • Batch culture • Continuous culture Production of Freeze-dried Brucella abortus Strain 19 Vaccine using Cells produced by Continuous Culture† K. J. Boyce, A. W. Edgar, Journal of Applied Microbiology, Volume 29, Issue 2, pages 401–408, August 1966 11 VACCINE PRODUCTION AS A UNIT PROCESS,PROF.DR.T.O. WIKE'N,1971 Chapter 3.3,pp65-71
  • 12. Batch culture • The micro-organism are grown in a closed vessel. • All the raw materials are put in the fermenter at the start and then the micro-organism is added. • The system is then left for a long time – possibly a week – until all the raw materials have been used up and there is loads of the product. • The fermenter is then emptied and other processes are used to separate the product from the micro-organism. 12 VACCINE PRODUCTION AS A UNIT PROCESS,PROF.DR.T.O. The tularaemia vaccine: review. Sandstrom, G. Journal of Chemical Technology & Biotechnology. WIKE'N,1971 Chapter 3.3,pp65-71 Vol. 59, no. 4, pp. 315-20. Apr. 1994
  • 13. Continuous culture • The micro-organism are grown in an open system. • Continuous culture aims to keep a culture growing indefinitely. This can be done if: • fresh nutrients are continually supplied • Accumulated cells and waste products are removed at the same rate • Conditions such as temperature and pH are kept at their optimum values. The tularaemia vaccine: review. Sandstrom, G. Journal of Chemical Technology & Biotechnology. Vol. 59, no. 4, pp. 315-20. Apr. 199413 VACCINE PRODUCTION AS A UNIT PROCESS,PROF.DR.T.O. WIKE'N,1971 Chapter 3.3,pp65-71
  • 14. Here the raw materials are trickled in at the top of a column in which there are immobilised micro- organisms. • The product flows out the bottom in a pure state. • However this process can only be used for reactions that are fast – possibly taking 10 minutes. • E.g. - in the cultivation of Corynebacterium diphtheriae 14 VACCINE PRODUCTION AS A UNIT PROCESS,PROF.DR.T.O. WIKE'N,1971 Chapter 3.3,pp65-71
  • 15. • Viruses are grown either on primary cells e.g.for influenza, or Growing on continuous cell lines,e.g. for hepatitis A. Viruses • Cell culture • Embryonated Eggs 15 Recommendations for production and control of influenza vaccine ,WHO OIE Terrestrial Manual 2010 C H A P T E R 2 . 8 . 8 . SWINE INFLUENZA,
  • 16. Cell culture • Cell culture is the complex process by which cells are grown under controlled conditions, generally outside of their natural environment. • Cell cultures are separated into 3 types:- - Primary cell culture - Secondary cell culture - Continuous cell line 16 Mammalian Cell Culture Technology: An Emerging Field ,D. Eibl, R. Eibl, and R. Pörtner
  • 17. Primary cell culture- • Cells that are cultured directly from animal or human tissues and can be subcultured only once or twice . e.g. Primary monkey kidney cell • For most of the mammalian vaccines the use of primary cells is not acceptable for the manufacture of vaccines. • If a vaccine has to be produced on primary cells, they should be obtained from a SPF herd or flock with complete protection from introduction of diseases. Secondary cell culture- • are derived from human fetal tissue and can be subcultured 20 to 50 times e.g. Human diploid fibroblasts such as MRC-5 17 Mammalian Cell Culture Technology: An Emerging Field ,D. Eibl, R. Eibl, and R. Pörtner
  • 18. Continuous cell lines – • a single cell type that can propagated indefinitely in culture. • e.g. Vero cells, Hep2 Cell Line Selection : • If a cell line is used for the manufacture of vaccines it shall normally be produced according to a Seed Lot System. • The history of the cell line must be known in detail (e.g. origin, number of passages and media used for their multiplication, storage conditions). • The cell line used to cultivate the virus must be able to propagate the virus in large quantities , rapid, efficient in expressing the desired virus, and suitable for a wide variety of virus strains. • The cells must be checked for their appearance , rate of growth and for contamination with bacteria, virus, fungi, mycoplasma. 18 The BRIDGE,Cell-Culture-Based Vaccine Production: Rino Rappuoli p 26-27,
  • 19. • Preparation of a cell line for propagation begins with the thawing of the cell line seed lot (e.g., EBx™, VERO, or MDCK). • Cell line propagation begins with the small scale pre-culture propagation of seed cells after thawing. • The cells are then introduced to the fermenter vessel with the selected nutrient medium. • When the cell line reaches a predetermined cell density, the virus is introduced and begins to propagate in the cell line. • Two methods of mass cultivation of cells are recognized in the industry today, microcarrier cultures and free-cell suspension cultures. • Both systems begin cultivation of the cell line in a fermenter, which can be scaled up to thousands of liters. 19 The BRIDGE,Cell-Culture-Based Vaccine Production: Rino Rappuoli p 26-27,
  • 20. In microcarrier systems- • Cells are anchorage dependent and grow on solid or macroporous microcarriers. (microbeads.) • Cell expansion often occurs in roller-flasks. • In the presence of nutrient media, the cells grow and proliferate covering the beads uniformly. • Microbeads provide a high surface-area-to-volume ratio, which can lead to high cell densities. • Once a bead is covered, the cells are dislodged, dispersed, and allowed to reattach to achieve another round of cell growth on the surface of the bead. 20 The BRIDGE,Cell-Culture-Based Vaccine Production: Rino Rappuoli p 26-27,
  • 21. Suspension culture - • Suspension cultures are derived from cells that can survive and proliferate without attachment (on-adherent) • These cells are maintained by continuous stirring with a magnet and can multiply while suspended in a suitable medium. • Larger volumes of media are required because the cell line proliferates while growing freely suspended in the nutrient medium. • However, the scaling up of the system is easier, and there is no limit to the volume. 21 The BRIDGE,Cell-Culture-Based Vaccine Production: Rino Rappuoli p 26-27,
  • 22. Embryonated Eggs • If the vaccine is to be produced in embryonated eggs, the eggs to be used should be from closed, specific-pathogen-free, healthy flocks. • This flock shall be monitored at regular intervals for Bacteria, Virus and Mycoplasma. • Many viruses can be propagated in embryonated chicken eggs but the method is now only used for Influenza viruses. • At 5 to 14 days after fertilization, a hole is drilled in the shell and virus injected into the site appropriate for its replication (yolk sac, chorioallantoic membrane, amniotic cavity, allantoic cavity). • The eggs are incubated at about 33 C for 2 to 3 days, candled for viability and lack of contamination from the inoculation, and then the allantoic fluid is harvested. 22 RECOMMENDATIONS FOR PRODUCTION AND CONTROL OF INFLUENZA VACCINE (INACTIVATED) WORLD HEALTH ORGANIZATION)
  • 23. Herpes simplex virus Pox virus Rous sarcoma virus Influenza virus Mumps virus Influenza virus Mumps virus New castle disease virus Avian adenovirus Herpes simplex virus GROWTH OF VIRUSES IN EMBRYONATED EGG – An embryonated chicken egg showing the different compartments in which viruses may grow. The different routes by which viruses are inoculated into eggs are indicated. 23 http://www.virology.ws/2009/12/10/influenza-virus-growth-in-eggs/
  • 24. Harvesting & Purification of microorganism • After propagation, the virus is harvested. • Harvesting of virus is largely a manual process that requires extracting infected cells, breaking down cell walls, and then collecting the virus. • After treatment of the infected cell line, the virus is released into the supernatant, and the cellular debris is centrifuged away by use of appropriate Centrifugation method. • Purification selectively separates and retains the desired product at the highest purity per its pre-determined specification. (Remove unwanted compounds) 24 An international technology platform for influenza vaccines: Jan Hendriksa,∗, Marit Hollemanb, Otto de Boerb, Patrick de Jongc, Willem Luytjesb
  • 25. Centrifugation: • Centrifugation is a process by which solid particles are sedimented and separated from a liquid using centrifugal force as a driving force. • Centrifugation is used to separation and purification of pathogenic virus antigens and other agents used in the production of vaccine. • Centrifugation is also used to remove dead cells, cell debris etc. Example : Influenza vaccine, rabies vaccine , Hepatitis B vaccine, and Japanese encephalitis vaccine production. 25 An international technology platform for influenza vaccines Filtration Technique in Jan Hendriksa,∗, Marit Hollemanb, Otto de Boerb, Patrick de Jongc, Willem Luytjesb Vaccine Manufacturing
  • 26. Chromatography • A group of physical separation techniques, which are characterized by the separation of mixtures due to differences in the distribution coefficient of sample components between two phases, one stationary and the other mobile phase. • Example : Modified Vaccinia Ankara virus (Small pox vaccine) Filtration • Filtration is a process for separating two substances of two different physical states. It is used for separating solids from turbid liquids (filtrate), pure gases or solids. • Separation of particles from liquid by applying a pressure to the solution to force the solution through a filter. Filtration Technique in Vaccine Manufacturing 26 An international technology platform for influenza vaccines Jan Hendriksa,∗, Marit Hollemanb, Otto de Boerb, Patrick de Jongc, Willem Luytjesb
  • 27. Inactivation And splitting of microorganism • Following purification, the virus is inactivated through a chemical process. • After inactivation, the whole virus can be purified, split, and ultra purified as a “subunit.” • Virus splitting follows because only fractions of specific viral surface proteins are required for the subsequent vaccine. (influenza ) • Further purification procedures are then performed. • At this point, the development phase of vaccine is complete. 27 The BRIDGE,Cell-Culture-Based Vaccine Production: Rino Rappuoli p 26-27,
  • 28. KILLED / INACTIVATED VACCINE • The term killed generally refers to bacterial vaccines, whereas inactivated relates to viral vaccines (Levine et al., 1997). • For viruses, the outer virion coat should be left intact but the replicative function should be destroyed. • Virus inactivation works by one of the following two mechanisms: - By attacking the viral envelope or capsid and destroying its ability to infect or interact with cells. - By disrupting the viral DNA or RNA and preventing replication. • Killed vaccines may take the route of heat or chemicals (Turner et al., 1970). 28 The Biomedical Engineering Handbook: Second Edition. Ed. Joseph D. Bronzino ,Aunins, J. G., Lee. A. L.,Volkin, D. B. “Vaccine Production.”
  • 29. Chemical treatment - • The chemicals used for killed vaccines include formaldehyde or beta-propiolactone (Lo Grippo, 1960; Gard, 1960). • The traditional agent for inactivation of the virus is formalin (Weil & Gall, 1940; Kim & Sharp, 1967). • The agent is chosen for effectiveness without destruction of antigenicity. • For whole organisms, the inactivation abolishes infectivity. • For antigens such as the diphtheria and tetanus toxins, formaldehyde treatment removes the toxicity of the antigen itself as well as killing the organism. • Such detoxified antigen, called toxoids, are safe for use in vaccines. 29 Recombination and Point Mutations in Type G Rotavirus Strains: The Challenges of Vaccine Development, Abid Nabil Ben Salem1, Rouis Zyed1, Buesa Javier2 and Aouni Mahjoub1
  • 30. Solvent/detergent (S/D) inactivation – • Effective with lipid-coated viruses. • The detergents used in this method, Disrupts the interactions between molecules in the lipid coat , rendering the coat dysfunctional and impeding replication. • Most enveloped viruses cannot live without their lipid coating, so they die when exposed to these detergents. Other viruses may still live, but they are unable to reproduce, rendering them non-infective. • The detergent typically used is Triton-X 100. 30 The Biomedical Engineering Handbook: Second Edition. Ed. Joseph D. Bronzino ,Aunins, J. G., Lee. A. L.,Volkin, D. B. “Vaccine Production.”
  • 31. By Heat - A physical inactivation method that leaves intact virus, bacteria. The heat inactivates the infectious agents, by destroying there surface antigen. Heat inactivation usually done at 56 C for 30 minutes. e.g. A normal suspension of pertussis cells contains a thermolabile toxin that is inactivated by heating at 56 C for 10 minutes. Ultraviolet (UV) inactivation - • UV rays can be used to inactivate viruses since virus particles are small and the UV rays can reach the genetic material, inducing the dimerisation of nucleic acids. • Once the DNA dimerised, the virus particles cannot replicate their genetic material. 31 The Biomedical Engineering Handbook: Second Edition. Ed. Joseph D. Bronzino ,Aunins, J. G., Lee. A. L.,Volkin, D. B. “Vaccine Production.”
  • 32. LIVE WHOLE VACCINES: Several methods have been used to attenuate viruses for vaccine production. a) Use of a related microorganism from another animal - The earliest example was the use of cowpox to prevent smallpox. b) Administration of pathogenic or partially attenuated microorganism by an unnatural route - The virulence of the virus is often reduced when administered by an unnatural route. 32 Recombination and Point Mutations in Type G Rotavirus Strains: The Challenges of Vaccine Development, Abid Nabil Ben Salem1, Rouis Zyed1, Buesa Javier2 and Aouni Mahjoub1
  • 33. c) Passage of the microorganism in an "unnatural host" or host cell • The major vaccines used in man and animals have all been derived this way. • Example : - the 17D strain of yellow fever was developed by passage in mice and then in chick embryos (Norrby, 2007). - Polioviruses were passaged in monkey kidney cells (Chezzi et al., 1998). - Measles in chick embryo fibroblasts (Katz, 1958). 33 Recombination and Point Mutations in Type G Rotavirus Strains: The Challenges of Vaccine Development, Abid Nabil Ben Salem1, Rouis Zyed1, Buesa Javier2 and Aouni Mahjoub1
  • 34. Formulation of vaccine Finally, the vaccine is formulated by adding adjuvant, stabilizers, and preservatives as needed.Other than microorganism or its part (antigen), a vaccine contain the following components: Component Purpose Example Example of Vaccines Adjuvants Enhance the immune Aluminium salts Diphtheria-pertussis-tetanus response to a vaccine (Alum) Diphtheria tetanus(DT) DT combined with Hepatitis B (HBV) Haemophilus influenza B Inactivated polio virus(IPV) Hepatitis A (HAV) Preservatives Prevent bacterial or Thimerosal Diphtheria-tetanus-acellular fungal contamination of pertussis (DTaP) vaccine Hepatitis B, Haemophilus influenza type B (Hib). 34
  • 35. Compone Example of Purpose Example nt Vaccines Stabilizers Protects vaccines from adverse Gelatine, 17D Yellow Fever conditions such as freeze-drying Monosodium virus vaccine, or heat, thereby maintaining a glutamate (MSG) Rabies,Varicella vaccine’s potency Inactivating agents - used to Formaldehyde Influenza virus, inactivate bacterial products for Poliovirus, Diphtheria toxoid vaccines, to kill and Tetanus toxins. unwanted viruses and bacteria β-propiolactone Rabies virus that might contaminate the Glutaraldehyde Residuals vaccine during production Acellular pertussis from Antibiotics - prevent bacterial DTaP-IPV/Hib Neomycin, manufactur contamination during Streptomycin, Influenza, MMR ing process manufacturing process Polymyxin B Influenza and yellow Suspending fluids – Egg proteins fever vaccines kill or weaken the organism for Hepatitis B vaccines use in vaccines. Yeast proteins
  • 36. QUALITY CONTROL AND LOT RELEASE Schedule of final product testing for a veterinary vaccine Test Purpose of Test Sterility Demonstrates that no live microorganisms are present in product Safety Demonstrates that overdose of the product causes no harm Residual toxicity Demonstrates that the product contains no material that can cause harm Efficacy Demonstrates that each antigen in the product meets the recommended guideline level in internationally recognised tests. Increase in With live vaccines, there is concern that the organism might be shed from virulence tests the host and transmitted to contact animals, causing disease if it retains residual virulence or reverts to virulence. All live vaccines should be tested for virulence by means of passage studies. Interference tests For products with two or more antigenic components, tests must confirm that there is no interference between individual components, that is, one PRINCIPLES OF VETERINARY VACCINE component causing a decrease in the protective immunological response PRODUCTION, OIE Terrestrial 36 Manual 2008 to another component.
  • 37. Lot release BATCH/SERIAL RELEASE FOR DISTRIBUTION : Prior to release, the manufacturer must test each batch/serial for purity, safety, and potency. 1. Batch purity test – Purity is determined by testing for a variety of contaminants. Tests to detect contaminants are performed on: master seeds, primary cells, MCSs(Master cell stock), and each batch of final product prior to release. 37 PRINCIPLES OF VETERINARY VACCINE PRODUCTION, OIE Terrestrial Manual 2008
  • 38. 2. Batch safety test - Batches are considered satisfactory if local and systemic reactions to vaccination with the batch to be released are in line with those described in the registration dossier and product literature. 3. Batch potency test - Batch/serial potency tests, required for each batch prior to release, are designed to correlate with the host animal vaccination–challenge efficacy studies. 38 PRINCIPLES OF VETERINARY VACCINE PRODUCTION, OIE Terrestrial Manual 2008
  • 39. Sampling : Samples should be selected from each batch/serial of product. The selector should pick representative sample. Filling , Packaging and Labelling Once all procedures of vaccine production are completed, the vaccine is blended, filled the doses into vials and packaged. Which are then sealed and carefully inspected before labels are applied to show the vaccine batch,lot numbers, and expiration date. Standards for labelling products will vary from country to country. Field tests (safety and efficacy) Performance monitoring 39 PRINCIPLES OF VETERINARY VACCINE PRODUCTION, OIE Terrestrial Manual 2008
  • 40. Processes of Egg-Based Vaccine Production Embryonated chicken eggs Inoculation Incubation The upstream A seed ampoule This is followed by a 3 process, begins is used to day incubation period with embryonated inoculate the during which the virus eggs brought in chick eggs grows to ensure that on a daily basis during the sufficient quantities from biosecure inoculation can support further flocks. phase. manufacturing. Harvest (pool Candling allantoic fluid) After 3 days, all of the eggs are The allantoic fluid is candled to make sure there are no then harvested; a low- cracks or contamination; the eggs Clarification speed clarification are then chilled to 2° to 8°C to process follows. constrict vessels and make harvesting easier. 40 The BRIDGE, Egg-Based Production ofInfluenza Vaccine:James T. Matthews page 21
  • 41. 1st inactivation Filtration Concentration The first step in the Zonal centrifugation downstream Extensive filtration and concentration process is steps yield a concentrate, which is inactivation, which then loaded onto zonal centrifugation involves the equipment. addition of formalin to inactivate the virus. Triton fragmentation 2nd inactivation Centrifugation Ultrafiltration The material is then The first purified clarified by bulk virus, which is An ultrafiltration centrifugation to recovered from the (UF) step is remove large centrifugation followed by terminal particulates and process, is split in sterile filtration to Sterile filtration treated with a fragmentation generate one formalin in a step by treatment monovalent bulk second inactivation with Triton concentrate. step. detergent. 41 Final product The BRIDGE, Egg-Based Production of Influenza Vaccine:James T.
  • 42. Cell Culture Based Vaccine Production centrifugation virus cell (production seed)    filtering Cell culture Inoculation Harvest Bulk Purification  Add Adjuvant Stabilizer     Preservative Packaging Labeling Inspection Filling Formulation 42 ccines / [edited by] Stanley A. Plotkin, Edward A. Mortimer, Jr. Influenza Vaccines (Tina Kröber, Thomas Jarosch, and Laura Fischer) Max-Planck-Gesellschaft, Münche
  • 43. Thank you 43
  • 44. 44
  • 45. • Production of Freeze-dried Brucella abortus Strain 19 Vaccine using Cells produced by Continuous Culture† K. J. Boyce, A. W. Edgar ,Journal of Applied Microbiology, Volume 29, Issue 2, pages 401–408, August 1966 • The tularaemia vaccine: review. Sandstrom, G. Journal of Chemical Technology & Biotechnology. Vol. 59, no. 4, pp. 315-20. Apr. 1994 The live vaccine can be produced in fermenter cultures and the bacteria have to undergo quality controls for each batch of vaccine. It is important to estimate the amount of non-immunogenic bacteria in each batch and to disclose the immunogenicity of the vaccine in man. 45

Hinweis der Redaktion

  1. OPV-Oral polio vaccine sabin,MMR-measles,mumps,rubella –live attenuated vaccine.Rab-Rabies,Flu-Influenza (killed viral),Ap- Acellularpertussis (Subunit vaccine,surface protein) Hepatitis A(killed viral vaccine)
  2. There are different methods which vaccine manufacturers use to produce vaccines, and they are:
  3. preservative free
  4. Following cultivation, the antigen is recovered, isolated in crude form, further purified, and/or inactivatedto give the unformulated product; these steps are referred to collectively as thedownstream process
  5. Culture incubated in a closed vessel with a single batch of medium.
  6. in the cultivation of C.diphtheriaecontinually constantly or frequent occuringMany environmental factors (e.g. pH, oxygen levels, nutrients and temperature) can be controlled very precisely.The culture is stirred continuously - ensuring nutrients and oxygen reach the cells and metabolic products are distributed away from them.
  7. Catalyst a substance that increaes the rate of a chemical reaction without itself undergoing any permanent chemical change
  8. (e.g. disease barriers, filters on air inlets, no new animals introduced without appropriate quarantine).
  9. a homogenous population of single cell types, which can divide up to 100 times before dying. The most common are those established from human embryos e.g. WI 38 from human embryonic lungs.
  10. PerC.6 (Crucell)• EBx™: a stem cell line derived from chicken embryos(Sigma-Aldrich Group)• VERO: a kidney cell from the African green monkey(GSK)• MDCK : Madin-Darby canine kidney cells used byChironCell lines. Cultures of cells that have a high capacity for multiplication in vitro.
  11. culture cells growing on microcarrier beads, MDCK cells on microcarrier
  12. anchorage independent. In contrast to cells that grow in plastic dishes to form a monolayer, other cells are non-adherent and can be maintained as suspension cultures. Larger volumes of media are required to achieve the same results with free-cell suspension because the cell line proliferates while growing freely suspended in the nutrient medium.
  13. Newcastle disease virus and other avian parainfluenza viruses, avian reticulo-endotheliosis virusspecific agents: Mycobacterium avium , fowl pox virus, Newcastle disease virus and, avian encephalomyelitis virus, infectious laryngotracheitis virus,, Marek's disease virus, infectious bursal disease virus, Haemophilusparagallinarum , Salmonella gallinarum, Salmonella pullorum, Mycoplasma gallisepticum and Mycoplasma synoviae.
  14. This occurs in a clean, closed environment, whereas harvesting of an egg based virus is largely a manual process that requires extracting infected cells, breaking down cell walls, and then collecting the virus.
  15. Removal of microbes by passage of a liquid or gas through a screen like material with small pores
  16. Initial chromatography with ultrafiltration is often followed by treatment with beta-propiolactone.Since seasonal influenza vaccines contain three viral strains, the production process must be performed for each strain. Initial chromatography with ultra filtration is often followed by treatment with beta-propiolactone, which deactivates the virus; final splitting of the virus is followed by ultracentrifugation. This ultrapurification technology is basically similar to the egg-based vaccine ultrapurification process, and the resulting purified subunit vaccine is identical in composition to egg-based vaccine.
  17. The outer virion coat should be left intact but the replicative function should be destroyed. For nonattenuated whole organisms or for toxin antigens, the preparation must be inactivated to eliminate pathogenicity.
  18. Chemicals used include formaldehyde(e.g.Polio,Hepatitis), glutaraldehyde, and beta- propiolactone(e.g. Rabies, influenza)
  19. Typical incubation lasts for 10 hours and is performed at 60°C
  20. But this inactivation of surface antigen results in poor immune response. dimer is a macromolecular complex formed by two, usually non-covalently bound, macromolecules like proteins or nucleic acids. It is aquaternary structure of a protein. Inactivation of poliovirus in 10 minutes required an 8% concentration of formalin, but all other viruses tested were inactivated with 2% formalin 72.
  21. This principle is used in the immunization of military recruits against adult respiratory distress syndrome using enterically coated live adenovirus type 4, 7 and (21).
  22. After repeated passages, the virus is administered to the natural host.The initial passages are made in healthy animals or in primary cell cultures. Human diploid cells are now widely used such as the WI-38 and MRC-5.
  23. Formulation is a manual process consisting of the addition of diluent to achieve the required 15 microgram antigenic component per strain (H1, H3, and B strain) for each dose of vaccine. Other than microorganism or its part (antigen), a vaccine contain the following components:
  24. toxoid vaccines, (these are vaccines that use an inactive bacterial toxin to produce immunity.) Inactivate toxins contained in acellularpertussis vaccines. Influenza and yellow fever vaccines, which are prepared using chicken eggs
  25. Sterile filling of vials or syringes and subsequent inspection of the filled vials or syringes are
  26. .influenza seed virus, is added to the cell-containing bioreactor (container) where the virus then infects the cells and multiplies, making more virus particles. After several days the influenza virus has infected and destroyed all the cells in the bioreactor. The virus is then harvested by removing the debris made by the cells and made non-infectious, before being further purified. This purified, non-infectious solution is then blended, concentrated and filled into syringes or vials ready for use.