Xerovac: an ultra rapid method for the dehydration and preservation of live attenuated Rinderpest and Peste des Petits ruminants vaccines

The accepted procedure for the long-term preservation of live viruses and bacteria in vaccines has been lyophilisation. We show that thermolabile viruses can be dehydrated in vitro, within 18 h, in an excipient containing trehalose. We further demonstrate that in the resulting dehydrated state, where the viruses are captive in a metastable glass composed of trehalose, they are capable of resisting 45°C for a period of 14 days with minimal loss of potency. The degree of thermotolerance achieved matches that of current ‘thermostable’ lyophilised vaccines, but with the distinct advantage of a shorter, cheaper and simpler process. The development and utilisation of this process can make significant improvements in current live virus vaccine production. It presents a further step away from dependence on mandatory low temperature refrigerated storage and could lead to greater confidence in vaccine stability, potency and efficacy.