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[Display omitted] • The internal microstructure of dried particles varies with excipients. • Viral activity decreased as the total (internal + external) solid-air interfacial area increased. • The viral vector analogue is predominantly located at or near the solid-air interfaces. • Surface area within spray dried particles is an indicator of activity. • Internal voids can mask the effects of operating conditions and excipient selection. To maintain the activity of sensitive biologics during encapsulation by spray drying, a better understanding of deactivation pathways in dried particles is necessary. The effect of solid-air interfaces within dried particles on viral deactivation was examined with three binary excipient blends, mannitol/dextran (MD), xylitol/dextran (XD), and lactose/trehalose (LT). Particles encapsulating human serotype 5 adenovirus viral vector (AdHu5) were produced via both spray drying and acoustic levitation. The particles' internal microstructure was directly visualized, and the location of a viral vector analogue was spatially mapped within the particles by volume imaging using focused ion beam sectioning and scanning electron microscopy. The majority of the viral vector analogue was found at, or near, the solid-air interfaces. Peclet number and crystallization kinetics governed the internal microstructure of the particles: XD particles with minimal internal voids retained the highest viral activity, followed by MD particles with a few large voids, and finally LT particles with numerous internal voids exhibited the lowest viral activity. Overall, AdHu5 activity decreased as the total solid-air interfacial area increased (as quantified by nitrogen sorption). Along with processing losses, this work highlights the importance of surface area within particles as an indicator of activity losses for dried biologics. [ABSTRACT FROM AUTHOR]

[Display omitted] Increasing viral dosage within dry powder vaccines reduces the powder mass required to elicit an immune response through pulmonary delivery. This work analyzes how cryoprotective agents affect viral activity, particle properties and thermal stability of a spray dried, inhalable vaccine vector under high viral loading. Stock suspensions of a human serotype 5 adenovirus (AdHu5) vector in either neat phosphate buffered saline (PBS), 10% glycerol in PBS, or 5% trehalose in PBS were added to a mannitol-dextran formulation prior to spray drying. At high viral loading, spray dried powder containing glycerol had a viral titre log loss of 2.8 compared to 0.7 log loss using neat PBS. Powders containing glycerol had a lower glass transition temperature (T g) compared to all other formulations, permitting greater viral mobility and exposure to heat damage. Inclusion of glycerol also promoted particle cohesion during spray drying and lower yields. Using 5% trehalose as a cryogenic alternative, viral powders had a viral log loss of 1.5 and the highest displayed thermal stability over time. Additionally, trehalose-containing powders had smaller particles with lower water moisture content and higher powder yield compared to glycerol-containing powders. These findings demonstrate the importance of cryoprotective agent selection when developing thermostable vaccine powders. [ABSTRACT FROM AUTHOR]

[Display omitted] Development of thermally stable spray dried viral-vectored vaccine powders is dependent on the selection of a proper excipient or excipient blend for encapsulation, which can be a time and resource intensive process. In this work, a diffusion-based droplet drying model was developed to compute droplet drying time, size, and component distribution. The model predictions were validated using an acoustic levitator to dry droplets containing protein-coated or fluorescently labelled silica nanoparticles (as adenoviral vector analogues) and a range of excipient blends. Surface morphology of the dried particles was characterized by atomic force microscopy and the distribution of silica nanoparticles was quantified by confocal microscopy. The modelled distributions of adenovirus agreed with the microscopy results for three mannitol/dextran excipient blends with varying molecular weight dextrans, verifying the equations and assumptions of the model. Viral vector activity data for adenovirus in a range of (poly)saccharide/sugar alcohol formulations were also compared to the model outputs, suggesting that viral activity decreases when the model predicts increasing adenovirus concentrations near the air–solid interface. Using a validated model with excipient property inputs that are readily available in the literature can facilitate the development of viral-vectored vaccines by identifying promising excipients without the need for experimentation. [ABSTRACT FROM AUTHOR]