biostudies-literatureLyu FMRC SIR GrantUniversity of KwaZulu Natal Research grantNRFUniversity of KwaZulu-NatalThe Key Research and Development Program of Jiangsu ProvinceJiangsu Agricultural Science and Technology Independent Innovation Fund359https://www.ebi.ac.uk/biostudies/studies/S-EPMC11153293biostudies-literatureUnknown108(1)Vacuum foam drying (VFD) has been shown to improve the thermostability and long-term shelf life of Newcastle Disease Virus (NDV). This study optimized the VFD process to improve the shelf life of NDV at laboratory-scale and then tested the optimized conditions at pilot-scale. The optimal NDV to T5 formulation ratio was determined to be 1:1 or 3:2. Using the 1:1 virus to formulation ratio, the optimal filling volumes were determined to be 13-17% of the vial capacity. The optimized VFD process conditions were determined to be at a shelf temperature of 25℃ with a minimum overall drying time of 44 h. The vaccine samples prepared using these optimized conditions at laboratory-scale exhibited virus titer losses of ≤ 1.0 log₁₀ with residual moisture content (RMC) below 3%. Furthermore,Applied microbiology and biotechnologyThermostable vacuum foam dried Newcastle disease vaccine: Process optimization and pilot-scale study.PMC11153293121275CX (22) 2016BE2020336Zhao YHLu YZeng MQOlaniran ALyu FZhou MXKhoza TJiao JJDeng BHHou JNyide BJie HYZuo XXfalseThermostable vacuum foam dried Newcastle disease vaccine: Process optimization and pilot-scale study.Vacuum foam drying (VFD) has been shown to improve the thermostability and long-term shelf life of Newcastle Disease Virus (NDV). This study optimized the VFD process to improve the shelf life of NDV at laboratory-scale and then tested the optimized conditions at pilot-scale. The optimal NDV to T5 formulation ratio was determined to be 1:1 or 3:2. Using the 1:1 virus to formulation ratio, the optimal filling volumes were determined to be 13-17% of the vial capacity. The optimized VFD process conditions were determined to be at a shelf temperature of 25℃ with a minimum overall drying time of 44 h. The vaccine samples prepared using these optimized conditions at laboratory-scale exhibited virus titer losses of ≤ 1.0 log₁₀ with residual moisture content (RMC) below 3%. Furthermore,2024-01-01T00:00:00Z2024 Jun2026-05-07T14:12:15.668Z2026-04-07T22:51:35.263ZS-EPMC111532933883688510.1007/s00253-024-13174-7