Physicohemical characterization of the freezing behavior of mannitol-human serum albumin formulations

The goal of the study was to analyze the impact of human serum albumin (HSA) quality (stabilized or nonstabilized HSA), the addition of NaCl, and the HSA stabilizers Naoctanoate and Na-N-acetyltryptophanate on the freezing behavior of mannitol-HSA formulations. The focus was on crystallization, Tg' (glass transition temperature of the maximally freeze-concentrated phase), and Tc (collapse temperature). Differential scanning calorimetry (DSC), cryomicroscopy, and low-temperature x-ray powder diffraction (LTXRD) were used to study the frozen state. In mannitol-HSA formulations. mannitol crystallization was inhibited and Tg' lowered to a greater extent by stabilized HSA (containing Na-octanoate, Na-N-aceyltraptophanate, and NaCl) than by unstabilized HSA. Detailed DSC and LTXRD studies showed that in the concentrations used for stabilizing HSA, NaCl led to changes in the freezing behavior, an effect that was less pronounced for the other stabilizers. NaCl further lowered the Tc, which was determined by cryomicroscopy. As the freezing behavior governs the lyophilization process, the changes have to be taken into consideration for the development of a lyophilization cycle, to avoid collapse and instabilities.     

Leakage of a trapped fluorescent marker from liposomes: effects of eutectic crystallization of NaCl and internal freezing.

Leakage of trapped carboxyfluorescein from DL-alpha-dipalmitoylphosphatidylcholine multilamellar liposomes (diameter 1-2 microns) in NaCl solutions was measured after rapid freezing to temperatures between -15 and -55 degrees C. Leakage was low after freezing between -15 and -35 degrees C, but increased steeply between -35 and -45 degrees C. From DSC measurements it was found that the increase in leakage was associated with two crystallization processes: Eutectic crystallization of NaCl and freezing of undercooled solvent trapped in the interior of the liposomes ("internal freezing"). Damage caused by the former process could effectively be prevented by small amounts of trehalose (1% less than or equal to w less than or equal to 1.5%). Trehalose in these concentration also decreased damage due to internal freezing, but to a minor degree. In addition to these damaging transitions, a time-dependent process was found to cause leakage from the liposomes at -25 degrees C. The association between leakage and thermal activity suggests that DSC supplements cryomicroscopy and leakage measurements in the characterization of cryostability of liposomes.     

Freeze-drying of Lactobacillus coryniformis Si3--effects of sucrose concentration, cell density, and freezing rate on cell survival and thermophysical properties

Freeze-drying is commonly used to stabilize lactic acid bacteria. Many factors have been reported to influence freeze-drying survival, including bacterial species, cell density, lyoprotectant, freezing rate, and other process parameters. Lactobacillus coryniformis Si3 has broad antifungal activity and a potential use as a food and feed biopreservative. This strain is considered more stress sensitive, with a low freeze-drying survival, compared to other commercialized antifungal lactic acid bacterial strains. We used a response surface methodology to evaluate the effects of varying sucrose concentration, cell density and freezing rate on Lb. coryniformis Si3 freeze-drying survival. The water activity of the dry product, as well as selected thermophysical properties of importance for freeze-drying; degree of water crystallization and the glass transition temperature of the maximally freeze concentrated amorphous phase (Tg') were determined. The survival of Lb. coryniformis Si3 varied from less than 6% to over 70% between the different conditions. All the factors studied influenced freeze-drying survival and the most important factor for survival is the freezing rate, with an optimum at 2.8 degrees C/min. We found a co-dependency between freezing rate and formulation ingredients, indicating a complex system and the need to use statistical tools to detect important interactions. The degree of water crystallization decreased and the final water activity increased as a function of sucrose concentration. The degree of water crystallization and Tg' was not affected by the addition of 10(8)-10(10) CFU/ml. At 10(11) CFU/ml, these thermophysical values decreased possibly due to increased amounts of cell-associated unfrozen water.     

Phase Transition Stability of Cocoa Butter Emulsions

The impact of tempering-crystallization on microstructure and stability of water-in-cocoa butter (w/o) emulsions was analyzed using differential scanning calorimetry (DSC). The type and volume fraction of the disperse phase, and cooling rate during DSC analysis were systematically varied. Freshly prepared emulsions were additionally characterized by microscopy and laser diffraction. Fresh cocoa butter emulsions were composed of small and well dispersed droplets of an average size of 2.24 μm and 1.96 μm for water and 50 % sucrose solution as disperse phase, respectively. The thermograms revealed that the dissolved sugar lowered freezing and melting temperature and, dependent on volume fraction, the dispersion in the oil phase led to a change in solidification behavior. The temperature at the solidification peaks gives qualitative information about droplet size whereas width and number of exothermic events are related to particle size distribution (mono/polydispersity and mono/multimodality) and microstructure. Emulsions with water as dispersed phase show a clear shift of the freezing peaks of the disperse phase which points on modified emulsion microstructure because of droplet coalescence, which is more pronounced at higher volume fraction and lower cooling rate. Emulsions with sucrose solution as dispersed phase showed the greatest stability, wherein the volume fraction and the cooling rate does not matter. The results allow conclusions about the mechanisms of crystallization processes in cocoa butter emulsions resulting as network crystallization.     

Effect of polyols on the conformational stability and biological activity of a model protein lysozyme

The purpose of this study was to investigate the stabilizing action of polyols against various protein degradation mechanisms (eg, aggregation, deamidation, oxidation), using a model protein lysozyme. Differential scanning calorimeter (DSC) was used to measure the thermodynamic parameters, mid point transition temperature and calorimetric enthalpy, in order to evaluate conformational stability. Enzyme activity assay was used to corroborate the DSC results. Mannitol, sucrose, lactose, glycerol, and propylene glycol were used as polyols to stabilize lysozyme against aggregation, deamidation, and oxidation. Mannitol was found to stabilize lysozyme against aggregation, sucrose against deamidation both at neutral pH and at acidic pH, and lactose against oxidation. Stabilizers that provided greater conformational stability of lysozyme against various degradation mechanisms also protected specific enzyme activity to a greater extent. It was concluded that DSC and bioassay could be valuable tools for screening stabilizers in protein formulations.     

Protecting activity of desiccated enzymes

Protein‐based biological drugs and many industrial enzymes are unstable, making them prohibitively expensive. Some can be stabilized by formulation with excipients, but most still require low temperature storage. In search of new, more robust excipients, we turned to the tardigrade, a microscopic animal that synthesizes cytosolic abundant heat soluble (CAHS) proteins to protect its cellular components during desiccation. We find that CAHS proteins protect the test enzymes lactate dehydrogenase and lipoprotein lipase against desiccation‐, freezing‐, and lyophilization‐induced deactivation. Our data also show that a variety of globular and disordered protein controls, with no known link to desiccation tolerance, protect our test enzymes. Protection of lactate dehydrogenase correlates, albeit imperfectly, with the charge density of the protein additive, suggesting an approach to tune protection by modifying charge. Our results support the potential use of CAHS proteins as stabilizing excipients in formulations and suggest that other proteins may have similar potential.     

A new generation of sodium chloride porogen for tissue engineering

Porogen leaching is a widely used and simple technique for the creation of porous scaffolds in tissue engineering. Sodium chloride (NaCl) is the most commonly used porogen, but the current grinding and sieving methods generate salt particles with huge size variations and cannot generate porogens in the submicron size range. We have developed a facile method based on the principles of crystallization to precisely control salt crystal sizes down to a few microns within a narrow size distribution. The resulting NaCl crystal size could be controlled through the solution concentration, crystallization temperature, and crystallization time. A reduction in solution temperature, longer crystallization times, and an increase in salt concentration resulted in an increase in NaCl crystal sizes due to the lowered solubility of the salt solution. The nucleation and crystallization technique provides superior control over the resulting NaCl size distribution (13.78 ± 1.18 μm), whereas the traditional grinding and sieving methods produced NaCl porogens 13.89 ± 12.49 μm in size. The resulting NaCl porogens were used to fabricate scaffolds with increased interconnectivity, porous microchanneled scaffolds, and multiphasic vascular grafts. This new generation of salt porogen provides great freedom in designing versatile scaffolds for various tissue-engineering applications.     

A new approach for freezing of aqueous solutions under active control of the nucleation temperature

An experimental setup for controlled freezing of aqueous solutions is introduced. The special feature is a mechanism to actively control the nucleation temperature via electrofreezing: an ice nucleus generated at a platinum electrode by the application of an electric high voltage pulse initiates the crystallization of the sample. Using electrofreezing, the nucleation temperature in pure water can be precisely adjusted to a desired value over the whole temperature range between a maximum temperature Tn(max) close to the melting point and the temperature of spontaneous nucleation. However, the presence of additives can inhibit the nucleus formation. The influence of hydroxyethylstarch (HES), glucose, glycerol, additives commonly used in cryobiology, and NaCl on Tn(max) were investigated. While the decrease showed to be moderate for the non-ionic additives, the hindrance of nucleation by ionic NaCl makes the direct application of electrofreezing in solutions with physiological salt concentrations impossible. Therefore, in the multi-sample freezing device presented in this paper, the ice nucleus is produced in a separate volume of pure water inside an electrode cap. This way, the nucleus formation becomes independent of the sample composition. Using electrofreezing rather than conventional seeding methods allows automated freezing of many samples under equal conditions. Experiments performed with model solutions show the reliability and repeatability of this method to start crystallization in the test samples at different specified temperatures. The setup was designed to freeze samples of small volume for basic investigations in the field of cryopreservation and freeze-drying, but the mode of operation might be interesting for many other applications where a controlled nucleation of aqueous solutions is of importance.     

Equilibrium and nonequilibrium phase transformations of quaternary solutions based on a physiologic support medium containing NaCl, dimethyl sulfoxide, and glycerol

Insight into the circumstances attending the freezing and thawing of biological materials suspended in cryoprotective solutions might be expected to result from knowledge of the colligative properties and glass behavior in systems based on typical physiological media, NaCl, and important cryoprotective agents. Differential thermal analysis has been used to determine phase diagram relationships in the aqueous-rich region of the quaternary system composed of a complex physiological support medium (Eagle's minimum essential medium), NaCl, and two cryoprotective compounds (glycerol and dimethyl sulfoxide). Thermograms revealed behavior corresponding to the primary crystallization of ice from sample solutions as well as the glass transition and devitrification of nonequilibrium amorphous phases. In most quaternary solutions, equilibrium-phase formation in the form of a pseudoeutectic transformation was inhibited and the formation of a metastable amorphous phase was observed as the final mode of solidification.     

Effect of Chemical Stabilizers on the Thermostability and Infectivity of a Representative Panel of Freeze Dried Viruses

As a partner of the European Virus Archive (EVA) FP7 project, our laboratory maintains a large collection of freeze-dried viruses. The distribution of these viruses to academic researchers, public health organizations and industry is one major aim of the EVA consortium. It is known that lyophilization requires appropriate stabilizers to prevent inactivation of the virus. However, few studies have investigated the influence of different stabilizers and lyophilization protocols on the thermostability of different viruses. In order to identify optimal lyophilization conditions that will deliver maximum retention of viral infectivity titre, different stabilizer formulations containing trehalose, sorbitol, sucrose or foetal bovine serum were evaluated for their efficacy in stabilizing a representative panel of freeze dried viruses at different storage temperatures (-20°C, +4°C and +20°C) for one week, the two latter mimicking suboptimal shipping conditions. The Tissue Culture Infectious Dose 50% (TCID₅₀) assay was used to compare the titres of infectious virus. The results obtained using four relevant and model viruses (enveloped/non enveloped RNA/DNA viruses) still serve to improve the freeze drying conditions needed for the development and the distribution of a large virus collection.     

Rapid optimization of protein freeze‐drying formulations using ultra scale‐down and factorial design of experiment in microplates

Retaining biopharmaceutical proteins in a stable form is critical to their safety and efficacy, and is a major factor for optimizing the final product. Freeze‐dried formulations offer one route for improved stability. Currently the optimization of formulations for freeze‐drying is an empirical process that requires many time‐consuming experiments and also uses large quantities of product material. Here we describe a generic framework for the rapid identification and optimization of formulation excipients to prevent loss of protein activity during a lyophilization process. Using factorial design of experiment (DOE) methods combined with lyophilization in microplates a range of optimum formulations were rapidly identified that stabilized lactose dehydrogenase (derived from Lactobacillus leichmanii) during freeze‐drying. The procedure outlined herein involves two rounds of factorially designed experiments—an initial screen to identify key excipients and potential interactions followed by a central composite face designed optimization experiment. Polyethylene glycol (PEG) and lactose were shown to have significant effects on maintaining protein stability at the screening stage and optimization resulted in an accurate model that was used to plot a window of operation. The variation of freezing temperatures and rates of sublimation that occur across a microplate during freeze‐drying have been characterized also. The optimum formulation was then freeze‐dried in stoppered vials to verify that the microscale data was relevant to the effects observed at larger pilot scales. This work provides a generic approach to biopharmaceutical formulation screening where possible excipients can be screened for single and interactive effects thereby increasing throughput while reducing costs in terms of time and materials. Biotechnol. Bioeng. 2009; 104: 957–964. © 2009 Wiley Periodicals, Inc.     

Crystal growth and solid-state structure of poly(lactide) Stereocopolymers

Solid-state structure and melting behavior for random stereocopolymers of L-lactide with meso-lactide (P(L-LA-co-meso-LA)) with different meso-LA compositions of 0, 2, 4, and 10 mol % were investigated under various isothermal crystallization conditions. The crystalline morphology of P(L-LA-co-meso-LA) samples changed from the spherulitic aggregates to hexagonal lamellae stacking with a rise in crystallization temperature. Under each crystallization condition, P(L-LA-co-meso-LA) samples formed alpha-crystal modifications for homopolymer of L-LA. By using the atomic force microscopy and small-angle X-ray scattering, the stacking structure of lamellar crystals was examined for the isothermally crystallized P(L-LA-co-meso-LA) thin films. The lamellar thickness of P(L-LA-co-meso-LA) ranged from 6.2 to 15.5 nm, and the values increased with crystallization temperature. Melting profiles of crystalline regions were examined by the differential scanning calorimetry (DSC) for the P(L-LA-co-meso-LA) samples. Distinct two melting peaks were detected in the DSC thermograms of several samples. Investigations on the time-dependent changes in lamellar structure and melting temperature of the P(L-LA-co-meso-LA) samples under isothermal crystallization conditions provided the evidence that a small amount of D-lactyl units was trapped in the crystalline regions during early stage of crystallization process under the certain crystallization condition. In addition, it was found that the D-lactyl units trapped in crystalline regions were excluded from crystalline lamellae to form the thermally stable crystals without changes in crystal thickness during further isothermal storage at a crystallization temperature. The equilibrium melting temperature (T(m)0) of P(L-LA-co-meso-LA) samples was estimated by using modified Hoffman-Weeks methods, and the obtained values decreased from 215 to 184 degrees C as the meso-LA composition was increased from 0 to 10 mol %. Furthermore, the crystal growth kinetics of the P(L-LA-co-meso-LA) samples was analyzed by using the secondary nucleation theory. Transitions of crystalline regime both from regime III to regime II and from regime II to regime I were detected for each sample. The transition temperature from regime II to regime I of each of the P(L-LA-co-meso-LA) samples was very close to the temperature region revealed the morphological changes in the crystalline aggregates from the spherulitic aggregates to hexagonal lamellae stacking.     

Mixture of three amino acids as stabilizers replacing albumin in lyophilization of new third generation recombinant factor VIII GreenGene F

A formulation with stabilizers replacing albumin was developed for lyophilization of recombinant factor VIII (FVIII), GreenGene F (WHO INN: beroctocog alfa), to achieve stability and eliminate safety issues of blood‐derived albumin. L ‐Arginine (hydrophilic amino acid, positively charged side chain), L ‐glutamic acid (hydrophilic amino acid, negatively charged side chain), and L ‐isoleucine (hydrophobic amino acid, nonpolar) were selected as stabilizers, and the mixture of the three amino acids were optimized. The mixture had results comparative with albumin and other commonly used stabilizers showing good preservation of recombinant FVIII during lyophilization, robust stability with consistently high recovery of FVIIII, very low aggregate formation, and good storage stability without alterations in protein characteristics. In vivo test results showed that the efficacy was maintained and had no signs of toxicity. The study demonstrated that the three amino acid mixture acts as a good stabilizer for lyophilization of recombinant FVIII and as a safe excipient. © 2012 American Institute of Chemical Engineers Biotechnol. Prog., 2012     

Nature of the salt dependence of the envelope of a Dead Sea archaebacterium,Haloferax volcanii

The external layer was released from Haloferax volcanii cells and envelopes when the divalent cation concentration was lowered in the presence of NaCl. NaCl alone could not stabilize the isolated envelopes and divalent cations were absolutely required at concentrations which depended on that of NaCl and on the temperature. NaCl and divalent cations had a cooperative or an antagonistic effect according to their relative concentrations. The envelopes were optimally stabilized by a combination of NaCl and divalent cations, which probably ensured an equilibrium between the hydrophobic bonds and the charge shielding effects involved in the structure of cell envelope (cytoplasmic membrane and external layer).Deceased 1990     

Long-term preservation of anammox bacteria

Deposit of useful microorganisms in culture collections requires long-term preservation and successful reactivation techniques. The goal of this study was to develop a simple preservation protocol for the long-term storage and reactivation of the anammox biomass. To achieve this, anammox biomass was frozen or lyophilized at two different freezing temperatures (−60°C and in liquid nitrogen (−200°C)) in skim milk media (with and without glycerol), and the reactivation of anammox activity was monitored after a 4-month storage period. Of the different preservation treatments tested, only anammox biomass preserved via freezing in liquid nitrogen followed by lyophilization in skim milk media without glycerol achieved stoichiometric ratios for the anammox reaction similar to the biomass in both the parent bioreactor and in the freshly harvested control treatment. A freezing temperature of −60°C alone, or in conjunction with lyophilization, resulted in the partial recovery of the anammox bacteria, with an equal mixture of anammox and nitrifying bacteria in the reactivated biomass. To our knowledge, this is the first report of the successful reactivation of anammox biomass preserved via sub-zero freezing and/or lyophilization. The simple preservation protocol developed from this study could be beneficial to accelerate the integration of anammox-based processes into current treatment systems through a highly efficient starting anammox biomass.     

The Role of Caprylate Ligand Ion on the Stabilization of Human Serum Albumin

Sodium caprylate was added to a pharmaceutical-grade human serum albumin (HSA) to stabilize the product. In this study we have aimed to establish how caprylate ligand protects HSA from thermal degradation. The fatty acid stabilizer was first removed from commercial HSA by charcoal treatment. Cleaned HSA was made to 10% w/v in pH 7.4 buffered solutions and doped with sodium caprylate in serial concentrations up to 0.16 mmol/g-protein. These solutions as well as a commercial HSA, human serum, and enriched-albumin fraction were subjected to differential scanning calorimetry (DSC) within the temperature range of 37–90°C at a 5.0°C/min scanning rate. The globular size of the cleaned HSA solutions was measured by dynamic light scattering. The denaturing temperatures for albumin with sodium caprylate and a commercial one were significantly higher than for albumin only. It was found that the protein globules of cleaned HSA were not as stable as that of the native one due to aggregation, and the caprylate ion may reduce the aggregation by enlarging the globules’ electrical double layer. A rational approximation of the Lumry-Eyring protein denaturation model was used to treat DSC denaturing endotherms. The system turned from irreversible dominant Scheme: to reversible dominant Scheme: with the increase in caprylate concentration from null to ~0.08 mmol/g-protein. It was postulated that the caprylate ligand may decrease the rate of reversible unfolding as it binds to the IIIA domain which is prone to reversible unfolding/refolding and causes further difficulty for irreversible denaturation which, in turn, HSA can be stabilized.KEY WORDS: differential scanning calorimetry, human serum albumin, Lumry-Eyring model, protein denaturation, sodium caprylate     

Evaluation of efficacy of stabilizers on the thermostability of live attenuated thermo-adapted <Emphasis Type="Italic">Peste des petits ruminants</Emphasis> vaccines

In this study, thermo-adapted (Ta) PPR vaccines were assessed for their stability at 25, 37, 40, 42 and 45°C in lyophilized form using two extrinsic stabilizers {lactalbumin hydrolysate-sucrose (LS) and stabilizer E} and in reconstituted form with the diluents (1 mol/L MgSO₄ or 0.85% NaCl). The lyophilized vaccines showed an expiry period of 24–26 days at 25°C, 7–8 days at 37°C and 3–4 days at 40°C. LS stabilizer was superior at 42°C with a shelf-life of 44 h, whereas in stabilizer E, a 40 h shelf-life with a comparable half-life was observed. At 45°C, the half-life in stabilizer E was better than LS and lasted for 1 day. Furthermore, the reconstituted vaccine maintained the titre for 48 h both at 4°C and 25°C and for 24–30 h at 37°C. As both the stabilizers performed equally well with regard to shelf-life and half-life, the present study suggests LS as stabilizer as a choice for lyophilization with 0.85% NaCl diluent, because it has better performance at higher temperature. These Ta vaccines can be used as alternatives to existing vaccines for the control of the disease in tropical countries as they are effective in avoiding vaccination failure due to the breakdown in cold-chain maintenance, as this vaccine is considerably more stable at ambient temperatures.     

Morphological behavior of lipid bilayers induced by melittin near the phase transition temperature

Morphological changes of DMPC, DLPC, and DPPC bilayers containing melittin (lecithin/melittin molar ratio of 10:1) around the gel-to-liquid crystalline phase transition temperatures (Tc) were examined by a variety of biophysical methods. First, giant vesicles with the diameters of approximately 20 microm were observed by optical microscopy for melittin-DMPC bilayers at 27.9 degrees C. When the temperature was lowered to 24.9 degrees C (Tc = 23 degrees C for the neat DMPC bilayers), the surface of vesicles became blurred and dynamic pore formation was visible in the microscopic picture taken at different exposure times. Phase separation and association of melittin molecules in the bilayers were further detected by fluorescent microscopy and mass spectrometry, respectively. These vesicles disappeared completely at 22.9 degrees C. It was thus found that the melittin-lecithin bilayers reversibly undergo their fusion and disruption near the respective Tcs. The fluctuation of lipids is, therefore, responsible for the membrane fusion above the Tc, and the association of melittin molecules causes membrane fragmentation below the Tc. Subsequent magnetic alignments were observed by solid-state (31)P NMR spectra for the melittin-lecithin vesicles at a temperature above the respective Tcs. On the other hand, additional large amplitude motion induced by melittin at a temperature near the Tc breaks down the magnetic alignment.     

Phase behavior of freeze-dried phospholipid-cholesterol mixtures stabilized with trehalose

A study is presented of the role of cholesterol content on the gel-to-liquid crystalline phase transition of freeze-dried liposomes stabilized with trehalose, a well known lyoprotectant. The phospholipids considered in this work, DPPC and DPPE, belong to the two predominant phospholipid species found in numerous biological membranes. Cholesterol is found in abundance in mammalian plasma membranes. DSC measurements reveal that cholesterol-containing liposomes exhibit multiple phase transitions upon dehydration. Addition of trehalose to these systems lowers the phase transition temperature and limits the phase separation of the lipidic components upon freeze-drying. This work provides strong evidence for the effectiveness of trehalose in stabilizing cholesterol-containing membranes upon lyophilization.     

Unfolding properties of recombinant human serum albumin products are due to bioprocessing steps

We have used differential scanning calorimetry (DSC) to determine the unfolding properties of commercial products of human serum albumin (HSA) prepared from pooled human blood, transgenic yeast, and transgenic rice. The initial melting temperatures (T_m1) for the unfolding transitions of the HSA products varied from 62°C to 75°C. We characterized the samples for purity, fatty acid content, and molecular weight. The effects of adding fatty acids, heat pasteurization, and a low pH defatting technique on the transition temperatures were measured. Defatted HSA has a structure with the lowest stability (T_m of ～62°C). When fatty acids are bound to HSA, the structure is stabilized (T_m of ～64–72°C), and prolonged heating (pasteurization at 60°C) results in a heat‐stabilized structural form containing fatty acids (T_m of ～75–80°C). This process was shown to be reversible by a low pH defatting step. This study shows that the fatty acid composition and bioprocessing history of the HSA commercial products results in the large differences in the thermal stability. © 2014 American Institute of Chemical Engineers Biotechnol. Prog., 31:62–69, 2015