Improving the Quality of Lyophilized Animal Vaccines: A Review of Optimization Strategies for Freeze-Drying Processes.

Authors

Fangjing Huang, Jiajie Jiao, Zexi Wang, Hongying Jie, Jiahao He, Xiaoxin Zuo, Yanhong Zhao, Yu Lu, Jianhong Gu, Fang Lyu

Published in

Veterinary sciences. Volume 13. Issue 9. Sep 16, 2026. Epub Sep 16, 2026.

Abstract

Vacuum freeze-drying, commonly referred to as lyophilization, is one of the primary processes in vaccine industrial manufacturing. It offers significant advantages, including a marked extension of the shelf-life of dried products, effective preservation of biological activity, and user convenience. However, in the production of animal freeze-dried vaccines, the diverse nature of antigens, the complexity of heat-stable protectant formulations, and variations in manufacturing equipment pose substantial challenges to process design for animal freeze-dried vaccines. Commercially available animal freeze-dried vaccines commonly suffer from antigen potency loss, insufficient product stability, low production efficiency and high manufacturing costs. Freeze-drying process optimization can markedly improve the quality of freeze-dried vaccines, with key evaluation indicators including vaccine stability, shelf-life, sample morphology, and residual moisture content. Focusing on multiple types of animal vaccines, this review summarizes research advances in improving the quality of animal freeze-dried vaccines from the perspectives of modifying material properties, enhancing freezing-stage regulation, increasing the specific surface area for drying, and optimizing heat conduction. Finally, future research strategies for animal freeze-dried vaccines are prospected. Although numerous approaches have been proposed to enhance the quality of animal freeze-dried vaccines, comprehensive considerations from multiple dimensions are still required to provide more holistic theoretical support for cost reduction and efficiency improvement in the production of animal freeze-dried vaccines.

PMID:
42798006
Bibliographic data and abstract were imported from PubMed on 26 Sep 2026.

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