Avian Influenza (AI) is a disease syndrome of avian infections caused by influenza A viruses, which is categorized into Highly Pathogenic Avian Influenza (HPAI) and Lowly Pathogenic Avian Influenza (LPAI).Avian Influenza of subtype H9N2 is a Lowly Pathogenic Avian Influenza (LPAI).H9N2 subtype Avian Influenza viruses were isolated for the first time from chickens on the mainland of China in 1994, and since then the viruses started to spread in Since then, the virus began to spread within the chicken flocks in China, causing huge economic losses to the poultry industry. Vaccine immunization is the main means of epidemic prevention. Our company aims to develop an efficient, inexpensive and cost-effective avian influenza vaccine. The project is designed from cell line screening, reactor culture, virus production evaluation and animal experiments, to subsequent scale-up to a bioreactor for whole-suspension culture of cells to produce viral vaccines, with small production batch-to-batch variations, low cost, and easy scale-up. The aim of this work is to find out a mature and stable production process and apply it to large-scale production to prepare an efficient and cheap avian influenza vaccine.
Avian influenza virus belongs to the influenza virus genus A influenza virus of the family Orthomyxoviridae, influenza A virus host is extremely wide. the pathogenicity of influenza A viruses and strains and hosts have a lot to do with different strains of influenza A viruses on the same host or the same strain of the same host pathogenicity varies greatly. the H9N2 subtype AIV is the most widely involved in our country, the morbidity and mortality rate is low, but the harm can not be ignored. The virus in addition to causing avian respiratory diseases, but also violates the reproductive system of poultry, so that the egg production of laying hens fell sharply or egg production can not reach the peak: broiler infection growth is slow, reduce the meat ratio; H9 subtype AIV easy and other viral diseases (such as chicken Newcastle disease, etc.) or bacterial diseases (such as E. coli disease, etc.) mixed infection, can cause a higher mortality rate. Canine kidney epithelial cells (Madin-Darby canine kidney cells (MDCK)) are highly susceptible to influenza viruses, making them one of the best hosts for influenza vaccine production. In this paper, the MDCK-10, which has been successfully suspended and domesticated in the pre-laboratory, was validated for stability and evaluated for virus production, and then to animal experiments. From the development of shaking flask small test process, to the pilot test and large-scale production in bioreactors to carry out a full range of process mapping, so as to update the current stage of the production of chicken embryo as raw materials for the production of the inherent process, for the domestic low pathogenic avian influenza production enterprises to carry out the full-suspension serum-free large-scale production of the data base.
Experimental Materials and Methods
<svg viewbox="0 0 1 1" style="float:left;line-height:0;width:0;vertical-align:top;"></svg>MDCK-10 suspension cells were domesticated by Suzhou Wome Biological Co., Ltd; H9N2 subtype avian influenza viruses were isolated from our laboratory, expanded and re-strengthened on SPF chicken embryos, and harvested as the viruses used in the present experiments, and its chicken embryo half infectious dose (50%egg infectious dose, EID₅₀) was 8.50 LgEID₅₀/0.2 mL.Main reagents and instruments
MS01A serum-free suspension medium was developed by our company; trypsin was purchased from Gibco; 250mL, 500mL and 1L shake flasks were purchased from Corning, USA; automatic counter was purchased from Shanghai Ruiyu Biotechnology Company Limited; 14L and 35L glass reactor was purchased from Suzhou Diyoyi Biotechnology Co.<svg viewbox="0 0 1 1" style="float:left;line-height:0;width:0;vertical-align:top;"></svg>shake-flask passaging culture
Suspended MDCK-10 cells in the exponential growth phase were inoculated in Corning shaker flasks at a density of about 1.5×10⁶cells/mL, filled with 20-30% of the total volume of the flasks, and cultured in an incubator at 37℃, 5% CO₂, and 130 r/min; the subsequent successive passages were carried out by diluting the cell sap with fresh medium to 1.5×10⁶ cells/mL, and the cells were passaged every 48h. The subsequent successive passaging was performed by diluting the cell solution to 1.5×10⁶ cells/mL with fresh medium and passaging every 48h. After 40 generations of consecutive cell passages, the cell status was observed and data were summarized to support the stability of cell passages in continuous dilution.
Continuous passaging culture in 14L reactor
Suspension of MDCK-10 on a 14L glass bioreactor with a culture volume of 6L, cells were inoculated on the tank at a density of about 1.5×10⁶cells/mL, with a dilution ratio of 1:6, and the parameters of the reactor were controlled: temperature: 37℃; rotational speed: 60rpm; pH7.15; DO: 60%. Continuous dilution passaging culture was carried out on the reactor, and the successive 1:6 dilution was stabilized for about 10 generations. The continuity and reproducibility of cell culture on stirred reactor were compared.Shake flask pick-up process (H9N2 subtype)
MDCK-10 cells were cultured normally for about 48h, the density proliferated to 8-10×10⁶cells/mL, the cell solution was diluted according to the volume ratio of fresh medium to cell solution of 1:1, inoculated in 250mL shake flasks with a volume of 50mL, and different ratios of viral inoculation were set, which were 1/1000 of the diluted volume of the culture, 1/1000 of the volume of the culture, 1/1000 of the volume of the culture, and the concentration of trypsin was added as 10μg/mL, which was cultured in a 37℃, 5% CO₂ incubator, with a shaker speed of 130 r/min. /mL, placed in 37 ℃, 5% CO₂ incubator culture, shaker speed of 130 r/min. respectively, in the culture of 48h, 72h to collect the virus liquid, freeze-thaw once by chicken erythrocyte agglutination price to determine the virus titer. The optimal MOI and harvest time were determined.Process validation of 14L reactor and preparation of inactivated vaccines
Suspension MDCK-10 on the tank 14L glass bioreactor, culture volume 6L, density increase to 8-10 × 10⁶cells/mL, according to the fresh medium and cell solution volume ratio of 1:1 dilution of cell solution, respectively, inoculation of H9F6 strain, H9C1 strain, H9C2 strain, H9CD strain at the ratio of one ten-thousandth of the culture volume, trypsin addition concentration of 10 μg / mL, control Reactor parameters: temperature: 37°C; speed: 60 rpm; pH 7.15; DO: 60%. The viral solution was collected after 48-72h of incubation, and samples were taken to determine the viral titer after freezing and thawing once. A 37% formaldehyde solution was added at a final concentration of 0.1% to 37°C for 24h of inactivation, during which time it was stirred every 4h. Inoculation of chicken embryos to determine the inactivation effect: inoculated in 9-11 days old SPF chicken embryos, each chicken embryo inoculation 0.1mL, incubated at 37 ℃. 24h photo-embryo, non-specific death should not exceed 1. 24h after the embryo twice a day, observation for 5 days. The hemagglutination value of all embryos was determined separately, and no hemagglutination should occur. The inactivation was judged to be complete when the hemagglutination price was measured in all the embryos and transmitted blindly for one generation, and no hemagglutination was observed.
The four inactivated antigens (H9F6, H9C1, H9C2 and H9CD strains) were diluted 2-fold and 4-fold with sterilized saline, and after dilution, 6% Tween-80 was added to them respectively, and the aqueous phase and the oil phase were white oil. According to the ratio of water phase: oil phase is 1:3 emulsification seedling production.
Immunization of SPF chickens
SPF chickens of 21 days old were taken and divided into 8 groups of 10 birds each, the first to the eighth groups were H9F6 strain diluted 2 times; H9C1 strain diluted 2 times; H9C2 strain diluted 2 times; H9CD strain diluted 2 times; H9F6 strain diluted 4 times; H9C1 strain diluted 4 times; H9C2 strain diluted 4 times; H9CD strain diluted 4 times, respectively. Each group was immunized with the corresponding inactivated vaccine, 0.2ml/pc. A blank control group of 5 animals was also set up without immunization. The serum was collected on the 14th and 21st day after immunization, and the antibody potency of H9 serum was determined.Comparison of the immunization effect of cellular inactivated vaccine and embryo inactivated vaccine
(1)Preparation of inactivated cellular vaccines
Cellular inactivated vaccines of the H9CD strain were prepared according to methods 05 and 06.
(2)Preparation of embryotoxic inactivated vaccine
The H9CD strain was diluted 10-4-10-5 with sterilized saline and inoculated into 10-11 days old susceptible chicken embryos via allantoic fluid at 0.1 ml per embryo.The chicken embryos were selected to be dead within 48-120h after inoculation and survived for 120h, and then cooled at 2-8℃ for 24h, harvested chicken embryos' allantoic fluid, and inactivated according to the method of 05 and inactivation test, and then emulsified according to the method of 06 to make the vaccine.
(3)Immunization of SPF chickens
The 21-day-old SPF chickens were divided into 2 groups of 5 birds each, the first group was immunized with inactivated cytotoxic vaccine of H9CD strain, the second group was immunized with inactivated vaccine of H9CD strain, 0.2 ml/bird, and the other group was set up as a blank control group of 5 birds, which was not immunized. The serum was collected on the 14th and 21st day after immunization, and the antibody potency of H9 serum was determined.
<svg viewbox="0 0 1 1" style="float:left;line-height:0;width:0;vertical-align:top;"></svg>Shake flask passaging culture studies
Shake flasks were continuously cultured for 40 generations, with cell densities stabilized between 8.8×10⁶cells/ml and 9.6×10⁶cells/ml, and cell viability stabilized between 97% and 99%, indicating that MDCK cells can be stably passaged on shake flasks.<svg viewbox="0 0 1 1" style="float:left;line-height:0;width:0;vertical-align:top;"></svg>Reactor continuous dilution culture analysis
MDCK-10 cells were cultured in continuous dilution in 14L reactor for 10 generations, the cell density was stable between 8.9×10⁶cells/ml-9.4×10⁶cells/ml, the glucose residue continued to decrease in the culture of F1-F5, and stabilized at 1.0g/L~1.5g/L in the culture of F6-F10, which indicated that MDCK-10 cells could be stably passaged on the 14L reactor. indicating that MDCK-10 cells could be stably passaged on the 14L reactor.<svg viewbox="0 0 1 1" style="float:left;line-height:0;width:0;vertical-align:top;"></svg><svg viewbox="0 0 1 1" style="float:left;line-height:0;width:0;vertical-align:top;"></svg>Exploration of the optimization of the shaking bottle poisoning process
The H9 strain was inoculated in shake flasks at different inoculation ratios, and samples were taken at 48h, 72h and 96h after inoculation, and the viral content was determined after freezing and thawing once. The results showed that when the virus was inoculated at 0.001% v/v, the viral potency peaked at 72h, and the chicken erythrocyte agglutination value was 9log2HAU/25ul; when the virus was inoculated at 0.01% and 0.1% v/v, the viral potency reached the peak at 72h, and the chicken erythrocyte agglutination value was 11log2HAU/25ul. In order to save the amount of the seed virus for the large-scale production, the optimal inoculation ratio of 0.01% of the culture volume ratio was determined. In order to save the amount of seed virus used in large-scale production, the optimum inoculation ratio was determined to be 0.01% of the culture volume ratio, and the harvest time was 72h after inoculation. Sample cells were counted at different time points after poisoning and cell viability was determined. The results showed that the cell counts of different poisoning ratios increased within 48h of culture, and then the cell counts began to decrease after 48h; the cell viability of different poisoning ratios continued to decrease after poisoning, and the cell viability was only between 20%-26% after 96h, and the higher the proportion of poisoning, the faster the decline of cell viability.<svg viewbox="0 0 1 1" style="float:left;line-height:0;width:0;vertical-align:top;"></svg>Validation of reactor vaccination and vaccine preparation
H9F5 strain, H9C1 strain, H9C2 strain, H9CD strain four strains were inoculated with 14L reactor, 72h harvested freeze-thawed once to determine the viral content of the four strains of hemagglutination valence of 1:1024, chicken embryo half of the infected amount of the H9CD strain is slightly higher than the 8.6lgEID₅₀/0.2 ml, the lowest strain of the H9C1, 8.6lgEID₅₀/0.2 ml. four kinds of antigen with 0.1% formaldehyde solution inactivation, do inactivation test, the four antigen inactivation test are qualified. The four antigens were inactivated with 0.1% formaldehyde solution and then inactivation test was done, and all four antigens passed the inactivation test. The vaccine was prepared by emulsifying the antigens with sterilized saline in 2-fold and 4-fold dilutions, respectively.
<svg viewbox="0 0 1 1" style="float:left;line-height:0;width:0;vertical-align:top;"></svg>Immunized SPF serum antibody potency results
SPF chickens were immunized with the prepared vaccine at 21 days of age, and blood was collected after 21 days of immunization for the determination of serum antibody potency, which showed that the antibody potency of the 2-fold dilution group was higher than that of the 4-fold dilution group after 14 and 21 days of immunization. After 14 days of immunization, H9C2 strain had the lowest antibody potency, 1:25.5 in 2-fold dilution and 1:23.6 in 4-fold dilution; H9CD strain had the highest antibody potency, 1:28.7 in 2-fold dilution and 1:27.4 in 4-fold dilution; H9C1 strain had the lowest antibody potency, 1:25.2 in 2-fold dilution and 1:24.4 in 4-fold dilution after immunization. The H9CD strain had the highest immunization antibody potency, with 2-fold dilution of 1:29.4 and 4-fold dilution of 1:28.6. Based on the results of serum antibody potency on the 14th and 21st day of immunization, the H9CD strain was screened out as the vaccine strain for the subsequent tests. Note: The antibody potency of all 5 sera in the blank control group was 0
<svg viewbox="0 0 1 1" style="float:left;line-height:0;width:0;vertical-align:top;"></svg>Comparison of the immunization effect of cellular inactivated vaccine and embryo inactivated vaccine
The H9CD strain was amplified by cell and non-immune chicken embryo respectively, and the antigenic potency of the half-finished product was determined, the hemagglutination value of cell-toxic chicken erythrocyte was 1:2048, and the half infected amount of chicken embryo was 8.75lgEID50/0.2ml; the hemagglutination value of embryo-toxic chicken erythrocyte was 1:2048, and the half infected amount of chicken embryo was 8.6lgEID50/0.2 ml. Three kinds of antigens were inactivated with 0.1% formaldehyde The three antigens were inactivated with 0.1% formaldehyde solution, and then the inactivation test was done, and all three antigens passed the inactivation test, and the vaccine was emulsified and prepared. The vaccine was immunized against SPF at 21 days of age, and blood was collected on the 14th and 21st day of immunization to determine the serum antibody potency. The results showed that after 14 days of immunization, the average antibody potency of the mixed group was 1:28.4, which was higher than that of the embryotoxin 1:26.8 and that of the cellular vaccine 1:27.28; after 21 days of immunization, the antibody potency of the cellular vaccine and embryo vaccine was comparable to that of the cytotoxic vaccine and embryo vaccine, with the average antibody potency of cytotoxic vaccine 1:210.2, and embryotoxic vaccine 1:210.4. The mean antibody potency of the cellular vaccine was 1:210.2, and embryo vaccine 1:210.4. It shows that the immunization effect of cytotoxic and embryotoxic is comparable, and the antibody production of cytotoxic is faster than embryotoxic. The average value of the mixed group of vaccines was 1:211.2, which was higher than that of cytotoxic and embryonic vaccines, indicating that the mixed group of vaccines had the good immunogenicity of embryonic vaccines, and also took into account the rapid response of cytotoxic vaccine immunization.<svg viewbox="0 0 1 1" style="float:left;line-height:0;width:0;vertical-align:top;"></svg><svg viewbox="0 0 1 1" style="float:left;line-height:0;width:0;vertical-align:top;"></svg> 1. in the process of cell culture, it was determined that in the process of shaking flask culture, the loading volume of 20-30% cells can be normal value-added, and maintain a good cell state, in the process of continuous culture in the reactor, it was determined that the parameters: temperature: 37 ℃; rotational speed of 60 rpm; pH 7.15; DO: 60%, the cells can be continuously diluted in the 14L reactor for the passaging of the cell value-added and stable, and the culture media was rich in nutrients, which could maintain the cells in good condition and subsequent inoculation; 2. Through animal experiments of strain screening, the H9N2-CD strain was determined to have the best immunization effect and faster and higher antibody production; 3. Compared with traditional embryo seedling, cellular seedling is not weaker than embryo seedling at all, and the immunization effect is comparable, but the mixed use is better.