Title: Engineering a new tuberculosis vaccine for inhalation
Description: Tuberculosis is a disease estimated to infect over one-third of the world's population. With the increasing incidence of tuberculosis and drug resistant disease in developing countries due to HIV/AIDS, there is a need for vaccines that are more effective than the present vaccine. The anti-tubercular vaccine, Bacillus Calmette-Guérin (BCG), the most widely administered childhood vaccine in the world, has shown variable degrees of protection ranging from 0% to 80%. The current drying method, lyophilization, renders up to 90% of the whole cell vaccine inactive. Current limitations of the vaccine include cold chain storage, which is difficult to maintain and affects vaccine viability, and requires delivery via subcutaneous injection, which is challenging to administer and does not confer adequate lung specific immunity for a primarily pulmonary disease. This dissertation demonstrates that the M. bovis BCG vaccine can be dried without traditional lyophilization and can be delivered via the pulmonary route. This dry powder formulation maintains remarkable refrigerated and room-temperature stability for months by spray drying. By eliminating the presence of salt and cryoprotectants during the spray drying process, the significant osmotic pressures that are normally produced on bacterial membranes through droplet drying can be reduced sufficiently to minimize loss of viability on drying by up to two orders of magnitude. This dry powder vaccine was designed with a ten fold higher viability and has ideal powder characteristics for pulmonary delivery.

The powder has the unusual cylindrical geometry of the dried bacteria combined with the spherical geometry of the excipient, L-leucine particle. This characteristic is important to provide an improved vaccine for tuberculosis that has the advantage of stability and pulmonary delivery. This two-particulate form has two dimensions, a micrometer-size and a nanometer-size. We refer to this structure as a "nanomicroparticle" a result of geometry of the bacterium, with a combination of two axes of nanoscale dimensions and a third axis of micron dimension. This latter dimension permitting effective micron-like physical dispersion and the former alignment of the principal nano-dimension particle axes with the direction of airflow, thus possesses an ideal ability to aerosolize and highly efficient delivery targeted to the deep lung. Applications studying the immunological effects of delivery of the nanomicroparticles via the pulmonary route exhibited high efficiency delivery and peripheral lung targeting capacity from a low-cost and technically simple delivery system. We studied this possibility by aerosol delivery of the BCG nanomicroparticle to guinea pigs that were subsequently challenged with virulent Mycobacterium tuberculosis. We found a significant reduction of M. tuberculosis burden and lung pathology for the aerosol group relative to both untreated and control animals immunized with the standard BCG via subcutaneous injection.