Significant research is being done to develop and improve delivery mechanisms for biopharmaceuticals and vaccines, including pulmonary (
inhalation), nasal, transdermal, and oral alternatives. Market projections indicate that the delivery of proteins and vaccines by
inhalation and oral formulation has become and will continue to be increasingly important. These delivery mechanisms, to be effective, will require better stabilization of the biologicals so that they can maintain
potency and effectiveness at ambient temperatures for extended periods of time. The novel Preservation by
Vaporization (PBV) Technology described herein provides cost-effective and efficient
industrial scale stabilization of proteins, viruses,
bacteria, and other sensitive biologicals, thereby allowing a production of products that are not possible to be produced by existing methods. The suggested new PBV process comprises primary
drying under vacuum from a partially frozen state (i.e.
slush) at near subzero temperatures followed by stability
drying at elevated temperatures (i.e., above 40 degrees Celsius). The new suggested method can be performed aseptically in unit doze format (in vials) and / or in bulk format (in trays, bags, or other containers). The
drying can be performed as a continuous load process in a
manifold vacuum dryer comprising a plurality (e.g., 30) of vacuum chambers attached to a condenser during the drying.