Break in cold chain mainly results in:
Break in cold chain defined as temperature excursion outside recommended range due to equipment failure, power outage, improper conditioning of ice packs causing freezing, transport delays, human error leaving vaccines outside refrigerator. Consequences mainly vaccine failure due to irreversible potency loss. Heat exposure accelerates physico-chemical degradation: proteins unfold aggregating via hydrophobic interactions, deamidation of asparagine residues altering epitopes, hydrolysis of phosphodiester bonds in mRNA vaccines producing fragmented inactive RNA, replication titer of live attenuated vaccines drops logarithmically losing ability to induce immunity, toxoids dissociate from aluminum adjuvant losing depot effect. Freezing aluminum-adjuvanted vaccines causes aluminum salts to agglomerate forming large crystals visible as granular sediment after shake test failing, reducing surface area and adjuvanticity causing injection site abscess. Once potency lost cannot be restored by returning to cold chain because degradation covalent. Administration of compromised vaccine yields seronegativity, primary vaccine failure documented outbreaks despite high documented coverage, as observed with measles resurgence investigation tracing to frozen DTP hepatitis B carriers causing no seroconversion, requiring costly revaccination campaigns, mistrust, loss of herd immunity threshold, morbidity mortality. Therefore strict compliance and VVM monitoring vital to discard affected vials immediately preventing ineffective immunization.
Ref: Matthias et al. Bull WHO 2007 85:400 Break cold chain vaccine failure; WHO VVM guidance.