Aggregation of proteins, even under conditions favoring the native state, is a ubiquitous problem in biotechnology and biomedical engineering. Providing a mechanistic basis for the pathways that lead to aggregation should allow development of rational approaches for its prevention. We have chosen recombinant human interferon-␥ (rhIFN-␥) as a model protein for a mechanistic study of aggregation. In the presence of 0.9 M guanidinium hydrochloride, rhIFN-␥ aggregates with first order kinetics, a process that is inhibited by addition of sucrose. We describe a pathway that accounts for both the observed first-order aggregation of rhIFN-␥ and the effect of sucrose. In this pathway, aggregation proceeds through a transient expansion of the native state. Sucrose shifts the equilibrium within the ensemble of rhIFN-␥ native conformations to favor the most compact native species over more expanded ones, thus stabilizing rhIFN-␥ against aggregation. This phenomenon is attributed to the preferential exclusion of sucrose from the protein surface. In addition, kinetic analysis combined with solution thermodynamics shows that only a small (9%) expansion surface area is needed to form the transient native state that precedes aggregation. The approaches used here link thermodynamics and aggregation kinetics to provide a powerful tool for understanding both the pathway of protein aggregation and the rational use of excipients to inhibit the process.Formation of biologically inactive proteins by aggregation is a problem of considerable importance in many disciplines (1-3). For example, protein aggregates can be formed in vivo and in vitro during folding of nascent polypeptide chains, eliminating or reducing the protein's biological function (4, 5). Misfolded protein aggregates often can be observed as inclusion bodies (6, 7) and are implicated in amyloid deposition in vivo (8). In the biotechnology industry, protein aggregation is encountered routinely during purification, refolding, sterilization, shipping, and storage processes because of the presence of chemical, physical, and thermal stresses (9).In addition to significant losses in protein activity, clinical dangers result from parenteral administration of aggregated material (10). Even aggregation levels as low as 1% over a 2-year shelf life can render a product clinically unacceptable. Thus, proteins must be protected against even relatively mild stresses by the addition of proper excipients. Rational choice of these excipients requires insight into the mechanism of aggregation.The detailed mechanism of protein aggregation is still unclear. Usually, the aggregation pathway is modeled as shown in Scheme 1 by using the Lumry-Erying framework (11,12). The model involves a first-order reversible unfolding of the protein and subsequent aggregation of nonnative species in a higher order process (2, 11-13):In this scheme, N refers to native protein, and A refers to an intermediate conformational state preceding aggregation. A m refers to an aggregated form composed of m pro...