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Research ArticleResearch

A Method To Quantitatively Define and Assess the Risk of Cosmetic Glass Defects on Tubing Glass Vials

April W. Loui
PDA Journal of Pharmaceutical Science and Technology July 2011, 65 (4) 380-391; DOI: https://doi.org/10.5731/pdajpst.2011.00677
April W. Loui
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Abstract

The pharmaceutical and biotechnology industries have long been challenged with setting appropriate cosmetic defect size acceptance criteria on glass vials. Limits are rarely data-driven and scarce information is available on defect survivability through shipping and handling downstream of final product visual inspection. This study was undertaken to quantitatively understand cosmetic defect dynamics on glass vials and their impact on patient safety.

Scratch and bruise defects were artificially manufactured on product or placebo-filled, inspected, and glass defect–free tubing vials. The vials were processed and filled using commercial filling operations (i.e., vial washing, heat tunnel, conveyors, lyophilization, etc.). The defects were quantitatively characterized, subjected to automated packaging simulations, manually packaged in the approved commercial configurations, and subjected to ASTM Level I (highest intensity) shipping simulations in both pallet and small package configurations. The defects showed no statistically significant or applicable level of propagation, post-packaging and shipping simulation. Additionally, all test vials were subjected to dye leak testing, post-shipping simulation. All vials, except for one, met acceptance criteria for dye leak testing. Data-driven cosmetic defect dimensions for scratches and bruises were established based on this study.

LAY ABSTRACT: When delivering life saving medicines from the manufacturing plant to the patient, it is of great importance that the medicines arrive without damage that might harm the patient. In the case of medicines filled into glass vials, it is paramount that manufacturers understand whether minor cosmetic defects in the glass (such as small scratches and bruises) may weaken the vial enough to cause damage that might allow contamination of the contents.

This study was performed to determine if scratches and bruises on the glass vials might propagate during operations that occur downstream of the manufacturer's final vial inspection. The study vials were filled with product or placebo on the commercial filling lines to fully simulate environmental factors in a typical run. Scratches and bruises were then artificially created on the vials. Each defect was measured microscopically and labeled. The study population was then manually packaged into the approved configurations and subjected to the highest level intensity shipping simulations (ASTM Level 1).

Upon completion of the simulations, the vials were unpackaged and defects re-measured microscopically. The defects showed no statistically significant or applicable level of propagation. Additionally, all test vials were subjected to dye leak testing, post-shipping simulation. All vials, except for one, met acceptance criteria. Data-driven cosmetic defect dimensions for scratches and bruises were established based on this study.

  • Andersen-Darling test
  • ASTM
  • ASTM D4169-08
  • ASTM D7386-08
  • Cosmetic defects
  • Defect propagation
  • Dunnage
  • Dye leak testing
  • Glass defects
  • Heel sticker
  • Mann-Whitney test
  • Packaging simulation
  • Paired T-test
  • Pallet
  • Power values
  • Shipper
  • Shipping simulation
  • Small parcel
  • Tubing glass vials
  • Vial scratch
  • Vial bruise
  • Visual inspection
  • White light interferometry
  • © PDA, Inc. 2011
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PDA Journal of Pharmaceutical Science and Technology: 65 (4)
PDA Journal of Pharmaceutical Science and Technology
Vol. 65, Issue 4
July/August 2011
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A Method To Quantitatively Define and Assess the Risk of Cosmetic Glass Defects on Tubing Glass Vials
April W. Loui
PDA Journal of Pharmaceutical Science and Technology Jul 2011, 65 (4) 380-391; DOI: 10.5731/pdajpst.2011.00677

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A Method To Quantitatively Define and Assess the Risk of Cosmetic Glass Defects on Tubing Glass Vials
April W. Loui
PDA Journal of Pharmaceutical Science and Technology Jul 2011, 65 (4) 380-391; DOI: 10.5731/pdajpst.2011.00677
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  • Article
    • Abstract
    • Introduction
    • Vial Supply
    • Vial Defect Selection and Defect Manufacture
    • Defect Characterization—Pre-Shipping Simulation
    • Packaging Simulations
    • Packaging and Transport to Contract Lab for Shipping Simulations
    • Arrival at Contract Lab and Shipping Simulations
    • Defect Characterization—Post-Shipping Simulation
    • Dye Leak Testing
    • White Light Interferometry: 3-Dimensional Defect Metrology
    • Conclusion
    • Conflict of Interest Declaration
    • Acknowledgements
  • Figures & Data
  • Info & Metrics
  • References
  • PDF

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