Blogs

Automated Container Closure Integrity Testing (CCIT) of pre-filled syringes is a critical quality control process that ensures the product inside the syringe remains safe and effective during its shelf life. Pre-filled syringes are used to package and deliver various injectable drugs, such as vaccines, insulin, and other biologics.

The container closure integrity of pre-filled syringes can be compromised due to various factors such as: microcracks, defects in the rubber stopper, or improper sealing. To detect any potential defects in pre-filled syringes, automated CCI testing is done. This testing involves subjecting the pre-filled syringe to multiple conditions to check for any leakage or breakage in the container or closure.

Automated CCI testing of pre-filled syringes can be done utilizing techniques such as vacuum decay, high voltage leak detection, and tracer gas detection. These methods involve the use of specialized equipment to subject the pre-filled syringe to certain conditions including vacuum, high voltage, or exposure to a tracer gas. Any potential leaks or breakages in the container or closure can be detected by monitoring the pressure or electrical conductivity changes, or by the presence of the tracer gas

Automated CCI testing is crucial to ensure the safety and efficacy of pre-filled syringes. It is a reliable and efficient way of detecting potential defects in pre-filled syringes and ensuring that only products which meet the required quality standards are released to the market.

The E-Scan RTX platform is PTI’s fully automated, modular container closure integrity testing solution for pre-filled syringes. The RTX is a practical and reliable CCI solution that features a dynamic robotic design, tailored to fit your production requirements. This robust, adaptable platform utilizes MicroCurrent HVLD technology, a revolutionary form of HVLD that is the ideal CCI solution for high-risk, delicate biologic liquids. It provides a rapid PASS/FAIL result – its test cycle is only seconds – and is suitable for batch release testing, in line on production or in the lab.

PTI’s MicroCurrent HVLD technology uses a unique mode of DC voltage, applying no more than 50% of the voltage used on conventional high-voltage technologies. The nature of the PTI solution allows for the detection of leaks in packages with liquids of extreme low conductivities, including packages containing sterile water. The low voltage and current applied to the container also reduce the voltage the product is exposed to during the test. This technological advantage makes it the ideal solution for all parenteral and biologic solutions.

• MicroCurrent HVLD technology is effective across all parenteral products, including biologics and extremely low conductivity liquids including sterile water (WFI).
• Listed in USP Chapter 1207 as the recommended method for parenteral liquid package inspection.
• Robust method and good Signal-Noise-Ratio between good and defective products.
• Low voltage exposure reduces production of ozone.

PTI is a group of researchers, engineers, and professionals who are dedicated to enhancing the overall package quality experience over the course of the packaging lifecycle. To ensure container closure integrity, PTI has created and developed a number of inspection technology platforms. Each technology is based on the principle that there cannot be a test method without a valid test method. The technology solutions provided by PTI are centred on container closure integrity and give a deterministic measurement of package performance needed by critical applications. By delivering package performance data from the development stage to in-production online package inspection, the solutions are widely utilized to address a variety of packaging design and material difficulties.

Vacuum Decay is one of the most practical and sensitive vacuum-based leak detection techniques. This test provides the most accurate, repeatable, and reliable quantitative results, along with a pass/fail determination. The ASTM F2338 standard vacuum decay test method was developed using PTI’s VeriPac instruments. Additionally, it is recognized in the United States Pharmacopeia Chapter on CCI and classified in ISO 11607. The non-destructive container closure integrity testing (CCIT) method from VeriPac can use a differential pressure or absolute pressure transducer leak test device to find package leaks and undetectable defects.

PTI packaging and inspection systems transformed the traditional HVLD method and offered a new technology for assessing the integrity of all parenteral and biological products, including low conductivity liquids such as sterile water for injection (WFI). When compared to standard HVLD solutions, this innovative technology, known as Microcurrent HVLD, uses approximately 50% less voltage and exposes the product and environment to less than 5% of that voltage. The Microcurrent HVLD test method may detect and locate pinholes, micro-cracks, stopper/plunger leaks, non-visible leaks under crimping, and a variety of other defects.

Helium leak testing is the process of identifying leaks in various enclosed or sealed systems by utilizing helium as a "tracer" gas and measuring the concentration of the gas as it escapes as a result of a leak. Because it is non-toxic, non-flammable, non-condensable, and its atmospheric concentration is less than 5 ppm, helium is utilized as a tracer gas. Helium can pass through almost any cracks or openings since it is the second-smallest molecule in the periodic table. Additionally, helium is relatively safe to use because it does not react with other substances. This method uses a mass spectrometer leak detector (MSLD), also known as a helium leak detector, to locate and measure the leak.

PTI's proprietary Airborne Ultrasound technique is a non-destructive, non-invasive seal quality inspection method. Airborne Ultrasound technology offers thorough seal quality studies and is applicable to a wide range of packaging materials, including: Tyvek, paper, foil, film, aluminium, plastic, and poly. Defects of many forms, visible and invisible, leaking and non-leaking, process-related and random, can be detected. Airborne Ultrasound technology is an ASTM Test Method F3004 and an FDA-approved standard for testing seal quality.

The OptiPac One-Touch Tool-less technology is intended for non-destructive leak detection of blister packages. To identify leaks, the OptiPac uses volumetric imaging technology to measure the motion of a blister package under vacuum. With new blister package formats, the interface is practical and straightforward to set up, requiring no tooling changeover or extensive parameter modifications as seen with previous non-destructive blister package inspection systems. The system collects volumetric data from each cavity, responding to variable cavity shapes, sizes, and configurations of various blister pack forms.

Force Decay is a quantitative package integrity testing approach that is well-suited for low-headspace packaging. Non-porous materials, such as films, laminates, or foils, can be used in packaging formats. It does not harm or modify the sample packages because it is a non-destructive test method. When the test is finished, the packages can be returned to the batch without being discarded. The 410's force decay technology can measure force from a package's surface deflection during a conventional vacuum-based test cycle. VeriPac 410 force decay technology has been validated on a variety of package types, including: blister packs, transdermal patch sachets, and low headspace suture packs.

PTI’s continuous technology development has brought more technology and measurement solutions to market under one brand. Whether it be helium leak detection, high voltage leak detection, airborne ultrasound, or a vacuum-based solution, PTI - Science of Quality is the think tank you can rely on to provide the highest level of technology solutions for package quality. PTI continues to build on our journey, and we look forward to supporting you on yours.

Biological drug products are complex, large-molecule drugs that are derived from living organisms or their components. They are designed to mimic, augment or replace the function of naturally occurring molecules in the body. These drugs are often produced through biotechnology, which involves manipulating living cells to produce specific proteins or other molecules.

Examples of biological drug products include monoclonal antibodies, recombinant proteins, vaccines, and gene therapies. These drugs are used to treat a wide range of diseases, including cancer, autoimmune disorders, and genetic diseases.

Biological drug products are often more expensive than traditional small-molecule drugs because they are more complex to manufacture, require specialized facilities, and are subject to rigorous testing and regulatory requirements. However, they can also provide more targeted and effective treatments for certain conditions.

Package integrity testing is an essential part of ensuring the safety and efficacy of biologics. Any damage or compromise to the packaging of biologics can lead to degradation or contamination, which can impact their efficacy and safety. The choice of method depends on the specific biologic being packaged, the type of packaging used, and the regulatory requirements. It is important to perform Container Closure Integrity tests (CCIT) solutions. at multiple stages of the manufacturing process to ensure that the biologic remains safe and effective from production to patient use.

The E-Scan 655 is a revolutionary deterministic offline micro leak test instrument that utilizes a new class of HVLD technology to inspect vials, syringes, and other liquid filled parenteral products for container closure integrity. The E-Scan 655 technology is a MicroCurrent conductivity test method, HVLDmc, that is completely non-destructive to the container and product; exposing the package and product to lower voltage than other conductivity-based solutions.

The E-Scan MicroCurrent HVLD technology is often used in the pharmaceutical industry for detecting leaks in parenteral drug products, such as vials and syringes. E-Scan MicroCurrent HVLD technology is considered to be a reliable and efficient method for leak detection, ensuring the integrity of the drug product and patient safety.

The technology uses a non-contact and non-invasive test method that requires no sample preparation. The E-Scan 655 features a fast test cycle and simple operation. Additional benefits include quick changeover and easy recipe setup to accommodate a wide range of products and applications. E-Scan MicroCurrent HVLD technology can be migrated from laboratory to 100% inline production applications.

• Non-destructive, non-invasive, no sample preparation.
• High level of repeatability and accuracy
• Effective across all parenteral products, including extremely low conductivity liquids (WFI).
• Lower voltage exposure produces no ozone, eliminating risk to the product and environment
• Listed in USP Chapter <1207> as recommended method for parenteral liquid package inspection.
• Robust method and approximate 3x Signal-Noise-Ratio for a wide range of product classes and package formats.
• Simplifies the inspection and validation process.

Pouch seal inspection refers to the process of evaluating the quality of the seals on a pouch or bag. This can be done visually or through mechanical testing to ensure the seals are strong enough to maintain the integrity of the contents within the pouch. This is an important step in the packaging process to guarantee the integrity of the contents and to prevent product contamination or spoilage. The purpose of pouch seal inspection is to ensure that the seals will not break or leak, thereby preserving the quality and safety of the product.

Traditional seal integrity testing methods are unreliable because they miss unseen defects and mistakenly qualify pouches that have visual flaws. One of the most efficient techniques for non-destructive testing of flexible pouch packaging seals is Airborne Ultrasound technology. Seal-Sensor PQX is a non-contact Airborne Ultrasound technology technology to test package seals 100% online.

The Seal-Sensor PQX is a fully automated pouch seal inspection and handling technology. It comes with an integrated conveyor that can be readily connected into a production line. PTI's Seal-Sensor Airborne Ultrasonic technology is used to automatically scan the final pouch seal online at high speed. Seal-Sensor technology is an ASTM Test Method F3004 and an FDA consensus standard for inspecting seal quality.

Seal-SensorTM is an Airborne Ultrasonic Technology that inspects the final pouch seal 100% online and non-destructively. Seal-Sensor is a deterministic, quantitative, quick, and dependable approach for inspecting pouch seals for defects. Seal-Sensor detects incomplete seals, partial or weak areas in seals, and a variety of frequent defects in seals that appear visually acceptable but contain problems that impact product quality, value, and shelf-life. In less than one second, a single linear scan (L-Scan) of the pouch seal delivers a pass/fail result as well as quantitative, traceable data. At high outputs, a quick linear scan of the pouch seal allows immediate seal check/verification of seal quality. Data from tests is generated in seconds.

The Seal-Sensor PQX is a plug-and-play system for checking the quality of pouch seals inline. This simple-to-install system has a modest footprint and a full-screen HMI for displaying test result data as pouches are scanned. Inspection speeds can reach 350 mm/sec. A built-in reject chute swiftly removes flaws from the line, and a built-in stack light makes determining pass/rail outcomes simple.

• 100% pouch seal inspection
• Easy integration into production lines
• Adjustable for different size pouches
• Manual load or robotic pick & place
• Built-in reject chute