Blogs

06
Mar 2025

Why Moisture and Oxygen Are the Silent Threats in Medical Device Packaging

Why-Moisture-and-Oxygen-are-the-Silent-Threats-in-Medical-Device-Packaging

Medical device packaging plays a crucial role in maintaining product sterility, stability, and functionality. However, two of the most overlooked yet destructive environmental contaminants in medical device packaging are moisture and oxygen. While many packaging strategies focus on microbial contamination, the gradual ingress of oxygen and moisture can have severe implications for product performance and shelf-life.

For certain medical devices—such as drug-coated stents, moisture-sensitive bone cement, and oxygen-critical diagnostic kits—even minimal exposure to moisture or oxygen can result in degradation, rendering the product ineffective or unsafe. The key to mitigating these risks lies in ensuring package integrity through advanced testing methodologies like Vacuum Decay Technology

Moisture and Oxygen: Invisible Threats in Medical Device Packaging

Medical devices are often packaged in either porous or non-porous materials, each with distinct vulnerabilities:

  • Porous packaging allows for equalization of partial pressures, reducing microbial contamination risks but potentially increasing exposure to environmental contaminants like moisture and oxygen.
  • Non-porous packaging, on the other hand, creates a sealed environment but is susceptible to microleaks—tiny defects that permit oxygen and moisture ingress over time.

Unlike bacteria, moisture and oxygen ingress is more predictable and gradual, occurring through microleaks that might not be large enough for microbial entry. As pressure fluctuations and environmental conditions change, these contaminants steadily penetrate the packaging, compromising sterility, chemical stability, and device performance.

Medical Device Package Integrity Testing Using Vacuum Decay Technology

The VeriPac Vacuum Decay Technology, compliant with ASTM F2338 standards, is an advanced, deterministic, and non-destructive Container closure integrity test method (CCIT)for identifying microscopic leak. packaging. Designed for versatility, this technology is suitable for both rigid and flexible containers, making it an ideal solution for the pharmaceutical industry.

This innovative system follows a simple yet highly effective process. The primary packaging is placed inside a testing chamber, which is designed to accommodate various packaging formats. Once secured, a controlled vacuum is applied. A highly sensitive pressure transducer then monitors any vacuum decay, which may result from gas escaping or liquid vaporizing within the package—both clear indicators of potential leaks. Capable of detecting leaks as small as 5 microns or even smaller, this precise and reliable method ensures the highest level of package integrity.

Benefits of the VeriPac Series

  • High Sensitivity: Detects microscopic leaks with precision.
  • Non-Destructive: Allows manufacturers to test without damaging the product.
  • Adaptability: Suitable for both rigid and flexible packaging formats.
  • Efficiency: Provides fast, accurate, and quantitative results.

Moisture and oxygen pose silent but significant risks to medical device packaging. These contaminants can penetrate microleaks, degrading products and compromising patient safety. By integrating Vacuum Decay Technology into quality control processes, manufacturers can extend product shelf-life, enhance safety, and ensure the highest standards of medical device integrity.

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ccit, package integrity testing, container closure integrity testing, vacuum decay
268
15
Oct 2024

Advanced Solutions for Nebulizer Package Integrity Testing Challenges

Advanced-Solutions-for-Nebulizer-Package-Integrity-Testing-Challenges

Sterile packaging is a critical component in the administration of nebulizer drugs, especially given the vulnerability of respiratory medications to contamination. Nebulizers deliver medication directly to the lungs, requiring high levels of sterility to protect patients from the risks of microbial and particulate matter contamination. Any breach in package integrity can jeopardize the safety and efficacy of the drug, leading to potential health risks.

To ensure that the nebulizer medications remain sterile, rigorous package integrity testing is essential. Regulatory bodies like the FDA, USP, and EU have laid down guidelines, including FDA’s Container and Closure System Integrity Testing in Lieu of Sterility Testing (USP 1207) and EU Annex 1, to ensure that high-risk packaging like nebulizer cups and nebules meet the highest standards of sterility.

What are Nebulizers?

Nebulizers are medical devices used to deliver medication in the form of a mist that patients can inhale directly into their lungs. These devices are commonly used to treat respiratory conditions such as asthma, chronic obstructive pulmonary disease (COPD), and cystic fibrosis.

The effectiveness of nebulizer treatment hinges on maintaining the sterility and safety of the drug until it reaches the patient. Nebulizer medications are usually packaged in pre-filled nebulizer cups, syringes, or blow-fill-seal (BFS) packaging, often referred to as nebules. These packages must remain hermetically sealed to prevent contamination from external environments.

Package Integrity Testing of Nebulizers

Ensuring the integrity of nebulizer packaging is a complex process due to the unique characteristics of the packaging material and design. BFS packaging, one of the most common formats for nebulizer drugs, is prone to leaks in the seams and tear-off regions. Such vulnerabilities can allow gas, debris, or microbes to enter the packaging, compromising the sterility of the drug. On the other hand, egress of the medication from the packaging can occur if the integrity is compromised, leading to under-dosing or exposure to air.

To address these challenges, Container Closure Integrity Testing (CCIT) methods are employed to verify the sterility and stability of nebulizer packaging throughout its lifecycle. Traditional testing methods include visual inspection, dye ingress testing, and microbial challenge testing, but these methods often lack the sensitivity and efficiency needed for today’s complex packaging.

Package Integrity Testing Using Vacuum Decay Technology

Vacuum decay testing is a highly efficient and extensively validated method for Container Closure Integrity Testing (CCIT), recognized for its practicality and sensitivity in detecting leaks in vacuum-sealed containers. Based on fundamental physical principles, this method evaluates container integrity by providing reliable and precise quantitative results, classifying them as either pass or fail. It offers a non-destructive alternative to traditional approaches such as the blue dye test.

PTI's VeriPac system provides a non-invasive solution to conventional leak testing methods like water bath, bubble leak, and blue dye tests. VeriPac systems are specifically designed for testing the integrity of Tyvek and porous packaging, ensuring compliance with both regulatory standards and patient safety requirements. The VeriPac vacuum decay technology, codified as ASTM Test Method F2338 since its inception in 2003, was initially developed for testing Tyvek-lidded trays using PTI’s VeriPac instruments.

The technology operates by connecting VeriPac leak testers to a specially designed test chamber that houses the package sample. A vacuum is applied to the package inside the chamber, and the vacuum level, along with its variation over a predetermined test duration, is monitored using single or dual vacuum transducer technology. Changes in absolute or differential vacuum levels are analyzed to identify the presence of leaks or defects within the package.

Key Benefits of Vacuum Decay technology

  • Non-destructive and non-invasive
  • No sample preparation
  • ASTM approved test method
  • FDA Recognized Consensus Standard
  • Allows for increased sampling
  • Quantitative results
  • Repeatable
  • Rapid test time
  • Eliminates cost and waste of destructive testing
  • Test results can be easily validated
  • SPC laboratory testing or online applications
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ccit, package integrity testing, container closure integrity testing, vacuum decay
900
30
Sep 2024

Vacuum Decay Testing for CGMs - Enhancing Package Integrity and Patient Safety

Vacuum Decay Testing for CGMs - Enhancing Package Integrity and Patient Safety Package integrity testing is critical for CGM devices as any breach in packaging could compromise sterility, potentially leading to infections or product degradation. Packaging for CGMs typically includes materials like Tyvek® Poly or Foil pouches, and defects such as cold seals, channel leaks, or occlusions can occur during manufacturing or sterilization. Traditional visual inspections often fail to detect microleaks, which are capable of allowing harmful microorganisms or gases to penetrate the packaging.

 

This is where Vacuum Decay technology can be applied. Vacuum Decay technology is an FDA-recognized leak detection technique that can be used for CCI testing of high-risk package applications. The non-destructive nature of this process provides a greater understanding of the packages and reduces waste. Vacuum Decay technology is capable of sensitively testing leaks in sealed rigid, semi-rigid and flexible packaging made of non-porous or porous materials and is proven to provide repeatable, reliable and quantitative test results.

PTI’s VeriPac Vacuum Decay technology is an ASTM-approved, FDA-recognized test method with proven capabilities to provide reliable, reproducible, repeatable, and accurate quantitative results. It is a non-destructive container closure integrity test (CCIT) test capable of detecting leaks in a single-digit micron range while accommodating multiple packaging types including filled and sealed rigid, semi-rigid and flexible packaging made of non-porous or porous materials. Considered as a practical alternative to destructive testing methods like water bath or dye ingress, Vacuum Decay technology eliminates subjectivity, reduces waste and cost and is proven to provide a short-term return on investment. The VeriPac test systems detect critical packaging failures reliably and reveal valuable information on the packaging process.

In the medical device industry, where patient safety is paramount, ensuring the integrity of packaging is crucial. For CGMs, which are vital for diabetes management, any compromise in packaging could lead to severe health consequences. Vacuum Decay Technology provides an effective, non-destructive method for detecting leaks and maintaining the integrity of CGM packaging, thereby ensuring product safety and sterility. As this technology continues to evolve, it stands to play an even greater role in enhancing the reliability and safety of medical devices worldwide.

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vacuum decay, CGM, package integrity testing, vacuum decay technology
948
18
Sep 2024

Maximizing Package Safety - Tyvek Integrity Testing with PTI's VeriPac Series

Maximizing-Package-Safety-Tyvek-Integrity-Testing-with-PTI's-VeriPac-Series

In today's healthcare and pharmaceutical industries, ensuring the integrity of packaging is paramount. This is especially true for sterile products, where the failure of packaging can lead to contamination, posing serious risks to patient safety. Among the various packaging materials available, Tyvek has emerged as a popular choice due to its durability, breathability, and microbial barrier properties.

Tyvek, a synthetic material made from high-density polyethylene fibers, is widely recognized for its exceptional properties, making it a top choice for medical and pharmaceutical packaging. It combines outstanding durability, tear resistance, and breathability with superior microbial barrier protection. These qualities make Tyvek ideal for use in sterile barrier systems, medical device packaging, and pharmaceutical packaging. However, to ensure the highest levels of safety and quality, thorough integrity testing of Tyvek packages is essential.

Why is Tyvek Package Integrity Testing Important?

Ensuring the integrity of Tyvek packaging is crucial for several reasons:

  • Patient Safety: Compromised packaging can lead to contamination of sterile products, posing significant health risks to patients. Integrity testing ensures that the packaging remains intact, maintaining sterility until the point of use.
  • Regulatory Compliance: Regulatory bodies, such as the FDA and ISO, have stringent requirements for packaging integrity. Adhering to these regulations is essential for market approval and maintaining the reputation of the manufacturer.
  • Product Quality: Integrity testing helps in detecting defects, such as pinholes, leaks, and weak seals, which can compromise the quality of the packaged product. Ensuring robust packaging helps in preserving the efficacy and shelf life of the product.
  • Cost Efficiency: Identifying and rectifying packaging defects early in the production process can save significant costs associated with product recalls, rework, and liability claims.

Tyvek Package Integrity Testing Using PTI's VeriPac Series

Vacuum decay is a highly efficient and extensively validated Container Closure Integrity testing (CCIT) method, recognized as the most practical and sensitive technique for detecting leaks in vacuum-sealed containers. This method operates on the simple physical principles to evaluate container integrity, providing dependable and precise quantitative results, categorized as either pass or fail. It has become a non-destructive alternative to conventional methods such as the blue dye test.

PTI's VeriPac package integrity testing method offers a non-destructive alternative to traditional water bath leak tests, bubble leak tests, and blue dye leak tests. VeriPac leak test systems are suitable for package integrity testing of Tyvek and porous packaging, ensuring the product meets both regulatory and patient expectations. The VeriPac vacuum decay technology, an ASTM Test Method F2338 was first established in 2003, and was initially based on tests of Tyvek-lidded trays using PTI’s VeriPac instruments.

This technology functions by connecting VeriPac leak testers to a test chamber specifically designed to accommodate the sample package. Vacuum is applied to the package within the test chamber. The level of vacuum and the change in vacuum over a predetermined test period are monitored using single or dual vacuum transducer technology. Variations in absolute and differential vacuum are analyzed to detect the presence of leaks and defects within the package.

Benefits of VeriPac Inspection System:

  • Non-destructive test method that ensures quantitative test results
  • FDA recognized ASTM test method
  • Referenced in USP 1207 guideline
  • Cost-effective with rapid return on investment
  • Simplifies inspection and validation process
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ccit, package integrity testing, container closure integrity testing, vacuum decay
5125
29
Jul 2024

VeriPac Series - Safeguarding the Integrity of Nutraceutical Packaging

VeriPac-Series-Safeguarding-the-Integrity-of-Nutraceutical-Packaging

In today's health-conscious world, nutraceuticals – products that bridge the gap between food and pharmaceuticals – are experiencing a surge in popularity. But ensuring the safety, efficacy, and quality of these products extends beyond the formulation itself. Proper packaging plays a crucial role in protecting these sensitive nutraceuticals from contamination, degradation, and environmental factors throughout their shelf life.

Understanding Nutraceutical Products and their Packaging

Nutraceuticals encompass a wide range of products, including vitamins, minerals, dietary supplements, herbal remedies, and functional foods. These products often contain potent ingredients susceptible to moisture, oxygen, light, and temperature fluctuations. The packaging needs to be carefully selected to create a barrier against these external threats, ensuring the product maintains its potency and quality from production to consumption. Common nutraceutical packaging formats include bottles, capsules, blisters, pouches, and stick packs.

Why is Nutraceutical CCI Testing Important?

Maintaining container closure integrity is paramount for several reasons:

  • Consumer Safety: Leaky or compromised packaging can allow harmful contaminants like bacteria, mold, or moisture to enter the product, posing a health risk to consumers.
  • Product Efficacy: Exposure to oxygen, light, or moisture can degrade the active ingredients in nutraceuticals, rendering them less effective.
  • Shelf Life: Compromised packaging can shorten the shelf life of a product, leading to wasted inventory and financial losses for manufacturers.
  • Brand Reputation: Leaky or damaged packaging can negatively impact brand image and consumer trust.

Container Closure Integrity Testing Using VeriPac Series

PTI’s VeriPac series are non-destructive, non-invasive inspection systems for leak detection and package integrity testing . These systems reduce waste and provide operators with a clear understanding of package quality. The VeriPac test system produces real time results from precise quantitative measurements that identify packaging defects before critical process issues get out of control. Tests can be performed in any sequence and even repeatedly on a single sample. Good packages can be returned undamaged to the packaging line. Testing is more reliable, sensitive and efficient than destructive methods. VeriPac series utilizes the ASTM approved patented Vacuum Decay leak test method F2338, recognized by the FDA as a consensus standard for package integrity testing.

The VeriPac SPX offers a robust container closure integrity test (CCIT) solution for nutraceutical package inspection by leveraging Statistical Process Control (SPC). This system enables automated testing to significantly increase sampling rates, ensuring comprehensive quality assurance. Its design allows for seamless technology integration as an add-on to existing production lines, facilitating easy adoption. By improving process and quality control, the VeriPac SPX helps identify defects and early deviations promptly, thereby enhancing overall product integrity and reliability.

Technology Overview

PTI’s VeriPac leak testers connect to a test chamber that is specially designed to contain the package to be tested. The package is placed inside the test chamber to which vacuum is applied. The absolute transducer technology is used to monitor the test chamber for both, the level of vacuum as well as the change in vacuum over a predetermined test time. The changes in absolute and differential vacuum indicate the presence of leaks and defects within the package. The test cycle takes only a few seconds, results are non-subjective, and testing is non-destructive to both product and package. The sensitivity of a test is a function of the sensitivity of the transducer, the package design, the package test fixture and critical test parameters of time and pressure. Test systems can be designed for manual or fully automated operation. This inspection method is suitable for laboratory offline testing, QA/QC statistical process control, automated batch or inline testing.

Benefits of VeriPac Series

  • Non-destructive, non-subjective, no sample preparation
  • Deterministic, quantitative test method
  • Defect detection down to 0.2 ccm
  • High level of sensitivity, repeatability and accuracy
  • Short cycle time provides operator with PASS/FAIL result
  • Small footprint and modular portable design
  • Referenced in USP 1207 guidance
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ccit, package integrity testing, container closure integrity testing, vacuum decay
1013
30
Apr 2024

Navigating Oncology Drug Packaging Challenges with CCIT

Navigating Oncology Drug Packaging Challenges with CCIT

Oncology drugs pose significant challenges in packaging due to their potency, toxicity, and the risks of human and environmental contamination. Ensuring sterility is crucial for certain administration methods, while also safeguarding against potential harm to handlers and manufacturers. Improper packaging or material selection can result in weak seals, breaches in sterility, and product leakage, compromising both safety and efficacy.

Early-stage package development and ongoing in-process packaging checks are essential measures to guarantee effective packaging. While various tests like Extractables and Leachables (E&L) and Transportation tests contribute to product safety, they may not always detect leaks in packaging. Therefore, Container Closure Integrity Testing (CCIT) emerges as a robust and indispensable method for identifying poor packaging performance and guiding package development.

CCIT offers a comprehensive approach to assessing package integrity across a range of formats commonly used for oncology drugs, including rigid parenterals, bottles, IV bags, and blister packs. Each packaging format presents unique challenges, and CCIT offers tailored test methods for each, ensuring thorough evaluation and reliable results.

Blister packs, often utilized for oncology drugs, typically consist of a low headspace formed poly or foil tray with a flexible lid stock. For products packaged in aluminum cold form blisters, helium leak detection is employed for ultra-high sensitivity, capable of detecting leaks down to 1E-10 mBar/l*s. Additionally, force decay testing provides inline applications with sensitivity down to 15 microns, ensuring stringent quality control measures.

Rigid parenterals, another common packaging option, offer flexibility in testing methods, including Vacuum Decay and MicroCurrent High Voltage Leak Detection (HVLD). These methods can detect leaks down to 1 micron, both inline and offline, providing comprehensive assurance of package integrity.

In conclusion, addressing the unique packaging challenges of oncology drugs requires a multifaceted approach, with CCIT playing a pivotal role in ensuring product safety, efficacy, and regulatory compliance. By leveraging advanced testing methodologies tailored to specific packaging formats, manufacturers can mitigate risks and uphold the highest standards of quality assurance in oncology drug packaging.

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CCIT, drug packaging, oncology, CCI, Container closure integrity testing, vacuum decay, HVLD
5303
26
Dec 2023

Vacuum Decay Technology - Everything You Need to Know

Vacuum-Decay-Technology-Everything-You-Need-to-Know

In the pharmaceutical industry, the safety and efficacy of products are of utmost importance, and maintaining these qualities throughout the distribution and storage chain is a critical aspect of ensuring public health. One key element in achieving this goal is the rigorous implementation of Container Closure Integrity (CCI) testing.

CCIT refers to the evaluation of the ability of a pharmaceutical package to prevent the ingress of contaminants, as well as the escape of the product, ensuring that the package maintains its integrity over time. This process is essential in safeguarding the quality and safety of pharmaceutical products, as any compromise in the packaging can lead to contamination, degradation, or other adverse effects on the medication.

Traditional Container Closure Integrity (CCI) assessment has heavily relied on destructive testing methods, such as water bath and dye tests. These approaches involve immersing packaging materials in water or applying dyes to identify potential leaks. However, these methods present significant drawbacks. They are time-consuming, requiring substantial resources for testing and result analysis, which is highly subjective and varies from operator to operator. This prolonged process can hamper production efficiency and delay product release.

Moreover, the accuracy of these methods is questionable, as they may not reliably detect all types of leaks. The subjective nature of human interpretation in analyzing results leads to potential inconsistencies and misinterpretations. Additionally, the destructive nature of these tests contributes to product loss and waste, escalating production costs and raising environmental concerns.

In the context of a growing emphasis on sustainable practices, there is a rising demand for alternative, non-destructive, and objective CCI testing approaches that can address these limitations and align with contemporary production and sustainability standards.

CCI Testing using Vacuum decay technology

To guarantee integrity and consistency of packages, the ability to precisely detect leaks and defects is necessary. Over the years industry has seen an increasing demand for non-destructive package integrity testing methods. One such method is Vacuum Decay technology.

Vacuum Decay is a test method that has been proven over decades as the most practical and sensitive vacuum-based leak test method. It is a simple test method that challenges container integrity based on fundamental physical properties. Vacuum Decay technology creates reliable and accurate quantitative results with a pass or fail determination and has been established as a non-destructive deterministic alternative method to the blue dye test. The standard vacuum decay leak test method (ASTM F2338), developed using PTI's VeriPac instruments, is recognized by the FDA as a consensus standard for container closure integrity testing. The test method is listed in ISO 11607 and referenced in the United States Pharmacopeia Chapter on CCI (USP Chapter 1207)

How does Vacuum Decay Technology work?

Under this method, the leak testers are first connected to a test chamber that is specifically designed to hold the package to be tested. Vacuum is applied to the package placed inside the test chamber. Using single or dual vacuum transducer technology test chamber and level of vacuum are monitored along with a change in vacuum over a predetermined test time. The changes in absolute and differential vacuum indicate the presence of leaks and defects within the package. This inspection method is suitable for laboratory offline testing and can be designed for manual or fully automated operation. The test cycle is non-destructive to both product and package and takes only a few seconds. It provides significant savings by not wasting products for a leak test and generates a return on investment in under six months for many products.

Key Benefits of Vacuum Decay Technology

  • Non-destructive and non-invasive
  • No sample preparation
  • ASTM approved test method
  • FDA Recognized Consensus Standard
  • Allows for increased sampling
  • Quantitative results
  • Eliminates cost and waste of destructive testing
  • Test results can be easily validated
  • SPC laboratory testing or online applications
Readmore...
ccit, container closure integrity testing, vacuum decay, package integrity testing
1874
14
Sep 2023

PTI's Comprehensive Integrator and OEM Solutions

PTI-Comprehensive-Integrator-and-OEM Solutions

In today's fast-paced world, businesses across various industries are constantly seeking ways to streamline their operations, enhance productivity, and deliver innovative solutions to their customers. To meet these demands, many companies turn to Comprehensive Integrator and Original Equipment Manufacturer (OEM) solutions. These versatile services offer a range of benefits, from reducing development time to ensuring product quality and scalability.

PTI's Integrator and OEM Solutions are designed to help manufacturers automate their package integrity testing processes. PTI offers a variety of sensory technologies, including Airborne Ultrasound, Vacuum Decay, Microcurrent HVLD, and Force Decay, that can be integrated into existing packaging lines or used to create new PIT systems. PTI also works closely with OEMs to integrate its technologies into their equipment.

PTI's Integrator and OEM Solutions offer a number of benefits, including:

  • Increased productivity: By automating package integrity testing, manufacturers can free up operators to focus on other tasks, such as production or quality control.
  • Improved product quality: Automated package integrity testing can help to identify and remove defective products from the production line, preventing them from reaching customers.
  • Reduced costs: It can help to reduce the cost of labor and materials, as well as the risk of recalls.
  • Compliance with regulations: PTI's solutions can help to ensure that products meet regulatory requirements for package integrity.

If you are a manufacturer who is looking to automate your package integrity testing process, PTI's Integrator and OEM Solutions can help. PTI has a team of experienced engineers who can help you to select the right sensory technology and integrate them into your production line. PTI also offers a variety of services, such as training and support, to help you get the most out of your PIT system.

Here are some of the specific solutions that PTI offers:

  • Airborne ultrasound technology is used to inspect and analyze seals non-destructively. PTI's Seal-Scan® and Seal-Sensor products use airborne ultrasound to provide real-time seal quality inspection on the production line.
  • Vacuum decay technology is used to leak test packages and containers. PTI's VeriPac platform uses vacuum decay to provide a deterministic method for leak testing that is repeatable and reliable.
  • MicroCurrent HVLD technology is a CCIT test used to inspect packages for defects such as pinholes and cracks. PTI's MicroCurrent HVLD technology is non-destructive and can be used to inspect a variety of package materials.
  • Force decay technology is used to measure the force required to open a package. PTI's Force Decay technology can be used to detect counterfeit products or to verify the integrity of packages.

If you are interested in learning more about PTI's Integrator and OEM Solutions, please visit our website or contact us for a consultation.

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ccit, package integrity testing, vacuum decay, hvld
1593
01
Dec 2022

Vacuum Decay Technology An Overview of Applications

Vacuum Decay Technology: An Overview of Applications

The ability of container closure systems to maintain a sterile barrier against potential contaminants that could lower the quality of the finished product can be understood as container closure integrity. External contaminants may enter the product through even the smallest leak or breach of the sterile barrier, impairing its capacity to perform as expected. Despite being popular leak testing techniques, dye ingress and microbial ingress have been shown to produce results that are often inaccurate and subjective. Deterministic test methodologies that can be controlled, calibrated, and provide a firm determination of CCI have therefore been encouraged by regulatory bodies.

Vacuum Decay is a non-destructive container closure integrity testing (CCIT) method for detecting leak paths and package integrity. The test method is simple in principle and challenges container integrity based on fundamental physical properties. This test provides a quantitative result that is accurate, repeatable, reproducible, and reliable with a pass/fail determination.

Our line of non-destructive VeriPac package testing equipment is backed by the tradition of excellence and performance reliability that PTI brings. The FDA acknowledges the standard Vacuum Decay leak test method (ASTM F2338), which was created using PTI's VeriPac instruments, as a consensus standard for testing container closure integrity (CCI). The test method is referenced in the United States Pharmacopeia Chapter on CCI and listed in ISO 11607 (USP Chapter 1207). The test is conducted by drawing vacuum on a package inside of a test chamber, and the vacuum level is checked for any decay that might signify a leak. The technique has established itself as a non-destructive substitute for the water bath leak test. By avoiding product waste for a leak test, it offers significant savings and, for many products, achieves return on investment in less than six months.

Industry Applications:

1. Pharmaceutical Industry

Pharmaceutical manufacturers prioritize quality control and package integrity because defects in pharmaceutical product manufacturing can directly affect drug quality. Even minor defects in the packaging or container may allow outside elements or contaminants to enter the drug. A manufacturer prioritizes implementing the proper container closure system because it affects both the product and the patient. CCI testing is a non-destructive package inspection technology for detecting leaks and avoiding potential contamination. The regulatory bodies take CCI's negligence very seriously. The guidelines support deterministic, dependable test methods for measuring industry-wide quality standards.

2. Food and Nutrition Industry

Packaging is crucial to today's food and nutrition industry. Packaging serves a variety of purposes, including product safety, brand awareness, product promotion, product protection and product delivery. Food and nutrition products are packaged so that they stay fresh for the entire shelf life. However, the challenges associated with packaging food and nutrition products have increased due to frequent innovations in packaging formats and the move towards sustainable packaging materials.

In order to ensure that the products are free from any type of contamination or defect, manufacturers are encouraged to perform appropriate package integrity tests. Various Container Closure Integrity Testing techniques are now available on the market to guarantee the quality and sterility of packages for the duration of their shelf life or until they are delivered to the consumer. Vacuum Decay technology and Airborne Ultrasound technology, among other methods, are very useful in food and nutrition package inspection.

Benefits of Vacuum Decay Technology

  • Non-destructive, non-invasive, no sample preparation
  • Accurate, reliable, repeatable results
  • Supports sustainable packaging and zero waste initiatives
  • FDA recognized standard for package integrity testing
  • ASTM test method F2338
Readmore...
ccit, vacuum decay, package integrity testing, container closure integrity testing
2018
02
Aug 2022

Package Integrity Testing using VeriPac Series Products and Solutions

Package Integrity Testing using VeriPac Series Products and Solutions

There are certain aspects that need to be maintained regardless of whether you operate in the food packaging sector or the pharmaceutical products manufacturing industry to ensure that a quality product will be provided to the clients. Package integrity testing is required for items that must be packaged so that they can be sterilized and maintained sterile for a defined amount of time, throughout the product lifecycle.

Package Integrity Testing Using VeriPac 455

The VeriPac 455 is a non-destructive, non-invasive, and highly sensitive Container Closure Integrity Testing (CCIT) method that may be implemented into protocols at any stage of the handling process. Stability research, clinical trial investigations, quality assurance testing, and production statistical process control are examples of applications for this technology (SPC). Leak rates as low as 0.05 cc/min can be found with the VeriPac 455. Results have consistently outperformed and outperformed the dye ingress test in terms of accuracy.

The VeriPac 455 core technology is based on the ASTM vacuum decay leak test method (F2338-09) recognized by the FDA as a consensus standard for package integrity testing. This test method was developed using VeriPac leak test instruments. The VeriPac 455 is equipped with the patented PERMA-Vac dual vacuum transducer technology, which increases test sensitivity and yields reproducible, dependable results.

Additionally, the VeriPac 455 contains major improvements in networking and internet access that enable remote operation, system monitoring, and MES integration. Test systems can be built to operate automatically or manually. This inspection method is appropriate for QA/QC statistical process control and laboratory offline testing. The test cycle only lasts a few seconds, the results are objective, and the testing is non-destructive to the product and the package.

Inspection Criteria

  • Measures seal integrity of entire container or package
  • Measures and verifies container closure system integrity
  • Tests for gas leaks for dry products (lyophilized vials, powder filled)
  • Tests for liquid leaks (liquid filled vials, pre-filled syringes)

Benefits

  • Non-destructive, non-subjective, no sample preparation
  • Defect detection down to 0.01 cc/min
  • Highest level of sensitivity, repeatability and accuracy
  • Results proven superior to dye ingress
  • Deterministic, quantitative test method
  • Supports sustainable packaging and zero waste initiatives
  • ASTM test method F2338 and FDA standard for package integrity testing
  • Vacuum Decay technology referenced in USP 1207 guidelines
Readmore...
package integrity testing, veripac 455, ccit, vacuum decay, package quality inspection
2640
15
Feb 2022

How to Ensure Package Integrity of Medical Devices

How to Ensure Package Integrity of Medical Devices

Medical devices play a key role in the diagnosis and treatment of many conditions and life saving treatments. To insure patient safety, the effectiveness of such medical devices should be carefully evaluated. Package integrity testing of medical devices is a crucial part of the manufacturing process.

Medical device package testing methods offered by PTI

1. Airborne Ultrasound technology

PTI’s Airborne Ultrasound technology (ABUS) is a seal quality inspection test method, capable of non-destructively examining packaging seal quality for defects, primarily flexible packaging seals. Under this method, ultrasound waves are passed through the pouch seal, creating a reflection of sound waves. The signal strength variations are analyzed to identify the presence of seal defects. Airborne Ultrasound technology creates a quick analysis of the seal area without tampering with the packaging to identify many common seal defects, such as incomplete or missing seals, wrinkles, and channel defects. The technology is in high demand due to its applicability across several industries, specifically the medical device industry. “Ultrasound is the only technology capable of identifying what the quality of that physical bonded nature of the seal materials are,” comments Tyler Harris, applications engineer at PTI- Packaging Technologies & Inspection. Medical device packaging including TYVEK® pouches is a very common application for ABUS technology.

PTI's Seal Scan (Offline) and Seal-Sensor (Inline) technology have further redefined pouch seal integrity testing. Both these technologies utilize non-contact airborne ultrasonic testing technology. With these advancements, Airborne Ultrasound technology has positioned itself to be the most sensitive method for non-destructive seal quality testing, in both the laboratory and in automated 100% inline testing production lines. ABUS is an ASTM Test Method F3004, recognized by the FDA as a standard for seal quality inspection and also referenced in the USP 1207 chapter guidelines.

2. Vacuum Decay technology

For several decades, Vacuum Decay has been proven to be the most practical and sensitive leak detection method for medical device and pharmaceutical packaging. It is a Container Closure Integrity Test (CCIT) capable of evaluating a wide range of packaging formats including filled and sealed rigid, semi-rigid and flexible packaging made of non-porous or porous materials. Vacuum Decay, being a non-destructive test method, does not cause any damage to the package being tested. This reduces significant waste and allows operators to have a thorough understanding of package integrity and package quality.

PTI’s VeriPac inspection technique is an ASTM approved (F2338), FDA recognized testing method capable of evaluating a wide range of high-risk package applications. To conduct this test, packages are first placed in a well-fitted evacuation test chamber, which has an internal or external vacuum source. The test operator continuously monitors the vacuum levels to identify variations from a pre-determined targeted vacuum level. In the presence of a defect, air escapes from the package into the test chamber. Packages without any defect retain the air, maintaining a constant chamber vacuum level. It is an ideal solution for medical device manufacturers to assure that the product meets regulatory standards. Based on the packaging materials used and the level of test sensitivity required, manufacturers can select the appropriate VeriPac model.

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ccit, vacuum decay, airborne ultrasound, package integrity testing, medical device package testing
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Our technologies conform to ASTM and other regulatory standards.

Packaging Technologies & Inspection

PTI offers inspection systems for package leak testing, seal integrity and container closure integrity testing (CCIT). Our technologies exclude subjectivity from package testing, and use test methods that conform to ASTM standards. PTI's inspection technologies are deterministic test methods that produce quantitative test result data. We specialize in offering the entire solution including test method development and equipment validation.

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Packaging Technologies & Inspection

PTI offers inspection systems for package leak testing, seal integrity and container closure integrity testing (CCIT). Our technologies exclude subjectivity from package testing, and use test methods that conform to ASTM standards. PTI's inspection technologies are deterministic test methods that produce quantitative test result data. We specialize in offering the entire solution including test method development and equipment validation.

Sales Channel Partner Portal Login

ptiusa

Our technologies conform to ASTM and other regulatory standards.

Get in Touch

 
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