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In pharmaceutical packaging, choices made early in development often shape the performance and longevity of the final product. Packaging must protect contents from contamination, moisture, and leakage, especially when dealing with sterile or sensitive drug formulations. Early-stage container closure integrity (CCI) testing provides a structured approach to evaluating how well packaging systems maintain a sealed environment. By introducing CCI testing at the start of the design process, manufacturers can gather valuable insights about materials, formats, and sealing methods—allowing designs to be refined before they become fixed in later phases.

Why Early-Stage CCI Testing Matters?

Early-stage CCI testing creates opportunities to explore different packaging configurations before a final design is selected. It helps determine how well closures, seals, and materials perform under different conditions, including pressure variations, temperature exposure, and storage durations. By introducing testing at this point, it is possible to detect possible leak paths or inconsistencies without the time and cost impact of post-production fixes.

This early insight can reduce delays during regulatory filing and product validation by demonstrating how the package maintains its protective function over time. It also supports quality-by-design approaches by enabling packaging development to progress alongside product formulation, rather than as a separate or delayed activity.

CCI testing at the development stage is especially valuable for products requiring long shelf lives, or sterile delivery. It helps evaluate whether packaging choices will continue to perform reliably throughout their intended use, without relying solely on visual inspections or assumptions.

Integrating CCI Testing into Packaging Development

To apply CCI testing during development, several non-destructive technologies are available. Methods like vacuum decay, pressure decay, Microcurrent HVLD and airborne ultrasound can be applied during packaging studies to evaluate different container formats or sealing techniques. These methods can detect micro-leaks that would go unnoticed with conventional inspection techniques. Analytical methods such as Helium are applied for R&D CCI testing of pharmaceutical products (syringes, vials, cartridges). Common applications include component and material evaluation including low temp testing.

Vacuum Decay Technology

Vacuum Decay is a widely adopted, non-destructive technology for detecting leaks in pharmaceutical packaging. Recognized by the FDA and defined by ASTM Test Method F2338, it offers a sensitive and reliable approach to verifying container closure integrity. During testing, the package is placed in a sealed chamber connected to a vacuum source; once evacuated, sensors track pressure changes over time. A consistent vacuum indicates an intact seal, while any variation suggests a leak—even at a microscopic level. PTI’s VeriPac series uses this method to identify sub-micron leaks with precision, making it a preferred alternative to traditional techniques. Integrating Vacuum Decay leak testing into production helps manufacturers identify defects early, reduce product loss, and maintain high packaging quality standards. This approach ensures that only properly sealed, contamination-free products are released to the market, supporting product stability, patient safety, and regulatory compliance without damaging the tested units.

MicroCurrent HVLD Technology

MicroCurrent High Voltage Leak Detection (HVLD) is a non-invasive method for testing liquid-filled pharmaceutical containers such as pre-filled syringes, vials, ampoules, cartridges, and BFS bottles. It is effective across various formulations, including low-conductivity sterile water and protein-based biologics. The process involves scanning sealed containers with electrode probes that apply a low electrical current. An intact container allows a consistent current path, while any defect disrupts the flow, indicating a leak. Unlike traditional HVLD systems, MicroCurrent HVLD uses about 50% less voltage, reducing stress on products and minimizing risks to sensitive formulations. Operating with less than 5% of the voltage typically used, it offers a safer testing approach without compromising sensitivity. This makes it a reliable choice for maintaining container integrity in parenteral and biologic drug packaging.

Airborne Ultrasound Technology

Airborne Ultrasound technology is a non-destructive and precise method for evaluating seal quality in flexible pharmaceutical packaging. Standardized by ASTM Test Method F3004 and recognized by the FDA, it uses high-frequency sound waves transmitted through the seal to detect defects. As the ultrasound passes through, consistent signal patterns indicate intact seals, while disruptions reveal issues like voids, leaks, or weak spots. This approach allows for accurate detection of seal defects that visual inspection might miss. Its sensitivity and reliability make it a valuable tool for maintaining package integrity and ensuring product safety without damaging the tested items.

Helium Technology

Helium is a highly sensitive leak test technology, specifically designed for the detection of extremely small leaks and tortuous pathways which is not possible with any other leak testing methods. Using a high vacuum technique, the leak test thresholds can be set down as low as 1×10-10 mbar L/sec, a sensitivity level allowing unique comparisons between package components, materials selection, and production controls, for example.

Helium leak detection methods utilize a highly sensitive mass spectrometer detector to accurately evaluate each sealed package/system type. A vial, consisting of a container (glass or plastic) and elastomeric closure, is a good example of a package system. A vial can be helium-filled & and then subjected to vacuum pressure. Any amount of helium escaping from that vial container is quantitatively measured and stated as a leak rate (flow rate) expressed in mbar L/sec.

Starting CCI testing early in the packaging lifecycle provides valuable information that supports design improvements, faster development, and stronger product protection. By applying this testing while packaging formats are still flexible, potential issues can be identified and addressed before they grow into more complex challenges. This approach improves the overall reliability of pharmaceutical packaging and contributes to product success from development through delivery. Instead of reacting to failures, early-stage testing supports packaging strategies built on real data and performance under relevant conditions.

In pharmaceutical manufacturing, product quality relies heavily on a system-wide approach that identifies and controls potential issues before they impact safety or efficacy. Quality Risk Management (QRM) offers a structured framework to assess where challenges might arise and how they can be mitigated. Among the many factors assessed through QRM, packaging systems—and specifically container closure integrity (CCI)—receive heightened focus. As regulatory expectations shift and technology evolves, so too does the way manufacturers handle the assessment and assurance of CCI performance.

Quality Risk Management in Pharma: A Quick Overview

Quality Risk Management (QRM) in the pharmaceutical field provides a structured way to evaluate and address potential issues that may affect product quality. It combines scientific understanding with knowledge of processes to identify areas where challenges could arise and supports decisions that lead to more consistent outcomes. Using tools such as Failure Mode and Effects Analysis (FMEA) and risk ranking methods, manufacturers can prioritize actions based on the probability of occurrence and the possible consequences. This approach encourages proactive thinking and allows for adjustments before problems develop. It also supports clear documentation, which is useful for meeting regulatory expectations. QRM can be applied across all stages of a product’s lifecycle, from development and manufacturing to packaging and distribution. By helping teams focus on specific risks and their impact, QRM contributes to a more predictable and controlled manufacturing environment. It remains a widely adopted method for maintaining quality in increasingly complex production landscapes.

The Role of Container Closure Integrity in Quality Risk Management

Container Closure Integrity (CCI) is a significant aspect of Quality Risk Management (QRM) as it ensures that packaging maintains its ability to safeguard the product from contamination or degradation. In pharmaceutical manufacturing, CCI is evaluated to detect any flaws in the container that could compromise the sterility or stability of the product. Testing methods such as Vacuum Decay, Helium Mass Spectrometry, and High Voltage Leak Detection are used to identify leaks or defects in packaging that might not be visible to the naked eye. By including CCI testing in the QRM process, manufacturers can pinpoint risks associated with packaging and take steps to address them before they affect product quality. This approach supports more informed decision-making, helps meet regulatory requirements, and ensures that the product remains secure from production through distribution. Effective CCI testing contributes to maintaining product integrity and minimizing potential risks to both safety and performance.

Moving from Probabilistic to Deterministic Testing

The shift from probabilistic to deterministic testing in pharmaceutical manufacturing reflects a move toward more precise and consistent methods for evaluating packaging integrity. Probabilistic approaches, such as dye ingress or bubble emission, rely on visual interpretation and can yield variable results due to differences in test conditions or operator skills. In contrast, deterministic methods like Vacuum Decay, Helium Mass Spectrometry, and High Voltage Leak Detection provide quantitative data, offering more reliable and repeatable results. These techniques are increasingly adopted as they allow for better detection of even the smallest defects in packaging, enhancing product safety and stability. By moving to deterministic testing, manufacturers are able to reduce uncertainty in their risk assessments and make more confident decisions regarding packaging quality. This transition also aligns with evolving regulatory expectations, as deterministic testing methods are seen as more reliable for ensuring product integrity and maintaining consistent quality throughout production and distribution.

As pharmaceutical packaging becomes more complex, and product requirements more demanding, QRM provides a way to maintain control and adapt to evolving conditions. Within this framework, container closure integrity testing continues to gain attention. Moving toward deterministic test methods allows for better alignment with data-driven decision-making and supports more predictable outcomes. The transition reflects a broader industry shift toward precision, reproducibility, and ongoing improvement in product oversight. By integrating advanced CCI testing into QRM strategies, manufacturers are better positioned to uphold product quality from production through patient delivery.

Medical device packaging is designed to preserve product sterility, functionality, and safety from manufacturing to end use. However, packaging is constantly challenged by environmental factors—particularly moisture and oxygen. These elements, when they find even the smallest path into a sealed package, can compromise product performance, shorten shelf life, and increase the risk of contamination. Ensuring packaging integrity against such ingress is an ongoing concern, especially for devices that are highly sensitive or sterile. Understanding how to detect and prevent these breaches is vital for manufacturers aiming to maintain product quality and user safety.

Why Moisture and Oxygen Control Matters in Medical Device Packaging?

Controlling exposure to moisture and oxygen is important for many types of medical devices. Items such as wound dressings, diagnostic test kits, implants, and electronics are particularly vulnerable. Moisture can lead to microbial growth, corrosion, or degradation of sensitive components. Oxygen, on the other hand, may trigger oxidation processes that can affect the stability or effectiveness of the product.

Even low levels of ingress can be problematic. That’s why packaging must act as a reliable barrier, especially over time and across varying storage or transport conditions. Seal integrity is at the core of this barrier performance, and detecting leaks that permit moisture or oxygen entry requires precision technologies that go beyond traditional visual inspections or dye-based methods.

Vacuum Decay Technology: A Proven Solution for Moisture and Oxygen Leak Detection

Vacuum Decay technology is a non-destructive, FDA-recognized method used for container closure integrity (CCI) testing, particularly in applications where product safety is highly sensitive. This technique minimizes product waste while providing valuable insights into package performance. It effectively detects leaks in sealed rigid, semi-rigid, and flexible packaging, whether the materials are porous or non-porous. The method is known for delivering consistent, repeatable, and measurable results.

The process involves placing the package in a specially designed test chamber connected to a leak detection instrument. A vacuum is applied, and the chamber is monitored using single or dual transducers. Any change in absolute or differential vacuum over the test cycle reveals potential leaks. The changes in absolute and differential vacuum indicate the presence of leaks and defects within the package. With a test time of only a few seconds, it helps preserve product inventory and offers a fast return on investment.

Benefits of Vacuum Decay Technology

• Non-destructive and non-invasive, no sample preparation
• Deterministic test method
• ASTM approved test method
• FDA Recognized Consensus Standard
• Quantitative results
• Eliminates cost and waste of destructive testing
• Allows for increased sampling
• Test results can be easily validated

The threat of moisture and oxygen ingress in medical device packaging underscores the need for reliable integrity testing methods. Detecting even the smallest breach can help prevent product degradation, contamination, or failure. Vacuum Decay leak testing Technology stands out as an effective solution that offers non-destructive, repeatable, and highly sensitive testing. By adopting such deterministic technologies, manufacturers can enhance packaging quality assurance, support compliance efforts, and deliver products that perform as intended from factory to point of use.

Seal quality has a direct influence on product stability, cleanliness, and shelf life. For industries such as pharmaceuticals, medical devices, and food & nutrition packaging, being able to inspect seals without damaging the product or packaging offers clear advantages. Airborne ultrasound is a non-invasive method that evaluates seal quality through sound wave analysis. It allows manufacturers to identify issues like pouch seal voids, misalignment, and channel leaks—without the need to cut open or alter the package. This method supports consistent inspection practices while helping maintain production efficiency.

A Leap from Traditional Methods

Conventional seal quality testing methods such as dye penetration, burst testing, and peel strength measurement are well-established but often destructive. These approaches require opening or damaging the package, leading to sample waste and additional handling. They also tend to focus on random sampling, which means some defects may go undetected.

Airborne ultrasound offers a different approach. By transmitting high-frequency sound waves across the seal area, this method collects feedback on seal uniformity and strength. Variations in the signal reveal defects that may not be visible or detectable by other non-destructive means. The process is fast, repeatable, and does not rely on visual cues—making it suitable for both offline batch testing and inline inspection during production.

Use Cases Across Industries

Pharmaceutical Packaging

Sterile barrier pouches are widely used in the pharmaceutical industry to protect drug products and maintain stability throughout their shelf life. These packages must stay sealed through manufacturing, transport, and storage to prevent exposure to moisture, oxygen, or other contaminants. Small defects like microchannels or incomplete seals can compromise product integrity without visible signs. Airborne ultrasound offers a non-destructive method to evaluate seal quality by using high-frequency sound waves to detect hidden flaws. It allows manufacturers to inspect packages without breaking sterility, making it suitable for development, routine quality checks, and process control. This approach supports higher inspection rates, reduces product loss, and aligns with pharmaceutical packaging standards by enabling thorough, repeatable testing in regulated environments.

Medical Devices

Medical devices, including surgical kits, diagnostic equipment, and sterile disposables, rely on flexible barrier packaging that must remain sealed until use. Seals that appear intact may still contain inconsistencies that could affect sterility. Airborne ultrasound allows manufacturers to evaluate these seals without opening the packaging, reducing the need for destructive checks. By scanning the seal area, the system can highlight voids, seal folds, or misalignment that may not affect appearance but can impact barrier performance. The technology is adaptable to various packaging formats and helps manufacturers monitor production quality without slowing down operations. It supports more consistent inspection routines and helps reduce sample waste.

Food and Nutrition Products

Food and nutrition products often use vacuum-sealed or flexible pouches that must resist external contaminants and preserve freshness. Packaging failure can lead to spoilage, consumer dissatisfaction, and product recalls. Airborne ultrasound enables non-contact inspection of heat seals on production lines or in the lab. It helps detect issues like uneven pressure, foreign material in the seal, or channel leaks that may lead to gradual air or moisture ingress. This technology supports high-throughput environments by delivering fast, automated inspection, which helps manufacturers keep up with production demands while maintaining seal consistency. It also minimizes rework by identifying seal variations before distribution, supporting product shelf life and packaging performance.

Airborne ultrasound presents a practical way to inspect packaging seals without destroying the sample or slowing down production. Its application across multiple industries shows its versatility in addressing modern packaging needs. Whether used for pharmaceuticals, medical devices, or food products, this technology supports manufacturers in maintaining consistent sealing practices. By detecting small defects that could impact performance, it offers an added layer of quality assurance with minimal disruption.