Integrated Solutions for RNA-Based Drugs

Pre-fillable syringes have several components that compose the system, and deep cold storage is a big challenge to maintaining all the materials' integrity.

Chart: No CO₂ was detected in all 30 ITC filled syringes tested through Carbon Dioxide headspace analysis, indicating that no defect allowing CO₂ ingress occurred due to any material property changes at -70°C. The controls in both cases performed as expected, showing a substantial ingress of CO₂ for the positive control, and no CO₂ ingress for the negative controls.

We tested and confirmed no loss of CCI of EZ-fill^® ITC syringes after 7 days of storage at -70°C. Tests executed through CO₂ Headspace Analysis showed no relevant signals of carbon dioxide ingress after a 1-week freezing cycle whilst also verifying the plunger displacement phenomenon confirming the suitability of EZ-fill^® ITC system for mRNA applications.

Low temperature can also affect the functionality of the overall system. Two of the most important parameters that describe the system's functionality are Break Loose and Gliding Force.

Charts: The test showed that freezing storage has no impact on break loose and gliding force, confirming no functional impact from Room Temperature to -40°C.

We tested - after 1-week storage at -40°C - filled ITC syringes and they showed excellent Break Loose and Gliding Force* performance with comparable results before and after freezing storage.

* ISO 11040-4:2015 as a standard reference

ITC unscrewing torque and opening force

We tested the ITC closure unscrew* after 5 cycles at -50° storage with extraordinary results. The test showed no statistical difference in unscrewing torque (Tmax) between the sub-categories, confirming that ITC closure functionality is guaranteed after freezing condition, with no impact on usability for the final user.

Chart: No evidence of difference in unscrewing force for all the 50 ITC syringes tested for each category.

Deep cold storage may stress the glass barrel of a PFS system causing potential system failures.

Chart: Results at Room Temperature and at -40°C are comparable, confirming that freezing did not affect glass resistance to breakage.

Regarding mechanical properties, Burst Test* performed on Stevanato Group ITC syringe did not show difference in glass barrel resistance between -40°C and room temperature storage conditions, confirming good mechanical performances.

* ISO 7458:2004 as standard reference.

Market Insight

Covid-19 and the subsequent rise of mRNA vaccines brought new types of therapies to the market that require storage at deep-cold temperatures down to -80 °C.

Risk

The stress on the glass at these low temperatures increases the chance of vial breakage. The risk of breakage is extremely important to pharmaceutical companies due to the high values of drug cointained.

Need

Increased assurance about the compatibility of glass containers with cold storage conditions is key for pharmaceutical companies.

Solution

In this increasingly complex application, EZ-fill^® vials are a proven solution to make life easier for customers. Find out Fina^® Vial’s optimal performances with deep-cold drug applications and complex cold-chain requirements for both Mechanical & Container Closure Integrity (CCI) performance

Ensuring mechanical resistance with Vertical Compression Test & Burst Test (CTQAs investigated in the study)

Objective

Identify and determine the impact (if any) on glass vials’ mechanical resistance to Axial Load and Internal Pressure of storage conditions of -80°C over a period of 7 days

Method

Vertical Compression and Burst test

Results

2R Fina^® quality glass can withstand a conditioning at -80°C for a prolonged period of time without impacting its mechanical performance.

Ensuring Container Closure Integrity with Headspace Gas Analysis

Objective

Determine CCI during stability at 25°C/60% RH and -80°C at two different time points (T0 and T6 months) over a storage period of 6 months.

Method

Use of Headspace Gas Analysis technique, based on the measurement of the headspace carbon dioxide content in the samples after exposure to a carbon dioxide enriched environment at the target temperatures.

Results

No CO₂ detected in all the samples. 2R Fina^® vial geometry, in combination with different closure systems, can maintain CCI for a prolonged period of time under the testing conditions

The configurations tested showed no statistically significant difference before and after conditioning.

Mechanical Performances in Deep Freezing

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