Types of Vials for Pharmaceuticals: A Comprehensive Guide

Vial selection is important in the pharmaceutical industry for the stability and integrity of the drug and for the high standards required by regulatory authorities. Vials are the containers in which the medication must be placed to protect it from contamination and degradation by atmospheric conditions, such as lighting, air, and humidity.

This comprehensive guide will explore the various types of vials used in the pharmaceutical sector, focusing on their unique properties, applications, and why choosing the right vial matters for specific pharmaceutical needs.

Overview of Pharmaceutical Vials: Purpose and Importance

Pharmaceutical vials are small containers used primarily for storing medications in liquid form, though they are also used for powders and capsules. These vials ensure that medications are protected from external elements such as air, moisture, and light, which could degrade their quality. Vials must be robust, maintaining the sterility and quality of the contents until they are administered. The right vial not only preserves the quality of its contents but also ensures the safety of the patients who will eventually use these medications. By understanding the distinct properties and applications of different types of vials, professionals in the industry can choose the one that aligns with their specific pharmaceutical needs.

Types of Vials Used in the Pharmaceutical Industry: Their Advantages

Two main types of vials are used in pharmaceuticals: moulded and tubular. Each type comes with distinct advantages.

Moulded vials: These are thicker and more robust, making them suitable for drugs that require a sturdy container. They are also less likely to break, making them ideal for transporting and storing high-volume products.
Tubular Vials: Known for their precision and uniformity, tubular vials are often used for high-precision drugs, including those used in diagnostics and sensitive biomedical applications. Their uniform wall thickness ensures consistent chemical composition and interaction with the medication.

Material Choices for Pharmaceutical Vials: Glass vs. Plastic

Glass Vials: Glass is the most widely used material in pharmaceutical vials, and among them, Borosilicate glass is the ideal one that resists changes in temperature and chemical reactions. For instance, our product lines, like the VC40 – 40ML TOC VIAL & CLOSURE KIT and VC20 – 20ML GC-HS VIAL & CLOSURE KIT, provide durability along with chemical inertness so that the efficacy of the drug is maintained throughout the storage process. At Borosil Scientific, we use USP Type 1 and 100% Schott glass tubing for the best quality for our customers.
Plastic Vials: These are used to store medications which do not react to plastic. Plastic vials are relatively lighter and less prone to breakage than glass containers. This makes them safe from breaking and thus useful for over-the-counter preparations that must be frequently handled. Currently, these are not manufactured at Borosil Scientific.

Various Sizes of Pharmaceutical Vials

The size of the vial chosen depends on the dosage and administration requirements of the drug. Sizes can range from small 2 mL vials used in hospital settings for single doses to larger vials of up to 40 mL for medications requiring multiple doses or used by healthcare professionals.

Borosil Scientific offers versatile vial sizes from 1 mL to 100 mL nominal volumes for specific laboratory and pharmaceutical applications. Here are a few of the vial sizes and their utility:

Product Code	Capacity(mL)	Approx mouth ID(mm)	DimensionsO.D. x Lengthmm	Case lot(nos)
9913003	3	10	16 x 36	1050
9913005	5	10	16 x 55	1050
9913006	10	16.5	24 x 50	600
9913007	15	16.5	24 x 58	600
9913008	20	16.5	24 x 70	600
9913010	30	16.5	24 x 95	600

Each size ensures dimensional consistency for quality assurance. At Borosil Scientific, apart from the DIN / ISO standard dimension vials, we manufacture customised ones.

Vial types based on Colour

The colour of pharmaceutical vials plays a critical role in maintaining the efficacy of the stored substance. Clear vials allow easy visual inspection of the contents, making them suitable for non-light-sensitive formulations. On the other hand, amber vials protect drugs from UV and visible light, ensuring the stability of photosensitive compounds.

Vials Based on Type of Finish

The finish refers to the design of the vial’s opening, which determines compatibility with closures.

Serum collars (13 mm or 20 mm) are common in injectable applications, offering a precise fit for rubber stoppers and aluminium seals.
Screw collars provide a threaded design for secure and reusable closures.
Snap-on finishes enable easy and quick sealing, which is ideal for products requiring frequent access.

Vials based on Base Type

The base type affects the vial’s stability and functionality.

Liquid/Powder Filling: These have a concave bottom surface, ensuring stability during filling and storage.
Lyophilisation: These are designed with a specialised base to accommodate freeze-drying processes without compromising structural integrity.
Culture Tube: This is a semi-round bottom tube
Rounded bottom tube

Here is a summarised chart for vial types:

Basis	Type	Short Description
Manufacturing Method	Moulded Vials	Thicker and robust, it is ideal for high-volume drugs and secure transportation.
Manufacturing Method	Tubular Vials	Highly precise and uniform, ensuring superior parenteral quality for sensitive drugs.
Material	Glass Vials	Chemically inert and temperature-resistant, it is ideal for preserving drug efficacy. Best for parenteral drugs.
Material	Plastic Vials	Lightweight and shatterproof, used for non-reactive medications and frequent handling. Not ideal for parenteral drugs.
Size	Small Vials (< 1 – 5mL)	Common Sizes : 1mL, 2 mL, 3mL, 5mL.Typically used for single-dose applications in hospitals like high-potency drugs, vaccines or laboratory settings.
	Medium Vials (5-20 mL)	Common Sizes : 10mL, 15 mL, 20mL.Versatile use for large dosage injectables, Lyophilized drugs and diagnostic purposes.
	Large Vials (>20 mL)	Common Sizes : 25mL, 30 mL, 50mL, 100 mL.Suitable for multi-dose medications or professional healthcare applications.
Colour	Clear Vials	Allow visual inspection of contents suitable for non-light-sensitive drugs.
Colour	Amber Vials	Protect from UV and visible light, preserving photosensitive substances.
Type of Finish	Serum Collar (13/20 mm)	Designed for injectables, it is compatible with rubber stoppers and aluminium seals.
	Screw Collar	Threaded neck for secure sealing and reusability.
	Snap-On Finish	Quick-seal design for frequent access to content.
Base Type	Liquid/Powder Filling	Concave bottom surface for more stability.
	Culture Tube / Round Bottom Tube	These have a semi-round bottom or round bottom tube.
	Lyophilising Vials	The specialised base for freeze-drying processes.

Regulatory Standards and Quality Considerations for Vials

The vials used in the pharmaceuticals must meet quality standards, which include ISO certifications and Good Manufacturing Practices (GMP).

ISO Certifications: Vials must also follow specific International Organization for Standardization (ISO) standards that guide the production process on quality management and assurance.
Good Manufacturing Practices (GMP): These are guidelines provided by agencies that control the authorisation and licensing of the manufacture and sale of food and beverages, cosmetics, pharmaceutical products, dietary supplements, and medical devices. GMPs ensure products are consistently produced and controlled according to quality standards.
100% Dimensional Inspection: Each vial undergoes thorough dimensional checks to ensure that it meets precise specifications for size and volume, enhancing consistency and reliability in usage.
Chemical Inertness: The materials used, such as Borosilicate glass, are selected for their inert properties to ensure that they do not react with the contents, thereby maintaining the purity and efficacy of the pharmaceutical product.
Low-Leached Glass Elements: This characteristic is critical as it minimises the leaching of ions from the glass into the product, which could potentially alter its properties and efficacy.
Mechanical Stability: Vials are tested for their ability to withstand pressure and stress without breaking, ensuring they are safe to handle and can be transported without risk of exposure.

By manufacturing vials in an ISO 15378-certified plant, Borosil Scientific ensures each vial not only meets these stringent regulatory and quality standards but also supports the overall safety and efficacy of the pharmaceuticals it contains.

Conclusion

Choosing the right type of vial is crucial for maintaining the integrity and efficacy of pharmaceutical products. Whether it’s a tubular or moulded vial, glass or plastic, the selection must consider the specific requirements of the medication and the regulatory standards. At Borosil Scientific, we understand the critical role vials play in drug safety and efficacy. Our range of vials, made with precision and care, ensures you have the right packaging solutions to meet your pharmaceutical needs. Explore our selection today to find the perfect vial for your application.