How to choose the right vial: Influencing factors and solutions for liquid fills

In the development of injectable therapies – particularly biologics – the selection of primary packaging is a critical determinant of product success. Far from being a passive container, the vial plays an active role in maintaining drug stability, ensuring accurate dosing, and meeting regulatory requirements. Its influence spans formulation integrity, patient safety, and time-to-market. This article provides a structured analysis of the key factors influencing vial selection for liquid fills. It outlines how variables such as filling volume, pH, temperature, leachable sensitivity, and drug registration status interact with container properties to affect drug performance. With the injectable pipeline becoming increasingly diverse and complex, early and informed packaging decisions are essential to mitigate risks such as protein adsorption, glass delamination, and chemical incompatibility.