The frozen storage of biopharmaceuticals brings new challenges to the primary packaging material. Due to an increasing demand and the downsides of standard type I glass vials, such as vial breakage, novel vial types for special applications of parenteral drug products have been introduced to the market in the past years. Mechanical stresses due to dimensional changes experienced during freezing and thawing could change the material properties, hence affecting the interaction with the drug product stored in the vial or functionality such as overall integrity. Therefore, we studied the suitability of different vial qualities related to the thermally induced mechanical stresses experienced during frozen drug product preparation and storage. First, the possible failure modes for each vial type were identified. The interaction between vial surface and drug product were investigated considering surface hydrophobicity, surface free energy and surface roughness as well as microscopically visible changes analyzed by confocal laser scanning microscopy. Differences in surface hydrophobicity, roughness and surface free energy between the vial types did not impact the performance upon freeze-thaw stress and did not change with the stress. Screening the vial content for particles originating from the container using light and electron scanning microscopy combined with energy-dispersive X-ray spectroscopy showed only rare cases of particles in coated glass vials. Under extreme stress conditions, including a drop-test in the frozen state, a low number of particles was also detected in coated polymer vials. No quality issues regarding the functionality were observed upon container closure integrity testing, while the oxygen permeability was slightly increased for uncoated and especially coated polymer vials. Overall, the results show that several vial types are appropriate for the frozen storage of drug products and selection should be based on the formulation and other product requirements.
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