Cx5 14 Single Use Film Validation Guide REFER For ABOUT FILM
Cx5 14 Single Use Film Validation Guide REFER For ABOUT FILM
Cx5 14 Single Use Film Validation Guide REFER For ABOUT FILM
DOC0017 • Revision E
December 2017
Thermo Scientific CX5-14 film
Five-layer, 14 mil cast film
Thermo Scientific™ BioProcess Containers (BPCs) are built to meet
your single-use upstream and downstream bioprocessing needs.
Our films are engineered to meet the most demanding requirements
of your bioproduction processes. Thermo Scientific™ CX5-14 film is
developed specifically for liquid handling, storage, and transportation
in the biopharmaceutical industry.
Key benefits
• One film for your entire workflow from 50 mL to 2000 L
• Good toughness and puncture resistance to
maximize security • Standard and custom configurations available in 2D
pillow-style with seam or panel ports, and 3D square
• Highly flexible and stretchable material
tube–style configurations with top– and bottom–panel
• Non-animal origin formulation porting options supplied gamma irradiated and ready
to use
• High barrier properties maximizing stability
of content
Contents
Biocompatibility 5
Physical properties 6
Mechanical properties 7
Extractables 8
CX5-14 film specifications
Thermo Scientific™ CX5-14 film is a Property Test protocol Average values
five-layer, 14 mil cast film produced
Physical data (post–gamma irradiation, 25–40 kGy)
in a cGMP facility. The outer layer is a
polyester elastomer coextruded with Tensile strength ASTM D882 2316 psi 16.0 MPa
an ethyl vinyl alcohol (EVOH) barrier Elongation ASTM D882 476%
layer and a low-density polyethylene
Yield strength ASTM D882 1238 psi 8.5 MPa
product contact layer. CX5-14 film is
manufactured using non-animal 2% Secant modulus ASTM D882 37898 psi 261.3 MPa
origin components. Tensile toughness ASTM D882 235 lbf-in 2.7 kN-cm
ASTM D1003
Haze 70%
(outside dry/inside dry)
10-6 Sterility assurance level ANSI/AAMI/ISO 11137:2006 2.5–4 Mrad 25–40 kGy
All tests are run post–gamma irradiation unless otherwise noted. † Sub-zero conditions require proper support and handling.
4
Biocompatibility
Overview
Biocompatibility testing was conducted in order to help • EP 3.2.2.1 Plastic containers for aqueous solutions
ensure that the film and other contact surfaces have no for parental infusion: Testing is done to characterize
adverse effects on any biological material that may be the suitability and functionality of the materials
contained within the sample. USP <88> Class VI tests for used in the construction of polyethylene-based
in vivo reactions to the material, USP <87> tests for in vitro BioProcess Containers.
reactions (cytotoxicity), USP <661> tests for assessment
of the physicochemical properties of the film, and Results
USP <85> tests for the presence of bacterial endotoxins. A summary of biocompatibility testing is shown in Table 1.
––Intracutaneous reactivity: An extract of the test article Residue on ignition USP <661> <1 mg
was prepared for 72 hours at 50°C and injected under Appearance EP <3.2.2.1> Pass
the skin of an animal model, and signs of irritation were
Acidity and alkalinity EP <3.2.2.1> Pass
monitored.
Absorbance EP <3.2.2.1> Pass
––Intramuscular implantation: The test article was
Reducing substances EP <3.2.2.1> Pass
implanted into the muscle tissue of an animal model,
and the resulting tissue sections were examined grossly Transparency EP <3.2.2.1> Pass
for signs of infection, necrosis, discoloration, and
hemorrhage.
Conclusion
• USP <87> Cytotoxicity: An extract of the test article
Samples manufactured from the CX5-14 film were tested for
was prepared for 24 hours at 37°C in E-MEM cell culture
biocompatibility per USP and EP protocols. There were no
medium and cultured with L-929 mouse fibroblast cells.
signs of toxicity, irritation, inflammation, or cytotoxicity.
The resulting cell culture was monitored for morphological
changes and loss of viable cells.
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Physical properties
Overview
Permeability gases and water vapor are important properties • O2 transmission rate: Test articles were conditioned
of the film. Resistance to the transmission of oxygen, at 23°C and analyzed for O2 transmission rate using a
carbon dioxide, and other gases is important in controlling MOCON OX-TRAN™ 2/21 test system per ASTM D3985.
the pH and chemical properties of a single-use container’s The film was oriented so that the inner layer of the film
fluid content. Resistance to the transmission of water was exposed to 100% RH O2 gas and the outer layer
vapor is also important to the control of the concentration of the film exposed to 0% RH N2 gas. These conditions
of a container’s fluid content. Factors that affect a film’s simulate storage conditions, with the inner layer
permeability characteristics include film composition, film representing fluid contact (100% RH) and the outer
thickness, temperature, and relative humidity (RH). layer representing atmospheric contact (0% RH). Final
O2 transmission rates were recorded when the
Methods system equilibrated.
• Sample preparation: Test articles consisted of
10.8 x 10.8 cm (4.25 x 4.25 in.) swatches. The film Results
was always oriented so that the inner layer of the film Results for the above transmission rate testing protocols are
was exposed to relative humidity. shown in Table 2.
• Water vapor transmission rate: Test articles were Table 2. Summary of data for transmission
conditioned at 23°C and analyzed for water vapor rate testing.
transmission rate using a MOCON Permatran-W™ 700
Test Test conditions Results
test system per ASTM F1249. The film was oriented so
Water vapor 0% RH outside,
that the inner layer of the film was exposed to 100% RH 0.023 cc/100 in2/day
transmission rate 100% RH inside, 23°C
water vapor and the outer layer of the film exposed
to 0% RH N2 gas. These conditions simulate the
worst-case scenario and represents a higher water 0% RH outside,
CO2 transmission rate 0.089 cc/100 in2/day
100% RH inside, 23°C
vapor transmission rate than ambient conditions
(approximately 0% outside RH). Final water vapor
transmission rates were recorded when the 0% RH outside,
O2 transmission rate 0.024 cc/100 in2/day
90% RH inside, 23°C
system equilibrated.
6
Mechanical properties
Overview
The mechanical properties of a film are important to the • Glass transition temperature: Testing was based on
integrity of a BPC and its suitability for use under varying ASTM E1640: Standard Test Method for Assignment of
conditions. The mechanical properties evaluated were the Glass Transition Temperature by Dynamic Mechanical
tensile strength, elongation, yield strength, secant modulus, Analysis (DMA). Samples were analyzed using the DMA
tensile toughness, puncture resistance, and seam strength. method in tension mode: –145 to 50°C at 3°C per minute
using TA Instruments DMA Q800 equipment. The test
• Tensile strength is the maximum amount of stress was terminated when the sample yielded.
that a material can handle before breaking
• Haze: Testing was based on ASTM D1003: Standard
• Elongation is a measure of the ability of a material to Test Method for Haze and Luminous Transmittance of
resist changes of shape without crack formation Transparent Plastics. Material samples were conditioned
• Yield strength is the minimum amount of stress on for at least 24 hours at 23°C ± 2°C at 50% relative
a material at which it begins to permanently deform humidity. Values were measured using the Hazemeter
method using Byk Haze-Gard I equipment.
• Tensile toughness is a measure of the ability of a
material to absorb energy and deform up to the Results
point of failure (fracturing) The results of mechanical testing are shown in Table 3.
• Secant modulus is the measure of a material’s Table 3. Summary of data for mechanical testing.
elasticity and stiffness
Test Results
• Puncture resistance is a measure of the amount
Tensile strength (psi) 2316 psi
of force required to pierce a material
Elongation (%) 476%
• Seam strength is a measure the force required
to rupture a seam Yield strength (psi) 1238 psi
modulus testing were based on ASTM D882: Standard Seam strength 31 lbf/in
Test Method for Tensile Properties of Thin Plastic
Haze 70%
Sheeting. Test articles were placed into the grips of the
Instron™ 5565 equipment’s mechanical test frame and Glass transition temperature –28oC
pulled at 50.8 cm (20 in.) per minute.
Conclusion
• Puncture resistance: Testing was based on ASTM
BPCs manufactured from the CX5-14 film were tested to
F1306: Standard Test Method for Slow Rate Penetration
verify mechanical properties. These BPCs proved capable of
Resistance of Flexible Barrier Films and Laminates. Test
resisting the stresses that are incurred during shipping and
articles were installed in the Instron 5565 equipment’s
regular use.
fixture. The probe speed was 2.54 cm (1 in.) per minute
and the test article was tested until puncture.
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Extractables
Executive summary
BPCs are widely used in biopharmaceutical processes. Control samples were prepared by filling multiple 20mL
Buffers, media, and other process liquids are stored in the headspace vials with the appropriate extraction sample.
polyethylene (PE) BPCs integrated with other components Control samples for inorganic extractables testing were
such as filters, tubing, and connectors. Since these stored in chemically resistant Polytetrafluoroethylene
BPCs are used in critical bioprocessing operations, their (PTFE) vials.
interactions with biopharmaceutical fluids and final drug
formulations must be well understood and validated by Storage conditions
end users. To ensure the quality of the BPCs, analytical
• Samples and controls were stored in a chamber qualified
testing is conducted for the identification and quantification
at 60°C ± 2°C.
of extractables. Extractables are substances that can be
forced into solution from the BPCs using common solvents • Chamber qualification, temperature monitoring and
and physical conditions that are expected to be more contingency planning were conducted by the test
aggressive than normal conditions of use. The goal of this laboratory's Standard Operating Procedures (SOPs).
extractables study was to supply the worst-case extractable
data to support end users in their validation studies. Time points
During the study, high-performance liquid chromatography • At 24 hours, 30 days ± 8 hours, and 90 days ± 8 hours,
(HPLC), gas chromatography (GC) and inductively coupled one bag containing each of the common solvents was
plasma (ICP) separation techniques, and mass-spectrometry collected for sampling and analysis.
(MS) identification techniques were used. • A matching control sample was also removed for each of
the representative solvents at the same time points.
Objective
The objective of this study was to provide a comprehensive • All analyses for organic extractables were completed
assessment of metals, volatile, semi-volatile, and non-volatile within 7 days of the sample date.
organic compounds that can potentially be extracted from • All analyses for inorganic extractables were completed
fluid contact surface of gamma-irradiated BPCs. within 5 days of the sample date.
The selection of the tested solutions has been done to
cover a range of worst-case conditions for the extractable Analytical test method
analyses. The intent of this extractable analysis is to Volatileextractables
provide qualitative and quantitative information to assess
toxicological risks, and to evaluate the overall safety of A gradient GC-MS method was used.
BPCs for long-term storage.
Table 4. Volatile extractable reference standards
Methods Reference
Extraction solvents: The 5 extraction solvents are water- standard Name Manufacturer Purity
for-injection (WFI), 20% ethanol (EtOH), 4 M sodium chloride number
(NaCl), 3 M sodium hydroxide (NaOH), and 2 M hydrochloric RS690 Octamethyltetrasiloxane (D4) Aldrich 99.6%
acid (HCl).
RS864 Octamethyltetrasiloxane (D4) Aldrich 98.9%
Sample Preparation: 500 mL BPCs were filled with RS655 Dodecane (C12) Fluka 100.0%
216 mL of the common solvents listed above using a RS863 Dodecane (C12) Fluka 99.9%
graduated cylinder and funnels that were rinsed with RS897 1,3-ditert-butyl benzene Aldrich 97.4%
the common solvents before use.
RS893 2,4-ditert-butyl phenol Aldrich 99.5%
8
Extractables
Semi-volatile extractables Inorganic extractables
A gradient GC-MS method was used.
• The inorganic extractables analysis was performed by
Table 5. Semi-volatile extractable reference standards NSF International.
RS690 Octamethyltetrasiloxane (D4) Aldrich 99.6% Antimony Copper Iron Palladium Silver Uranium
RS864 Octamethyltetrasiloxane (D4) Aldrich 98.9% Arsenic Dysprosium Lanthanum Phosphorus Sodium Vanadium
RS572 Butylated hydroxytoluene Chem Service 99.5% Barium Erbium Lead Platinum Strontium Ytterbium
Table 6. Non-volatile extractable reference standards Chromium Indium Nickel Scandium Titanium
Reference
standard Name Manufacturer Purity
number Total organic carbon (TOC)
The TOC conditions listed in the current version of the test
RS800 Cyanox 1790 Aldrich 98.8%
laboratory's internal protocol used.
RS622 Stearic Acid Fluka 99.7%
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Extractables
Results
Tables 7-16 report the results of extractables testing
Table 7. Estimated limits of detection (LODs) for Table 8. Estimated limits of LODs for nonvolatile
volatile by headspace GC-MS and semivolatile by extractables by UPLC-PDA-MS
direct inject GC-MS extractables
LOD (μg/mL)
LOD (μg/mL)
Quantitation
Quantitation standard
standard 30 day 30 day
24 hour 30 day 90 day 24 hour 90 day
(WFI, EtOH) (HCI, NaOH, NaCI)
Volatiles Octamethylcyclotetrasiloxane 0.010 0.007 0.004
Irganox 1010 (MS) 0.95 1.05 1.60 0.46
Analysis
Dodecane 0.032 0.017 0.008
Stearic Acid 79.72 51.52 38.33 8.48
Octamethylcyclotetrasiloxane 0.272 0.108 0.125
Semi- Oleamide 0.24 0.14 1.18 0.49
Volatiles Butylated Hydroxytoluene 0.509 0.202 0.252 Irgafos 168 0.20 0.55 0.56 0.40
Analysis
2,4 di-tert-butylphenol 0.604 0.240 0.278 Irganox 1010 (PDA) 0.14 0.10 0.11 0.04
WFI NVOC ND ND
24 hours, 60°C Metals Potassium 7
pH - 5.08
TOC - 9.75
VOC 2,4-Di-tert-butyl phenol 0.071, 0.027, 0.030
SVOC ND ND
WFI NVOC ND ND
30 days, 60°C Metals ND ND
pH - 5.50
TOC - 11.3
VOC 2,4-Di-tert-butyl phenol <0.008, 0.008, <0.008
SVOC ND ND
WFI NVOC ND ND
90 days, 60°C Metals Boron 0.49
pH - 4.24
TOC - 12.8
10
Extractables
Table 10. Observed volatile, semivolatile, nonvolatile and inorganic extractables for 20% EtOH
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Extractables
Table 11. Observed volatile, semivolatile, nonvolatile and inorganic extractables for 4 M NaCl
VOC ND ND
SVOC ND ND
4 M NaCI
NVOC ND ND
24 hours, 60°C
Metals Potassium 47
pH - 5.51
VOC ND ND
SVOC ND ND
4 M NaCI
NVOC ND ND
30 days, 60°C
Metals Potassium 30
pH - 4.84
VOC ND ND
SVOC ND ND
4 M NaCI
NVOC ND ND
90 days, 60°C
Metals Potassium 130
pH - 4.92
Table 12. Observed volatile, semivolatile, nonvolatile and inorganic extractables for 3 M NaOH
VOC ND ND
SVOC 2,4-Di-tert-butyl phenol 1.179, 1.138, 1.168
3 M NaOH
NVOC ND ND
24 hours, 60°C
Metals Potassium 40
pH - 14
VOC ND ND
SVOC ND ND
3 M NaOH
NVOC ND ND
30 days, 60°C
Metals Potassium 19
pH - 14
VOC ND ND
SVOC ND ND
3 M NaOH
NVOC ND ND
90 days, 60°C
Metals Potassium 52
pH - 14
12
Extractables
Table 13. Observed volatile, semivolatile, nonvolatile and inorganic extractables for 2 M HCl
VOC ND ND
SVOC ND ND
2 M HCl
NVOC ND ND
24 hours, 60°C
Metals ND ND
pH - 0
VOC ND ND
SVOC ND ND
2 M HCl
NVOC ND ND
30 days, 60°C
Metals Sodium 6
pH - 0
VOC ND ND
SVOC ND ND
2 M HCl
NVOC ND ND
90 days, 60°C
Metals Boron 0.74
pH - 0
pH
Solvent Control
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Extractables
Table 15. Control sample TOC values
14
Bioprocessing films for all
your bioproduction needs
Four films, engineered for the most • Coextruded structure to minimize delamination potential
demanding applications
• Greater cleanliness and low leachable/extractable profiles
Our films are engineered to meet the most demanding
to support end-product purity and quality
requirements of your bioproduction processes.
Choose between: • Non–animal origin formulations for safer contact surfaces
• Thermo Scientific™ CX5-14 polyethylene film—one of the • High gas- and liquid-barrier properties for better
most widely used films in the industry, proven over 10 years content stability
• Thermo Scientific™ ASI™ 26/77 polyethylene film— • Films to meet your bioproduction needs across the
a two-layered film with extremely low extractables, for entire bioprocess stream
high-value application • Validation packages for assurance of product performance
• Thermo Scientific Aegis 5-14 polyethylene film—
™ ™
For Research Use or Further Manufacturing. Not for diagnostic use or direct administration into humans or animals.
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unless otherwise specified. DOC0017 REV E 1217