Universal Vial Fixture for Residual Seal Force Testing
Consistent Alignment and Repeatable Residual Seal Force Measurements Across Multiple Vial Sizes
In container closure integrity testing, consistency and repeatability are critical — especially when measuring residual seal force (RSF) across different vial formats. For laboratories that routinely switch between vial sizes, changing fixtures or reconfiguring setups can introduce unnecessary variability and slow down workflows.
The Universal Vial Fixture is designed to address these challenges. Engineered for flexibility and repeatable performance, it enables laboratories to perform residual seal force measurements across a defined range of vial sizes without compromising alignment, setup time, or data quality.
Designed for labs that regularly switch between vial formats, it helps reduce the number of change parts required between setups — simplifying workflows for operators and improving consistency.
Why Fixture Design Matters in Residual Seal Force Testing
Residual seal force testing depends heavily on proper vial alignment and secure holding within the load string. Even minor misalignment can introduce measurement variability, reduce test reproducibility, or require retesting.
Laboratories supporting medical device development, pharmaceutical manufacturing, and contract development and manufacturing organizations (CDMOs) often evaluate multiple container formats during development, validation, or ongoing quality testing. A fixture that accommodates multiple vial sizes within a set range can help standardize testing and reduce operational friction.
Universal Vial Fixture: Designed for Flexibility and Repeatability
The Universal Vial Fixture was developed to support residual seal force testing across vial diameters ranging from 16 mm to 50 mm (2R to 100R).
Rather than requiring size‑specific fixtures, this single adjustable solution allows labs to transition between vial formats while maintaining consistent test conditions.
Key Design Benefits
- Supports multiple vial sizes within a defined range
- Automatically aligns vials concentrically within the load string
- Reduces setup variability between operators and tests
- Improves repeatability of residual seal force measurements
- Minimizes change parts required when switching between vial sizes, simplifying setup for operators and reducing the potential for error
While the lower fixture is designed to accommodate a range of vial sizes, the upper fixture should be selected to match the vial cap geometry to ensure proper engagement during testing.
Automatic Concentric Alignment for Improved Measurement Reliability
Proper concentric alignment is essential for applying force evenly during residual seal force testing. The Universal Vial Fixture incorporates a self‑centering design that automatically aligns the vial when loaded, helping ensure consistent positioning without manual adjustment.
This alignment mechanism minimizes off‑axis loading and reduces one of the most common sources of test‑to‑test variation in residual seal force evaluation.
Simple, Secure Vial Loading
Ease of use was a key consideration in the fixture’s development. Vials are loaded directly into the fixture, which then securely holds them in place throughout testing — without excessive clamping force or complex adjustments.
This intuitive loading process helps:
- Reduce operator training time
- Increase testing throughput
- Support consistent handling across shifts and teams
Ideal Applications
The Universal Vial Fixture is well‑suited for laboratories that:
- Perform residual seal force testing on multiple vial formats
- Support development, validation, and quality control testing
- Want to minimize change parts and simplify workflows for operators in production environments
Typical users include:
- Medical device manufacturers
- Pharmaceutical companies
- CDMOs and contract testing labs
Supporting Better Data Through Smarter Fixture Design
Reliable residual seal force measurements depend not only on the test method, but also on how the vial is held and aligned during testing. By combining flexibility with consistent alignment and secure holding, the Universal Vial Fixture helps laboratories generate repeatable residual seal force measurements across a defined range of vial sizes — without unnecessary setup complexity.
Considering Throughput in Residual Seal Force Testing
The Universal Vial Fixture is designed to improve efficiency and repeatability when manually testing residual seal force across a range of vial sizes. For many labs, this level of flexibility addresses day‑to‑day testing needs without added complexity.
As testing volumes increase, some laboratories may look to a higher‑throughput solution. The AT2 Automated XY Stage represents the next level of efficiency, using custom, bolted‑on fixtures to hold vials in a predefined pattern for automated testing. These fixtures are typically designed for vials of the same size, though multi‑size configurations are possible depending on the application.
For labs with growing residual seal force throughput requirements, automation with the AT2 can help scale testing efficiency, while the Universal Vial Fixture continues to serve as a flexible solution for manual workflows.
Frequently Asked Questions (FAQs)
The Universal Vial Fixture is used to securely hold and align vials during residual seal force testing. It is designed to support consistent positioning and alignment across a defined range of vial sizes, helping laboratories generate repeatable and reliable measurement data without needing multiple dedicated fixtures.
Talk with our team about how the Universal Vial Fixture can support your residual seal force testing needs.
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About the Author
Sam Havel
Sam Havel is a Biomedical Product Specialist at Instron®, where she serves as a subject matter expert on testing solutions for pharmaceutical and medical device customers. She supports the selection and application of systems for material, component, and finished product testing across new product development and quality control. Drawing on her experience with Instron’s Applications Team, Sam provides practical, application-driven guidance that helps customers implement reliable and effective testing strategies tailored to the biomedical field.