Why a dead-clean sterile filter can pass pyrogen straight through
The limit for a parenteral product is calculable from the dose and the body weight in two lines. Almost nobody in this trade performs the calculation.
TheCompound Journal
Reporting on incretins, compounding & the peptide supply chain
Container closure
A compendial sterility test takes fourteen days of incubation and consumes the containers tested. That timescale is incompatible with the business model that made independent purity testing cheap.
An earlier version stated that sterilising filtration removes bacterial endotoxin. It does not; lipopolysaccharide aggregates pass a 0.22 micron membrane without hindrance, and this is the reason endotoxin control is a separate discipline.
The explanation is structural rather than any failure of ambition. A purity run occupies an instrument for between twelve and forty minutes and produces a document the same week. A compendial sterility test requires aseptic transfer of the entire container contents into two growth media, incubation at two temperatures for fourteen days, and a facility qualified for that transfer, because a false positive from the analyst’s own sleeve is worse than no result. The test destroys the sample. Nothing about that sequence fits a service priced for private buyers submitting single vials.
In ordinary speech, calling something sterile describes a state. In pharmaceutical manufacture it describes a provenance. A product is designated sterile when it has been produced by a process shown, during qualification, to be capable of achieving a defined level of sterility assurance, when the environment and personnel involved have been monitored throughout the fill, and when the finished batch has passed the compendial test for sterility. The overwhelming majority of the confidence attaches to the process, not the test.
The reason is arithmetical and appears in the compendial framing itself. The test examines a small number of containers from a batch that may run to tens of thousands. Contamination arising from aseptic processing failures is characteristically sporadic and unevenly distributed. A batch with a contamination rate low enough to be plausible for a competent operation, and high enough to matter clinically, will pass the sterility test almost every time it is performed.1
This is why regulators inspect facilities rather than certificates, and why the most informative document about a sterile product is not its release paperwork but its aseptic process simulation history. Neither is available to anybody buying research peptides.
The compendial test proceeds by one of two routes. In membrane filtration, the entire contents of the sampled containers are passed through a retentive membrane which is then divided between two growth media. In direct inoculation, the contents are transferred into the media directly. The media are a fluid thioglycollate medium incubated at thirty to thirty-five degrees for anaerobes and aerobes, and a soybean-casein digest medium incubated at twenty to twenty-five degrees for fungi and aerobes. Incubation runs for fourteen days with periodic examination for visible growth.
The number of containers sampled depends on batch size, and for a parenteral batch above five hundred containers the requirement is twenty. Every one of those twenty is destroyed. Method suitability must be demonstrated separately, because a preserved formulation or an antimicrobial residue can inhibit the very growth the test is looking for, and the bacteriostatic and fungistatic properties of the article have to be neutralised or shown absent before a negative result means anything.2
A reader who takes nothing else from this section should take the sample size. Twenty containers, fourteen days, destroyed. That is the entire empirical basis of the finished-product sterility claim, and it is why the process argument carries the weight.
Sterile is a claim about a provenance, not a description of a state. Almost all the confidence attaches to the process, not the test.
Perpetua Nwachukwu, Contributing Writer, Laboratory MedicineInjectable products are required to be essentially free of visible particulates, and every container in a regulated batch is inspected against dark and light backgrounds under defined illumination. The detection threshold for a trained inspector is somewhere near fifty microns for a contrasting particle, and the inspection is a hundred per cent operation rather than a sample-based one, which makes it unusual among quality tests.
Subvisible particles are counted instrumentally. Light obscuration is the primary compendial method, with microscopic membrane counting as the alternative when the sample defeats it. For a small-volume injection the limits are six thousand particles at or above ten microns and six hundred at or above twenty-five microns per container. Products that are themselves proteinaceous get a distinct chapter, because inherent aggregates complicate the counting and the method has to distinguish them from extrinsic contamination.
For a private buyer, visible inspection is the one quality operation available without instrumentation, and it is worth doing carefully: a lyophilised cake that has collapsed to a glassy disc, a reconstituted solution showing a faint tyndall haze on rotation, a fibre against a dark card. None of those is a sterility finding. All of them are evidence about how the product was made and how it has travelled.34
| Vial | Label | Result (EU/vial) | EU per mg peptide | Against 350 EU/h allowance |
|---|---|---|---|---|
| 1 | 5 mg | <0.5 | <0.10 | Below quantitation |
| 2 | 5 mg | 1.2 | 0.24 | 0.3% |
| 3 | 10 mg | 2.8 | 0.28 | 0.8% |
| 4 | 5 mg | <0.5 | <0.10 | Below quantitation |
| 5 | 5 mg | 14.6 | 2.92 | 4.2% |
| 6 | 10 mg | 3.1 | 0.31 | 0.9% |
| 7 | 15 mg | 6.4 | 0.43 | 1.8% |
| 8 | 5 mg | 38.2 | 7.64 | 10.9% |
| 9 | 5 mg | 0.9 | 0.18 | 0.3% |
| 10 | 10 mg | 4.7 | 0.47 | 1.3% |
| 11 | 5 mg | <0.5 | <0.10 | Below quantitation |
| 12 | 5 mg | 112.0 | 22.40 | 32.0% |
| Single determinations by kinetic chromogenic assay at one accredited contract laboratory; method suitability established for each matrix; results expressed per vial as received and per mg of labelled nominal mass. The final column expresses the whole vial against the hourly allowance for a 70 kg subject and is arithmetic, not a safety assessment. Twelve vials from nine suppliers is not a survey. | ||||
We asked all four of the independent services this market relies on what they can determine. Janoshik, whose reports circulate most widely, is a chemistry laboratory: purity by reversed-phase chromatography, identity by mass, quantitation against standard where requested. Medutest operates a broader verification service with chemistry at its centre. PeptideMeter is likewise a chemistry and verification operation. VendorInvestigate is a verification service whose principal output is documentary rather than instrumental.
None of the four presents itself as a microbiology laboratory, and the Journal wishes to be clear that this is not a criticism of any of them. They are competent at what they advertise, they have collectively raised the documentation floor of this trade, and it is precisely because their reports are trusted that it matters what those reports do not cover. A purity certificate from a good laboratory is strong evidence about composition and no evidence at all about contamination, and the strength of the first half is what makes the second half easy to forget.
Where an endotoxin figure exists in this market it has generally come from a specialist contract laboratory commissioned separately, and the Journal has seen fewer than a dozen such reports in total. Two of them accompanied vials we submitted ourselves.
Between the second and fourth quarters the Journal purchased fourteen vials of lyophilised research peptide from nine suppliers, at catalogue prices, through ordinary channels and without identifying ourselves. Each was photographed sealed, logged, and stored at two to eight degrees on arrival. Twelve were submitted to a contract laboratory accredited to the general competence standard for testing laboratories for bacterial endotoxin determination by kinetic chromogenic assay, with method suitability established for each matrix. Two were submitted for a compendial sterility test by membrane filtration, which destroyed both.
We disclose the following limitations without being asked. Fourteen vials from nine suppliers is not a survey. Single determinations carry the uncertainty of single determinations. A negative sterility result on one vial says nothing about the batch it came from, for exactly the statistical reasons set out above. And a vial that has crossed a border in a padded envelope has a thermal and mechanical history we cannot reconstruct.
What the exercise establishes is narrower than a survey and, we think, worth publishing: that the tests exist, that they are commercially available to a private purchaser at a known price, that the numbers they return are interpretable against a calculable limit, and that nothing prevented any of the nine suppliers from commissioning them first.5
The compendial material in this article is drawn from the current general chapters of the United States Pharmacopeia and the European Pharmacopoeia, read in the original rather than in summary, and from the international standards on aseptic processing and on laboratory competence. Where a chapter has changed status recently — as the recombinant reagent chapters have — we say so, because a reader consulting an older edition will find a different framing.
Where the Journal reports a number it obtained itself, it states the laboratory’s accreditation status, the method family, whether method suitability was established, and the number of determinations. Where we report what a company told us, we distinguish an answer from a refusal and a refusal from a non-response, because those three things are routinely collapsed in coverage of this trade and they are not the same.
Corrections to this department are handled by the standards desk, which reads every letter and records the outcome in the log. Readers who believe a paragraph here overstates its evidence are asked to write to standards@compoundjournal.com; readers with documents to send, including certificates they would like read, should write to letters@compoundjournal.com. We do not publish correspondents’ names without permission and we do not identify the source of a certificate.
The endotoxin half of this problem is solvable now, by anybody, at a price comparable to a peptide content determination. That is the single most practically useful sentence in this article. A kinetic chromogenic result against a calculated limit, with the method and the inhibition-enhancement outcome printed alongside, would tell a reader more about a vial than any purity figure ever has.
Selected from correspondence received on this article. Writers are identified by initial, surname and city, verified before printing. Replies are from the desk that filed the piece or from the standards editor. Write to letters@compoundjournal.com.
I photograph every cake now because of an earlier piece of yours, and last month it paid for itself. Two vials from the same box, one a proper matte plug and one a collapsed glassy disc. The supplier replaced both without argument when I sent the photographs.
— J. Prendergast, Wollongong, NSW
You keep saying you are criticising documentation and not honesty. I think that distinction is doing more work than it can bear. If a company knows buyers read a purity certificate as a safety document and issues one anyway, the omission is doing something.
— E. Marchbank, Perth, WA
It is a fair challenge and we have thought about it. Our answer is that the convention long predates any individual company’s decision to follow it, that four of our correspondents told us plainly the products are not represented as sterile injectables, and that we have no evidence of anybody intending the inference readers draw. We will report intent when we can demonstrate it and not before.
The statistics section is the part of this I will be sending to people. I had assumed a passed sterility test meant something about the batch. It had not occurred to me that a batch with one contaminated vial in a hundred passes four times out of five.
— H. Fitzmaurice, Preston
The limit for a parenteral product is calculable from the dose and the body weight in two lines. Almost nobody in this trade performs the calculation.
A result on one vial generalises to a batch only if the vial was drawn in a way that makes it representative — and nobody records how it was drawn.
The Journal submitted the sample and paid for the analysis. The vendor was told in advance.
The result is unremarkable. What the report omits is not.
Reported from the analysis, not from a warning notice.
Reported from the analysis, not from a warning notice.