Phial: From Glass Ampoule to Modern Laboratory Vessel – Development and Areas of Application
Last updated: 04 February 2026
A phial is a small container made of glass or plastic (e.g., COC, COP, polyethylene, or polypropylene). Classic glass phials are characterized by their pear-shaped design. In contrast, modern plastic phials are usually cylindrical or ergonomically shaped. The hermetic design supports container-closure integrity (CCI) and protects sterile contents from recontamination. In addition to traditional glass phials, plastic phials are increasingly used today, typically cylindrical or ergonomic in shape. The typical volumes range from 0.1 to 60 milliliters. Glass phials are highly resistant to chemical influences, while modern plastic phials prove mechanically robust in practice. In the blow-fill-seal process, hermetic sealing is achieved by melting the polymer. In combination with aseptic manufacturing, this allows for a long shelf life without preservatives. Traditional glass vials, on the other hand, are usually sealed with an elastomer stopper and crimp caps.
Distinctive properties:
- Polymer phials: High break resistance during transport and use – a key advantage over glass containers.
- A narrow neck reduces evaporation and contamination.
- Transparent walls enable visual inspection.
- Variable volumes allow customization for different needs.
- Aseptic manufacturing ensures a high level of sterility and contamination control.
These attributes make them indispensable in controlled production environments. In aseptic processes, they block microorganisms, and their low weight supports efficient transport. Integration into automated processes continues to increase.
Manufacturing Process
Traditional phials are produced by glassblowing, where heated material is expanded and shaped in molds. Machines carry out this process to ensure uniform results. For polymer-based phials, containers are typically made by extrusion and molding; in the blow-fill-seal (BFS) method, this forming process is directly integrated into the entire production cycle. Filling and sealing occur in a single step, significantly reducing the risk of contamination.
Quality inspections detect cracks and leaks, and automated lines increase output to over 20,000 units per hour (depending on volume and machine type). The Automated Optical Inspection (AOI) performs objective 100% inspection for particles and defects, which is now standard for GMP-compliant documentation.
High automation of BFS systems minimizes human intervention and thus the risk of contamination. Critical applications such as eye drops, inhalation solutions, or parenteral drugs benefit from BFS technology, as it provides maximum sterility assurance (SAL) with reduced cleanroom effort, since the critical zone is locally protected.
Main steps of the production process:
- Extrusion of the tube (parison) from sterile polymer granules.
- Forming the container (blow) in the cooled cavity.
- Aseptic filling (fill) with sterile product.
- Hermetic sealing (seal) by melting the polymer.
These steps ensure a high purity level of the final product. In glass processing, ampoules and vials are mainly made from borosilicate tubing, then fused or closed with stoppers. Numerous regulatory guidelines define the process standards.
Materials and Variants
Glass, especially borosilicate, remains the classic substrate due to its chemical resistance. Materials like polyethylene (PE) or polypropylene (PP) for pharmaceutical primary packaging ensure high break resistance in demanding environments. PE is ideal for flexible containers, while PP is used for rigid containers with greater thermal or chemical resistance. Multilayer structures can block gas penetration, and special variants include cell culture models with modified surfaces.
Ampoule-like forms enable foldable blocks, and special designs integrate attachments for gels. The use of recyclable plastics helps protect the environment. However, the choice of material depends on the content. Glass is traditionally used for many injectable preparations. Polymer containers, however, offer a decisive advantage in break resistanceand light weight, making them ideal for large-volume or critical parenteral drugs. Hybrid compositions combine the benefits of both materials.
Borosilicate glass minimizes ion exchange with the contents. Barrier layers reliably prevent oxidation. Versions with hanging devices facilitate use. The diversification addresses various requirements. The modern focus is on biocompatibility, and adaptation to sterile conditions remains central.
Material selection:
- Borosilicate glass for thermal stability.
- Polymers for break resistance.
- Multilayer structures for permeation resistance.
- Hybrid materials for combined properties.
Industrial Applications
In the pharmaceutical industry, phials store injection solutions, vaccines, and medicines. Their sterility protects against microbial contamination. The cosmetics industry uses them for fragrance samples, and chemical laboratories safely store reagents. Medical technology integrates them into diagnostic kits.
The food industry tests flavors with them, and research institutes grow cells in specialized forms. Automated filling systems increase productivity, and standards such as EU-GMP regulate handling. The filling of sterile liquids for pharmaceuticals remains the dominant application, while sample storage in laboratories represents another area of use.
Packaging for cosmetics and fragrances broadens the range. These application fields highlight their practical importance, and adaptation to mechanized systems continues to grow.