Different Vial Stoppers - Bromobutyl vs Chlorobutyl

Serum vial stoppers are readily available in bromobutyl and chlorobutyl rubber formulations for use in pharmaceutical and biological packaging. During the vulcanization process of natural rubber (heating and curing), cross-linking of individual polymer chains forms copolymers of isobutylene, and to a lesser extent, isoprene. By incorporating a halogen (bromine or chlorine) in the vulcanization process, the rate of vulcanization blending and curing performance is improved, and the cross-link bonding property is also significantly enhanced. Each specific halogen offers its own unique characteristics to the finished product.

Material Composition

Bromobutyl Rubber: a terpolymer of isobutylene, isoprene, and brominated isoprene.

Bromobutyl Vial Stoppers: Bromobutyl vial rubber is a copolymer of isobutylene and a small amount of isoprene, with bromine atoms added to the polymer chain. The bromination process enhances the barrier properties of the rubber, making it impermeable to gases such as oxygen and moisture. This characteristic is particularly advantageous for medications that are sensitive to oxidation or degradation caused by exposure to air or moisture.

Chlorobutyl Rubber: a terpolymer of isobutylene, isoprene, and chlorinated isoprene.

Chlorobutyl Vial Stoppers: Similarly, chlorobutyl rubber is a copolymer of isobutylene and a small amount of isoprene, with chlorine atoms incorporated into the polymer chain. Chlorination enhances the barrier properties of the rubber, providing resistance to gases and moisture. Chlorobutyl rubber offers excellent compatibility with a wide range of pharmaceutical formulations and is known for its low levels of extractables and leachables, making it suitable for sensitive drug formulations.

Processing with Bromine vs Chlorine

When bromine is used as the halogen for producing bromobutyl rubber, it is routinely added at a concentration of about 2%; whereas chlorine is added at a concentration of 1.1 – 1.5% in chlorobutyl rubber stoppers. Since bromine is more reactive than chlorine, a stabilizer is often added to the rubber (such as soybean oil at 1.3%) during the vulcanization of bromobutyl rubber. Since chlorine is more inert, it doesn't require the use of any stabilizers. The use of antioxidants (such as BHT) is routinely employed in both bromobutyl rubber and chlorobutyl rubber vial stopper manufacturing.

Advantages and Disadvantages: Bromobutyl Vial Stoppers vs Chlorobutyl Vial Stoppers

BROMOBUTYL

Advantages of Bromobutyl Rubber: It exhibits lower hygroscopicity and is preferable for applications involving freeze-dried or lyophilized products. Bromobutyl vial stoppers also offer higher stability and generally have a longer shelf life. Additionally, bromobutyl rubber boasts a faster cure rate and a shorter scorch or cure induction period, leading to more efficient production. This characteristic necessitates lower levels of curatives and enables the use of a wider range of accelerators.

Bromobutyl Rubber Disadvantages: stabilizers are required in the production of bromobutyl rubber vial stoppers (such as soybean oil). Bromobutyl rubber also has greater heat sensitivity.

CHLOROBUTYL

Chlorobutyl Rubber Advantages: chlorobutyl vial stoppers have better resistance to heat and is the preferred stopper formulation for high-heat sterilization techniques. Chlorobutyl rubber vial stoppers are more efficiently produced without the use of stabilizers.

Chlorobutyl Rubber Disadvantages: longer curing times, resulting in higher production costs

Gas Permeability

Bromobutyl Vial Stoppers: Bromobutyl rubber exhibits lower gas permeability compared to chlorobutyl rubber. This property is particularly advantageous for medications prone to degradation or potency loss due to exposure to oxygen. Bromobutyl stoppers effectively prevent oxygen ingress into vials, thereby preserving the integrity and efficacy of pharmaceutical products over extended storage periods.

Chlorobutyl Vial Stoppers: While chlorobutyl rubber also offers excellent gas barrier properties, it may not be as effective as bromobutyl rubber in preventing oxygen permeation. However, chlorobutyl stoppers still provide adequate protection against gas ingress, making them suitable for a wide range of pharmaceutical applications where oxygen sensitivity is not a primary concern.

Moisture Barrier

Bromobutyl Vial Stoppers: Bromobutyl rubber demonstrates superior moisture barrier properties compared to chlorobutyl rubber. This characteristic is particularly beneficial for medications susceptible to moisture-induced degradation or microbial contamination. Bromobutyl stoppers effectively seal vials, preventing moisture ingress and maintaining the stability and sterility of pharmaceutical formulations.

Chlorobutyl Vial Stoppers: Although chlorobutyl rubber also offers a good moisture barrier, it may not provide the same level of protection as bromobutyl rubber. However, chlorobutyl stoppers still offer sufficient moisture resistance for many pharmaceutical applications, particularly those with moderate moisture sensitivity.

Compatibility

Bromobutyl Vial Stoppers: Bromobutyl rubber is compatible with a wide range of drug formulations, including those containing acids, bases, and organic solvents. Its robust chemical resistance makes it suitable for various pharmaceutical applications, ensuring the integrity and stability of medications under diverse storage conditions.

Chlorobutyl Vial Stoppers: Similarly, chlorobutyl rubber exhibits excellent compatibility with a broad spectrum of pharmaceutical formulations. Its low levels of extractables and leachables make it suitable for sensitive drug products, including biologics and vaccines, where maintaining product purity is paramount.

Conclusion

In conclusion, both bromobutyl and chlorobutyl vial stoppers offer unique advantages and are suitable for different pharmaceutical applications. Bromobutyl rubber provides superior gas and moisture barrier properties, making it ideal for medications sensitive to oxidation and moisture-induced degradation. On the other hand, chlorobutyl rubber offers excellent compatibility and low levels of extractables, making it suitable for a wide range of pharmaceutical formulations.

When selecting vial stoppers for pharmaceutical packaging, it is essential to consider the specific requirements of the drug product and storage conditions. By understanding the differences between bromobutyl and chlorobutyl vial stoppers, pharmaceutical manufacturers can make informed decisions to ensure the integrity, stability, and safety of their products.