First, what is outgassing? Outgassing occurs when volatile compounds are released from materials, often as a result of manufacturing processes, environmental conditions, or material properties. In laboratory and packaging environments, this phenomenon poses significant risks. Septa used in vial caps, for example, can release trace chemicals that contaminate sensitive samples, compromising the accuracy of results or the stability of packaged products. For industries like pharmaceuticals, chemical testing, and food analysis, minimizing outgassing is critical to maintaining sample integrity and reliability.
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Ways to Prevent Septa Outgassing
Ways to Prevent Septa Outgassing
May 19, 2025
Why Analytically Clean Septa Are Critical for Preventing Outgassing
Septa contamination is one of the leading causes of outgassing in packaging and laboratory applications. Poorly manufactured septa or those exposed to contaminants during production can release volatile organic compounds (VOCs) when exposed to heat, pressure, or specific chemicals. These VOCs can infiltrate the sample or product, introducing contamination that skews analytical results or degrades the quality of sensitive contents.
In applications like pharmaceutical packaging, food testing, or chemical analysis, even minute levels of contamination can render a sample unusable or lead to erroneous conclusions. This underscores the need for septa that are not only well-manufactured but also thoroughly conditioned to remove potential contaminants before use.
How Low-Bleed Caps and Septa Mitigate Outgassing Risks
The choice of high-quality lined caps and low-bleed septa is a fundamental step in minimizing outgassing risks. Properly conditioned liners have been conditioned to ensure a reduced risk of out-gassing contaminants.
Septa specifically rated as low-bleed are typically treated or processed to eliminate residual compounds that could be released under operational conditions. When paired with a compatible cap, these septa provide a low-bleed option for gas chromatography testing. By selecting caps and liners tailored to the application, manufacturers and laboratories can significantly reduce the likelihood of outgassing events that compromise product or sample integrity.
Material Considerations for Septa in Lined Caps
Selecting the right septa material is crucial for managing outgassing. Different materials offer unique benefits and limitations depending on the application:
Foam Liners
Foam liners are lightweight and cost-effective but have limited chemical resistance. They are best suited for low-demand applications where chemical exposure and temperature extremes are not concerns.
Butyl Liners
Butyl liners are known for their low permeability, which makes them highly effective at preventing gas and moisture exchange between the vial and its surroundings. This characteristic is especially valuable in applications requiring long-term sample stability or storage of volatile substances.
Silicone/PTFE Liners
Silicone/polytetrafluoroethylene (PTFE) liners are chemically inert and highly resistant to extreme temperatures. Their non-reactive nature makes them the gold standard for preventing outgassing in high-sensitivity applications like chromatography, chemical storage, and pharmaceutical packaging.
How To Keep Septa and Packaging Low-Bleed
Preventing outgassing begins with selecting high-quality septa designed for the intended application. Here are some best practices to maintain cleanliness and performance:
- Choose Certified Clean Septa: Opt for certified low-bleed septa manufactured and tested under stringent quality control protocols to remove potential contaminants.
- Proper Storage: Store septa in a clean, dry environment away from potential sources of contamination, such as chemicals, oils, or dust.
- Minimize Handling: Use gloves or tools when handling septa to reduce the risk of transferring particles or residues.
- Inspect Before Use: Examine septa and caps for visible defects or signs of contamination before assembly.
Scenarios Where Septa Cleanliness is Essential
Certain applications are particularly sensitive to outgassing, making septa cleanliness a top priority:
Long-Term Chemical Storage
Containers used for long-term storage of volatile or reactive chemicals require low-outgassing septa to prevent contamination over time.
High-Sensitivity Sample Analysis
Analytical methods like gas chromatography or mass spectrometry depend on uncontaminated samples to produce reliable results. Clean septa prevent interference from outgassing.
Pharmaceutical and Medical Packaging
Medicines, vaccines, and biologics are often stored in environments where outgassing could compromise their safety or efficacy. Clean septa help maintain the integrity of these critical products.
Best Practices for Reducing Outgassing
Outgassing poses a significant challenge in packaging and laboratory environments, especially in high-sensitivity applications. By selecting clean, high-quality septa and adhering to proper handling and storage practices, manufacturers and laboratories can mitigate the risks associated with outgassing. Whether in pharmaceuticals, food analysis, or chemical testing, prioritizing the right materials and methods is essential for protecting products, maintaining accuracy, and ensuring long-term reliability.