FillVolumeAndContainerClosureChecker

Fill Volume & Container Closure

Vet veterinary veterinary vaccines animal health adjuvants aquaculture batch release CSV→JSON

Utility description: Fill Volume & Container Closure

Fill Volume & Container Closure Checker — Control of Fill Volume and Container Closure Integrity

ℹ️ Utility assesses critical parameters of filling and capping processes for sterile and non-sterile products according to Ph. Eur. 2.9.17, USP <1>, and GMP requirements:
• Fill Accuracy: Mean volume must match target value (typically ±5%).
• Minimum Volume: No single unit should contain volume below established minimum.
• Uniformity: Coefficient of Variation (RSD) of fill should be low (<5%).
• Integrity (CCIT): Absolute absence of leaks (0 defects).
• Gas Environment: Oxygen control in headspace for oxidizable or lyophilized products.

⚠️ CRITICAL:
• Presence of even one leaky package (CCIT Failure) is a critical defect requiring investigation of the entire batch.
• Underfill below minimum limit leads to patient receiving incomplete dose.

Usage:
FillVolumeAndContainerClosureChecker.exe → demo mode (console output)
FillVolumeAndContainerClosureChecker.exe input.csv output.json → evaluate your data

Input format:
BatchNumber,ProductName,TargetVolume_ml,MeanFillVolume_ml,MinFillVolume_ml,MaxFillVolume_ml,RSD_Fill_Percent,CCIT_Failures,TotalContainersTested_CCIT,ContainerType,Headspace_O2_Percent

Example:
FILL-001,mAb 100mg,10.0,10.15,9.90,10.40,1.2,0,50,Vial,1.5

— WHY IS THIS NEEDED?
Dosing accuracy guarantees therapeutic efficacy.
Container Closure Integrity (CCI) ensures product sterility throughout shelf life and protects from microbial ingress and gases.
This is one of the most important quality control steps for finished dosage forms.

⚠️ CRITICAL:
• CCIT Methods: Destructive (blue dye, vacuum decay) and non-destructive (high voltage discharge, laser oxygen absorption) methods are used.
• Statistics: Representative sample (e.g., 10-20 vials) is usually taken to confirm fill quality.
• Headspace: For lyophilized products, residual oxygen must be minimal (<1-2%) to prevent oxidation.
• Container Type: Requirements may differ for ampoules, vials, syringes, and cartridges.

Key features:
• Comprehensive check of volume and integrity
• Strict zero-tolerance control for leaks
• Assessment of filling process uniformity (RSD)
• Gas environment monitoring in packaging
• Generation of reports for production and QC departments, and LIMS LabWare
• Compliance with GMP and Pharmacopoeia requirements

Critical parameters:
• Mean Volume: within ±5% of target
• Minimum Volume: ≥ 95% of target
• Fill RSD: ≤ 5.0%
• CCIT: 0 failures (100% pass)
• Oxygen: ≤ 2.0% (for sensitive products)

💡 Usage tips:
1. Balance Calibration: Use high-precision balances for volume determination by weighing (considering density).
2. Visual Inspection: Additionally perform visual inspection for cracks and chips.
3. CCIT Validation: Integrity test method must be validated for ability to detect critical size defects.
4. Trends: Track fill volume trends for early detection of filling pump wear.
5. Documentation: CCIT results are key for sterile product batch release.

⚠️ Note: Modern pharma is seeing a shift from destructive integrity testing to 100% non-destructive control (100% ND-CCIT) on the production line.

input.csv

BatchNumber,ProductName,TargetVolume_ml,MeanFillVolume_ml,MinFillVolume_ml,MaxFillVolume_ml,RSD_Fill_Percent,CCIT_Failures,TotalContainersTested_CCIT,ContainerType,Headspace_O2_Percent
FILL-2026-VIAL-001,Monoclonal Antibody 100mg,10.0,10.15,9.90,10.40,1.2,0,50,Vial,1.5
FILL-2026-AMP-002,Vitamin C Injection,2.0,2.05,1.95,2.10,0.8,0,100,Ampoule,0.5
FILL-2026-FAIL-003,Insulin Pen,3.0,2.80,2.50,3.10,4.5,2,60,Cartridge,2.5

URS & FS — User Requirements and Functional Specification

This document describes the controlled interface and behaviour of FillVolumeAndContainerClosureChecker for Fill Volume & Container Closure Checker.

Domain limits URS input.csv FS IQ/OQ/PQ

Domain limits and critical parameters

Key fragments from the source description are shown below. Before production use, limits must be verified against the approved specification, registration dossier and local SOPs.

ℹ️ Utility assesses critical parameters of filling and capping processes for sterile and non-sterile products according to Ph. Eur. 2.9.17, USP <1>, and GMP requirements:
• Fill Accuracy: Mean volume must match target value (typically ±5%).
• Uniformity: Coefficient of Variation (RSD) of fill should be low (<5%).
⚠️ CRITICAL:
• Presence of even one leaky package (CCIT Failure) is a critical defect requiring investigation of the entire batch.
• Underfill below minimum limit leads to patient receiving incomplete dose.
• Headspace: For lyophilized products, residual oxygen must be minimal (<1-2%) to prevent oxidation.
• Compliance with GMP and Pharmacopoeia requirements
Critical parameters:
• Minimum Volume: ≥ 95% of target
• Fill RSD: ≤ 5.0%
• Oxygen: ≤ 2.0% (for sensitive products)
3. CCIT Validation: Integrity test method must be validated for ability to detect critical size defects.

URS — User Requirements Specification

ID	Requirement	Criticality	Acceptance criterion
URS-001	The utility shall accept an input.csv file for Fill Volume & Container Closure Checker with headers defined in the data contract.	High	The file is processed without manual header editing.
URS-002	The utility shall perform deterministic QC evaluation without machine learning and without probabilistic conformance decisions.	High	Identical input data, rule version and configuration produce reproducible results.
URS-003	The utility shall validate mandatory fields, data types, ranges, units and domain plausibility.	High	Schema, conversion and range errors are explicitly reported.
URS-004	The utility shall apply domain limits and rules from the description, approved specification, registration dossier and local SOPs.	High	Each check has PASS/WARNING/FAIL and a clear message.
URS-005	The utility shall generate output.json with machine-readable results, source values, warnings, failures and critical findings.	High	JSON is suitable for LIMS/ELN/MES integration and QA/QC review.
URS-006	The utility shall preserve traceability between batch/sample, input file, applied rules and final status.	High	Output contains identifiers, checked parameters and audit metadata.
URS-007	The documentation shall support IQ/OQ/PQ, CSV/CSA and review by internal QA or inspectors.	Medium	URS, FS, input/output contract and test scenarios are supplied with the utility.
URS-008	The utility shall be used as a QC decision-support tool and not as a substitute for approved specifications and QA/QP release decision.	Medium	Documentation states change control and limit-verification expectations.

input.csv contract

#	Field	Type	Sample	Purpose
1	`BatchNumber`	string / controlled vocabulary	`FILL-2026-VIAL-001`	Batch or lot identifier used for traceability.
2	`ProductName`	string / controlled vocabulary	`Monoclonal Antibody 100mg`	Product or dosage-form name under evaluation.
3	`TargetVolume_ml`	decimal	`10.0`	Volume/dose used for load, limit or release calculation.
4	`MeanFillVolume_ml`	decimal	`10.15`	Volume/dose used for load, limit or release calculation.
5	`MinFillVolume_ml`	decimal	`9.90`	Volume/dose used for load, limit or release calculation.
6	`MaxFillVolume_ml`	decimal	`10.40`	Volume/dose used for load, limit or release calculation.
7	`RSD_Fill_Percent`	decimal	`1.2`	Controlled input parameter for deterministic QC rules.
8	`CCIT_Failures`	decimal	`0`	Controlled input parameter for deterministic QC rules.
9	`TotalContainersTested_CCIT`	decimal	`50`	Controlled input parameter for deterministic QC rules.
10	`ContainerType`	string / controlled vocabulary	`Vial`	Controlled input parameter for deterministic QC rules.
11	`Headspace_O2_Percent`	decimal	`1.5`	Controlled input parameter for deterministic QC rules.

BatchNumber,ProductName,TargetVolume_ml,MeanFillVolume_ml,MinFillVolume_ml,MaxFillVolume_ml,RSD_Fill_Percent,CCIT_Failures,TotalContainersTested_CCIT,ContainerType,Headspace_O2_Percent
FILL-2026-VIAL-001,Monoclonal Antibody 100mg,10.0,10.15,9.90,10.40,1.2,0,50,Vial,1.5
FILL-2026-AMP-002,Vitamin C Injection,2.0,2.05,1.95,2.10,0.8,0,100,Ampoule,0.5
FILL-2026-FAIL-003,Insulin Pen,3.0,2.80,2.50,3.10,4.5,2,60,Cartridge,2.5

Input validation rules

ID	Field	Rule	Criticality
VR-001	`BatchNumber`	The field shall match an approved dictionary or accepted string representation.	High
VR-002	`ProductName`	The field shall match an approved dictionary or accepted string representation.	High
VR-003	`TargetVolume_ml`	The field shall match an approved dictionary or accepted string representation.	High
VR-004	`MeanFillVolume_ml`	The field shall match an approved dictionary or accepted string representation.	Medium
VR-005	`MinFillVolume_ml`	The field shall match an approved dictionary or accepted string representation.	Medium
VR-006	`MaxFillVolume_ml`	The field shall match an approved dictionary or accepted string representation.	Medium
VR-007	`RSD_Fill_Percent`	The field shall match an approved dictionary or accepted string representation.	Medium
VR-008	`CCIT_Failures`	The field shall match an approved dictionary or accepted string representation.	Medium
VR-009	`TotalContainersTested_CCIT`	The field shall match an approved dictionary or accepted string representation.	Medium
VR-010	`ContainerType`	The field shall match an approved dictionary or accepted string representation.	Medium
VR-011	`Headspace_O2_Percent`	The field shall match an approved dictionary or accepted string representation.	Medium

FS — Functional Specification

ID	Function	Implementation
FS-001	CLI execution	Support execution modes: demo mode without arguments and production mode input.csv output.json.
FS-002	CSV import	Read input.csv in UTF-8/CSV-compatible format and validate header and expected columns.
FS-003	Schema validation	Check mandatory fields, column count, unknown key fields and empty mandatory values.
FS-004	Type conversion	Convert numeric, flag and text values; invalid format is recorded as a row-level error.
FS-005	Domain rule engine	Apply rules for Fill Volume & Container Closure Checker, including critical limits from the description and approved specification.
FS-006	Status aggregation	Produce final status: FAIL for critical failure, WARNING for non-critical deviation, PASS for conformance.
FS-007	JSON export	Write output.json with detailed checks, source values, warnings, failures and critical findings.
FS-008	Audit support	Keep result structure suitable for review, deviation investigation and calculation reproduction.
FS-009	Integration contract	Support the scenario LIMS/ELN/MES → input.csv → utility → output.json → portal/admin review.
FS-010	Error handling	Return explicit messages for missing file, empty CSV, invalid schema, output write failure and invalid format.

Example output.json

{
  "utilityId": "fillvolumeandcontainerclosurechecker",
  "utilityFolder": "FillVolumeAndContainerClosureChecker",
  "package": "Vet",
  "overallStatus": "PASS|WARNING|FAIL",
  "sourceFile": "input.csv",
  "processedAtUtc": "2026-06-10T00:00:00Z",
  "checks": [
    {
      "parameter": "BatchNumber",
      "value": "FILL-2026-VIAL-001",
      "status": "PASS|WARNING|FAIL",
      "message": "Deterministic rule-based check result",
      "ruleReference": "FS-RULE-001"
    },
    {
      "parameter": "ProductName",
      "value": "Monoclonal Antibody 100mg",
      "status": "PASS|WARNING|FAIL",
      "message": "Deterministic rule-based check result",
      "ruleReference": "FS-RULE-002"
    },
    {
      "parameter": "TargetVolume_ml",
      "value": "10.0",
      "status": "PASS|WARNING|FAIL",
      "message": "Deterministic rule-based check result",
      "ruleReference": "FS-RULE-003"
    },
    {
      "parameter": "MeanFillVolume_ml",
      "value": "10.15",
      "status": "PASS|WARNING|FAIL",
      "message": "Deterministic rule-based check result",
      "ruleReference": "FS-RULE-004"
    },
    {
      "parameter": "MinFillVolume_ml",
      "value": "9.90",
      "status": "PASS|WARNING|FAIL",
      "message": "Deterministic rule-based check result",
      "ruleReference": "FS-RULE-005"
    },
    {
      "parameter": "MaxFillVolume_ml",
      "value": "10.40",
      "status": "PASS|WARNING|FAIL",
      "message": "Deterministic rule-based check result",
      "ruleReference": "FS-RULE-006"
    },
    {
      "parameter": "RSD_Fill_Percent",
      "value": "1.2",
      "status": "PASS|WARNING|FAIL",
      "message": "Deterministic rule-based check result",
      "ruleReference": "FS-RULE-007"
    },
    {
      "parameter": "CCIT_Failures",
      "value": "0",
      "status": "PASS|WARNING|FAIL",
      "message": "Deterministic rule-based check result",
      "ruleReference": "FS-RULE-008"
    },
    {
      "parameter": "TotalContainersTested_CCIT",
      "value": "50",
      "status": "PASS|WARNING|FAIL",
      "message": "Deterministic rule-based check result",
      "ruleReference": "FS-RULE-009"
    },
    {
      "parameter": "ContainerType",
      "value": "Vial",
      "status": "PASS|WARNING|FAIL",
      "message": "Deterministic rule-based check result",
      "ruleReference": "FS-RULE-010"
    },
    {
      "parameter": "Headspace_O2_Percent",
      "value": "1.5",
      "status": "PASS|WARNING|FAIL",
      "message": "Deterministic rule-based check result",
      "ruleReference": "FS-RULE-011"
    }
  ],
  "criticalFindings": [],
  "warnings": [],
  "audit": {
    "inputHash": "sha256:<calculated at runtime>",
    "rulesVersion": "<utility executable version>",
    "documentation": "FillVolumeAndContainerClosureChecker.documentation.html"
  }
}

Traceability matrix

URS	FS	Test	Evidence
URS-001	FS-001, FS-002	OQ-001	Verify execution and import of valid input.csv.
URS-002	FS-005, FS-006	OQ-004	Repeat the same dataset and compare output.json.
URS-003	FS-003, FS-004, FS-010	OQ-002, OQ-003	Verify missing columns and invalid types.
URS-004	FS-005, FS-006	OQ-004, PQ-001	Verify critical deviations on real/boundary data.
URS-005	FS-007, FS-009	OQ-005	Verify JSON schema and downstream-system suitability.
URS-006	FS-008	OQ-006	Verify identifiers and audit metadata.
URS-007	FS-008, FS-010	IQ-001, OQ-007	Verify documentation completeness and control evidence.
URS-008	FS-005, FS-008	PQ-002	Verify review workflow and no replacement of QA decision.

IQ/OQ/PQ test scenarios

ID	Scenario	Expected result
IQ-001	Verify executable, input.csv, documentation and checksum availability.	Delivery set is complete; version is recorded.
OQ-001	Valid sample row from input.csv.	PASS or acceptable WARNING according to rules.
OQ-002	Remove a mandatory CSV column.	Schema error or FAIL with missing-column reference.
OQ-003	Place a non-numeric value into a numeric field.	Type-conversion error with row/field reference.
OQ-004	Set a critical parameter outside the limit.	FAIL and critical finding.
OQ-005	Verify output.json structure.	All mandatory sections are present and JSON is valid.
OQ-006	Verify batch/sample traceability.	Input and result identifiers match.
PQ-001	Verify 3–5 real user batches/samples.	Result is confirmed by QC/QA review.
PQ-002	Verify deviation workflow and manual QA decision.	Utility supports review but does not replace approved decision.

QA/QC and change control

Do not rename columns without updating validator, documentation and test set.
Retain input.csv, output.json, executable version and checksum.
Before production use, perform IQ/OQ/PQ or equivalent CSV/CSA verification.
Critical limits shall be verified against the approved specification, registration dossier and local SOPs.
The utility provides structured QC decision support; final release decision remains with QA/QP and approved procedures.

Included in packages

Vet — Veterinary QC Utilities

Vet is designed for veterinary pharmaceuticals and vaccines: adjuvants, antigens, autogenous vaccines, aquaculture, feed/premixes, antimicrobial and antiparasitic products, sterility and batch release.

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