TRAY-BASED STERILE PACKAGING OF PHARMACEUTICAL VIALS AND VIAL CLOSURES

Small batch packaging for vial seals and vial stoppers is provided. The packaging includes a vial tray having a plurality of individual spaced-apart vial receptacles for receiving respective vials. The packaging also includes a vial seal tray having a plurality of individual spaced-apart seal receptacles for receiving respective vial seals. The packaging further includes a stopper tray having a plurality of individual spaced-apart stopper receptacles for receiving respective vial seals. A seal channel may extend through the plurality of individually spaced-apart seal receptacles to form a clearance for facilitating grasping of each vial seal. Similarly, a stopper channel may extend through the plurality of individually spaced-apart stopper receptacles to form a clearance for facilitating grasping of each vial stopper.

FIELD OF THE INVENTION

The present disclosure generally relates to trays for vials and vial closures, and more particularly, to sterile trays for pharmaceutical vial stoppers and vial seals.

BACKGROUND

Research and production of novel biological medicines, such as various gene therapies, requires manual or semi-automated filling of container closure systems in small quantities. During this process, the steps of filling medication containers, such as glass or polymeric vials, closing the vials with elastomeric stoppers, and capping the vials with crimped aluminum seals, are typically performed manually for small batch quantities using compact workspaces, such as small biosafety cabinets or laboratory desks having a hood. However, stoppers and seals for pharmaceutical vials are typically manufactured and shipped in large batch quantities as bulk packaging, such as in sterile bags. For instance, cell and gene therapy manufacturers typically use pharmaceutical closures available only in larger quantity bulk packs that were developed for fill and finish processes of large batches with automated filling machines. This can cause a complex and difficult process for unpacking of the closure bulk packs, as well as a complex and difficult aseptic transfer process of the closures onto corresponding vials when performed in a small biosafety cabinet. As a result, there is a substantial risk for microbial and particulate contamination to the assembled and filled pharmaceutical vials.

Moreover, such bulk packaging requires the user to unpack a small portion of the vial closure components from the bulk package, and then place them into a biosafety cabinet before use. This unpacking process often results in the user either dropping the closures onto a laboratory desk surface or refilling the contents of the bulk package into a separate container, such as a glass dish, under aseptic conditions. Such a process is also cumbersome since larger bulk pack formats are difficult to handle in the compact laboratory or biosafety cabinet setting. Furthermore, retrieving an individual closure member from a bulk pack requires multiple steps, which frequently leads to numerous closures being touched and moved. As a result, this process poses a substantial risk of breaching the intended sterility of the closures.

It is therefore a goal to allow a user to easily be able to access both vial seals and vial stoppers from corresponding small batch trays while working at a compact work space. Such an arrangement would be much easier than having to use conventional packaging methods for the seals and stoppers, which are bulk packaged in bags that the user first has to empty on the surface of the workspace and then spread out the individual closure members in order to pick out each one for placement on a vial. Such a conventional process is especially difficult to do with limited space in a biosafety cabinet or on a laboratory desk. Moreover, a substantial risk of contamination is present when a user has to reach into a bulk closure bag to grab one or more of the closure elements since there is a high risk of contaminating other components in the bag due to a breach of sterility therein.

Although conventional trays for the storage and stocking of medical or pharmaceutical preparations are typically used on a large scale, such trays are usually delivered to a pharmaceutical manufacturer or to a plant for further processing in a predetermined arrangement, such as while being held or accommodated in a supporting structure. However, such conventional trays are not well-suited for use in the laboratory or biosafety cabinet setting. Accordingly, there is a clear and substantial need for trays and associated kits that provide a novel small quantity presentation of sterile ready-to-use closure members, wherein the trays and kits are designed for easy handling and safe use in fill & finish processes carried out in a compact environment, including a laboratory desk or biosafety cabinet, such as those for small batch cell and gene therapy medications. Further, there is a need for trays and kits that are safer and easier to handle than conventional bulk packaging by allowing a user to touch one individual component stored in the tray at a time.

SUMMARY

The foregoing needs are met, to a great extent, by the packaging trays of the present disclosure, including a vial seal tray comprising a body having a top surface defining a receptacle array, the receptacle array comprising a plurality of receptacle rows, each of the plurality of receptacle rows comprising a plurality of individual spaced-apart receptacles configured to releasably secure a respective vial seal; a connection web disposed on the top surface of the vial seal tray and interconnecting the plurality of individual receptacles, each receptacle defining a hollow cavity extending downwardly from the top surface of the vial seal tray and forming a closed lower end, the hollow cavity configured to receive a portion of the vial seal; a region protruding upwardly from a central portion of the closed lower end of each receptacle for supporting the vial seal; and a channel extending through the plurality of individually spaced-apart receptacles disposed in each respective receptacle row, the channel forming a clearance on opposing sides of each receptacle for facilitating grasping of the vial seal held in the corresponding receptacle.

According to another aspect of the present disclosure, the plurality of receptacle rows are arranged parallel to each other and laterally offset from one another, such that the position of each receptacle in adjacent receptacle rows is correspondingly offset from one another.

According to another aspect of the present disclosure, each receptacle has a generally cylindrical shape.

According to another aspect of the present disclosure, the vial seal tray includes a base defining a flange protruding outwardly along a periphery of the vial seal tray.

According to another aspect of the present disclosure, a tray wall extends between the top surface and the base along the periphery of the vial seal tray.

According to another aspect of the present disclosure, the tray wall includes a notch configured to facilitate stacking with another vial seal tray.

According to another aspect of the present disclosure, the top surface of the vial seal tray includes a chamfered edge along its perimeter to facilitate stacking with another vial seal tray.

According to another aspect of the present disclosure, wherein the region includes a tip portion having a hemispherical shape.

According to another aspect of the present disclosure, a vial stopper tray comprises a body having a top surface defining a receptacle array, the receptacle array comprising a plurality of receptacle rows, each of the plurality of receptacle rows comprising a plurality of individual spaced-apart receptacles configured to releasably secure a respective vial stopper; a connection web disposed on the top surface of the vial stopper tray and interconnecting the plurality of individual receptacles, each receptacle defining a hollow cavity extending downwardly from the top surface of the vial stopper tray and forming a closed lower end, the hollow cavity configured to receive a portion of the vial stopper; a region protruding upwardly from a central portion of the closed lower end of each receptacle for supporting the vial stopper; and a channel extending through the plurality of individually spaced-apart receptacles disposed in each respective receptacle row, the channel forming a clearance on opposing sides of each receptacle for facilitating grasping of the vial stopper held in the corresponding receptacle.

According to another aspect of the present disclosure, each receptacle includes a bumper configured to releasably secure a portion of a corresponding vial stopper within the cavity.

According to another aspect of the present disclosure, the bumper extends radially inward from an inner wall of the receptacle, the bumper forming a constricted opening of the cavity.

According to another aspect of the present disclosure, the bumper is configured to snapingly engage a portion of the vial stopper.

According to another aspect of the present disclosure, the channel is further configured to permit steam to flow along the receptacle row for sterilizing each vial stopper disposed in the receptacle row.

According to another aspect of the present disclosure, a reinforcement rib may be disposed on the top surface of the stopper tray and extending perpendicularly to the channel for increasing stiffness of the top surface of the stopper tray.

According to another aspect of the present disclosure, each receptacle has a generally cylindrical shape.

According to another aspect of the present disclosure, the vial stopper tray includes a base defining a flange protruding outwardly along a periphery of the vial stopper tray.

According to another aspect of the present disclosure, a tray wall extends between the top surface and the base along the periphery of the vial stopper tray.

According to another aspect of the present disclosure, the tray wall includes a notch configured to facilitate stacking with another vial stopper tray.

According to another aspect of the present disclosure, the tray wall includes a pleat configured to provide increased stability to the stopper tray.

According to another aspect of the present disclosure, the vial stopper tray includes a chamfered edge along its perimeter to facilitate stacking with another vial stopper tray.

According to another aspect of the present disclosure, the region includes a tip portion having a hemispherical shape.

According to another aspect of the present disclosure, a stopper tray lid is configured to removably attach to the body of the vial stopper tray.

According to another aspect of the present disclosure, the stopper tray lid is configured to attach to the body of the vial stopper tray by a snap fit engagement.

According to another aspect of the present disclosure, the stopper tray lid includes a lid base having a side wall extending along a perimeter of the lid base, and a locking protrusion extending from a portion of the side wall for matingly engaging a portion of the body of the vial stopper tray.

According to another aspect of the present disclosure, the stopper tray lid includes a lid flange protruding outwardly along the perimeter of the stopper tray lid.

According to another aspect of the present disclosure, the stopper tray lid includes a bottom surface having a plurality of retention regions protruding therefrom, wherein each retention region is sized and shaped to fit within a corresponding receptacle of the vial stopper tray when the stopper tray lid is attached to the stopper tray.

According to another aspect of the present disclosure, the stopper tray lid includes a lid reinforcement rib protruding from a bottom surface of the lid base.

According to another aspect of the present disclosure, a kit comprises a vial tray comprising a tray base having a vial receptacle array, the vial receptacle array comprising a plurality of vial receptacle rows, each of the plurality of vial receptacle rows comprising a plurality of individual spaced-apart vial receptacles configured to receive a top portion of a respective vial; and a vial seal tray comprising a seal tray body having a top surface defining a seal receptacle array, the seal receptacle array comprising a plurality of seal receptacle rows, each of the plurality of seal receptacle rows comprising a plurality of individual spaced-apart seal receptacles configured to receive a respective vial seal, and a seal channel extending through the plurality of individually spaced-apart receptacles disposed in each respective seal receptacle row, the seal channel forming a clearance on opposing sides of each seal receptacle for facilitating grasping of the vial seal held in the corresponding receptacle; and a vial stopper tray comprising a stopper tray body having a top surface defining a stopper receptacle array, the stopper receptacle array comprising a plurality of stopper receptacle rows, each of the plurality of stopper receptacle rows comprising a plurality of individual spaced-apart stopper receptacles configured to receive a respective vial stopper, and a stopper channel extending through the plurality of individually spaced-apart stopper receptacles disposed in each respective stopper receptacle row, the stopper channel forming a clearance on opposing sides of each stopper receptacle for facilitating grasping of the vial stopper held in the corresponding receptacle.

According to another aspect of the present disclosure, the vial tray further comprises a vial tray lid including a plurality of recesses arranged to receive a bottom portion of a respective vial.

According to another aspect of the present disclosure, an outer periphery of the vial tray lid is shaped and dimensioned to fit within an open portion of the tray base for sealing each vial within the vial tray.

According to another aspect of the present disclosure, the vial tray lid is configured for snap fit engagement with the base of the vial tray.

According to another aspect of the present disclosure, a primary container is configured to receive the vial seal tray.

According to another aspect of the present disclosure, the primary container is a first sterile bag for providing a first sterile barrier.

According to another aspect of the present disclosure, a secondary container is configured to receive the vial seal tray and the primary container.

According to another aspect of the present disclosure, the secondary container is a second sterile bag. The secondary bag for the via seal trays may act as a second sterile barrier.

There has thus been outlined certain embodiments of the present disclosure in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional embodiments of the present disclosure that will be described below and which form the subject matter of the claims appended hereto.

In this respect, before explaining at least one aspect of the packaging trays in detail, it is to be understood that the packaging trays are not limited in their application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The packaging trays are capable of aspects in addition to those described, and of being practiced and carried out in various ways.

DETAILED DESCRIPTION

The present disclosure describes various configurations of sterile trays for closures, such as a stoppers and seals, for use with pharmaceutical vials.FIGS.1-4show a vial seal tray100comprising a receptacle array110having a plurality of individual receptacles120, wherein each receptacle is configured to releasably receive and secure a vial seal. The vial seal tray100may be disposed within a container for protection of the vial seals, such as from contamination that could render each vial seal contained in the vial seal tray100unsuitable for subsequent assembly with a medicine vial. The container may be made from a material which is suitable for sterilization. In some instances, the container may include one or more sterile bags sized and shaped to accommodate the vial seal tray, wherein the bag is heat-sealed once the tray is contained therein. For instance, the vial seal tray100may be contained within a primary heat-sealed bag having a partial vacuum applied thereto to remove excess air. According to another aspect, the vial seal tray100within the primary bag may be further contained within a secondary heat-sealed bag.

The vial seal tray100comprises a box-like body having a top surface112which is substantially rectangular in shape, and a base114defining a stabilization flange protruding outwardly along a perimeter of the seal tray. A tray wall116extends between the top surface112and the base114along the perimeter of the seal tray. The top surface112of the seal tray may include a chamfered edge113along its perimeter to facilitate stacking with another vial seal tray. The tray wall116may include one or more cutouts or notches115to similarly facilitate stacking with another vial seal tray. Further, each corner117of the vial seal tray100may be cut off to facilitate insertion of the tray into a primary bag during the packing process. Further, the corners117may also help to facilitate stacking, as well as reduce the amount of raw material and associated costs required to manufacture the tray.

The receptacle array110includes a plurality of spaced apart rectilinear receptacle rows130. The plurality of receptacle rows130are interconnected by a connection web140disposed on the top surface112of the vial seal tray100. Each receptacle row130includes a plurality of individually spaced apart receptacles120. Further, each receptacle row130defines a shallow channel132connecting each of the plurality of individually spaced apart receptacles120. The shallow channel132defines a clearance space that allows for access of tweezers or a user's fingers to facilitate removal of the vial seals from the tray, as will be discussed further below. Further, some implementations may include pleats on the tray wall to increase stiffness of the tray.

Each receptacle120is configured to receive a portion of the vial seal and may be substantially cylindrical in shape. The plurality of rectilinear receptacle rows130are arranged parallel and laterally offset from one another so that the position of the corresponding receptacles120in adjacent receptacle rows is similarly offset from one another. This arrangement reduces the overall footprint of the tray by minimizing the amount of the connection web140disposed between the receptacle rows130, thereby saving space on the top surface112of the vial seal tray. As a result, this arrangement allows a higher packing density of the vial seals. Thus, the alternating orientation of the receptacles120in adjacent receptacle rows130allows the receptacle array110to take up less space on the vial seal tray, and therefore allows the vial seal tray to be made smaller than conventional bulk trays.

In one implementation, the receptacle array110may include four spaced apart receptacle rows130, with two of the receptacle rows having eight receptacles120and the other two receptacles having seven receptacles120. Each receptacle120may be sized and shaped to accommodate a 20 mm vial seal. As such, the receptacle array110may be configured to releasably receive and secure up to thirty vial seals per tray. In other implementations, the receptacle array110may be configured to include more or less receptacle rows and associated receptacles. While the vial seal tray is shown as a box-like rectangular tray, in other implementations it may be made into alternative configurations suitable for its intended use, such as where the outer perimeter of the tray has a shape of a square, a circle, an oval, or various other shapes. In some implementations, the 20 mm vial seal tray may be manufactured using a female thermoform tool.

Each individual receptacle120includes a generally hollow cylindrical cavity122which extends downwardly from the connection web140at the top surface112of the tray to form a sidewall128bounded by a closed lower end124. A partial circular rim below the upper surface112of the vial seal tray forms a resting support contact provided for the button of the vial seal to rest on. A narrow central protrusion or region126extends upwardly from a central region of the closed lower end124. The region126includes a tip portion127configured to provide stiffness and stability to the cavity122, In some aspects, the region126and tip portion127may be configured to support a vial seal when the vial seal is received within the receptacle in a generally vertical orientation. The tip portion127of the region126may have a hemispherical or dome shape, among other shapes. The shallow channel132connecting each receptacle120within a corresponding receptacle row130provides sufficient clearance or grip space134between each adjacent receptacle within the row, as well as sufficient clearance or grip space135at each end of the row next to a respective receptacle.

These grip spaces134,135allow a user to manually grasp opposing sides of a vial seal disposed in a corresponding receptacle120in order to easily remove each individual vial seal from the tray by using either the user's fingers or a gripping tool. Further, these grip spaces134,135also allow adjacent vial seals within a corresponding receptacle row to be spaced apart in order to prevent or minimize contamination between the vial seals. For instance, the grip spaces134,135provide sufficient clearance that allows a user to remove a single vial seal from an individual receptacle120in the vial seal tray by gripping opposing sides of the vial seal by way of the respective grip spaces without touching or contaminating other vial seals disposed in the vial seal tray, such as a vial seal disposed in an adjacent receptacle120in the shared receptacle row130. Such a tray configuration makes it easier for a user working at a small work space, such as a biosafety cabinet, to remove the individual vial seals from the tray. Directly adjacent receptacles120in each receptacle row130are spaced apart by the shallow channel132, whereas adjacent receptacles120in adjacent receptacle rows120are separated by the connection web140.

The vial seal tray100may be formed from one or more rigid or semi-rigid polymeric materials, including, but not limited to, polyethylene, polycarbonate, polypropylene and/or a composite combination of materials chosen to maintain the integrity of the stored vial seals. Additionally, a material, such as gamma stable polypropylene, which is stable following exposure to gamma radiation sterilization processes, may be used to make the vial seal tray.

Another implementation of a vial seal tray200according to the present disclosure is illustrated inFIGS.5-8. The vial seal tray200comprises a receptacle array210having a plurality of individual receptacles220. Each individual receptacle is configured to releasably receive and secure a vial seal. The vial seal tray200may be disposed within a container for protecting the vial seals from contamination. For instance, the container may include one or more sterile bags sized and shaped to accommodate the vial seal tray, wherein the bag is heat-sealed once the tray is contained therein. The vial seal tray200may be contained within a heat-sealed primary bag having a partial vacuum applied thereto to remove excess air. According to another aspect, the vial seal tray200within the primary bag may further be contained in secondary heat-sealed bag.

The vial seal tray200comprises a box-like body having a top surface212which is substantially rectangular in shape, and a base214defining a stabilization flange protruding outwardly along a perimeter of the seal tray. A tray wall216extends between the top surface212and the base214along the perimeter of the seal tray. The top surface212of the seal tray may include a chamfered edge213along its perimeter to facilitate stacking with another vial seal tray. The tray wall216may include one or more cutouts or notches215to similarly facilitate stacking with another vial seal tray. Further, each corner217of the vial seal tray200may be cut off to facilitate insertion of the tray into a primary bag during the packing process. Further, the corners may also help to facilitate stacking, as well as reduce the amount of raw material and associated costs required to manufacture the tray.

The receptacle array210includes a plurality of spaced apart rectilinear receptacle rows230. The plurality of receptacle rows230are interconnected by a connection web240disposed on the top surface212of the vial seal tray200. Each receptacle row230includes a plurality of individually spaced apart receptacles220. Further, each receptacle row230defines a shallow channel232connecting each of the plurality of individually spaced apart receptacles220. The shallow channel232defines a clearance space that allows for access of tweezers or a user's fingers to facilitate removal of the vial seals from the tray, as will be discussed further below. Each receptacle220is configured to receive a portion of the vial seal and may be substantially cylindrical in shape. The plurality of rectilinear receptacle rows230are arranged parallel to and spaced apart from each other, whereby the connection web240on the top surface212interconnects the receptacle rows230.

The receptacle array210may include four spaced apart receptacle rows230, with each of the receptacle rows having ten receptacles220. Each receptacle220may be sized and shaped to accommodate a 13 mm vial seal. As such, the receptacle array210may be configured to releasably receive and secure up to forty vial seals per tray. In other implementations, the receptacle array210may be configured to include more or less receptacle rows and associated receptacles. While the vial seal tray is shown as a box-like rectangular tray, in other implementations it may be made into alternative configurations suitable for its intended use, such as where the outer perimeter of the tray has a shape of a square, a circle, an oval, or various other shapes. In some implementations, the 13 mm vial seal tray may be manufactured using a male thermoform tool.

Each individual receptacle220includes a generally hollow cylindrical cavity222which extends downwardly from the connection web240at the top surface212of the tray to form a sidewall228bounded by a closed lower end224. A partial circular rim below the upper surface212of the vial seal tray forms a resting support contact provided for the button of the vial seal to rest on. A narrow central protrusion or region226extends upwardly from a central region of the closed lower end224. The region226includes a tip portion227configured to provide stiffness and stability to the cavity222. In some aspects, the region226and tip portion227may be configured to support a vial seal when the vial seal is received within the receptacle in a generally vertical orientation. The tip portion227of the region226may have a hemispherical or dome shape, among other shapes. The shallow channel232connecting each receptacle220within a corresponding receptacle row230provides sufficient clearance or grip space234between each adjacent receptacle within the row, as well as sufficient clearance or grip space235at each end of the row next to a respective receptacle.

These grip spaces234,235allow a user to manually grasp opposing sides of a vial seal disposed in a corresponding receptacle220in order to easily remove each individual vial seal from the tray by using either the user's fingers or a gripping tool. Further, these grip spaces234,235also allow adjacent vial seals within a corresponding receptacle row to be spaced apart in order to prevent or minimize contamination between the vial seals. For instance, the grip spaces234,235provide sufficient clearance that allows a user to remove a single vial seal from an individual receptacle220in the vial seal tray by gripping opposing sides of the vial seal by way of the respective grip spaces without touching or contaminating other vial seals disposed in the vial seal tray, such as a vial seal disposed in an adjacent receptacle220in the shared receptacle row230. Such a tray configuration makes it easier for a user working at a small work space, such as a biosafety cabinet, to remove the individual vial seals from the tray. Directly adjacent receptacles220in each receptacle row230are spaced apart by the shallow channel232, whereas adjacent receptacles220in adjacent receptacle rows230are separated by the connection web240.

The vial seal tray200may be formed from one or more rigid or semi-rigid polymeric materials, including, but not limited to, polyethylene, polycarbonate, polypropylene and/or a composite combination of materials chosen to maintain the integrity of the stored vial seals. Additionally, a material, such as gamma stable polypropylene, which is stable following exposure to gamma radiation sterilization processes, may be used to make the vial seal tray.

Turning toFIGS.9-12, a vial stopper tray300according to the present disclosure is shown. The vial stopper tray300comprises a receptacle array310having a plurality of individual receptacles320. Each individual receptacle is configured to releasably receive and secure a vial stopper. Similar to the aforementioned vial seal trays discussed above, the vial stopper tray300may be disposed within a container for protecting the vial stoppers from contamination. Such a container may include one or more sterile bags sized and shaped to accommodate the vial stopper tray. In some aspects, the sterile bag may be heat-sealed once the stopper tray is contained therein. Similar to the vial seal trays previously discussed above, the vial stopper tray300may be formed from one or more rigid or semi-rigid polymeric materials, including, but not limited to, polyethylene, polycarbonate, polypropylene and/or a composite combination of materials chosen to maintain the integrity of the stored vial seals.

The vial stopper tray300comprises a box-like body having a top surface312which is substantially rectangular in shape, and a base314defining a stabilization flange protruding outwardly along a perimeter of the stopper tray. A tray wall316extends between the top surface312and the base314along the perimeter of the stopper tray. The top surface312of the stopper tray may include a chamfered edge313along its perimeter to facilitate stacking with another vial stopper tray. The tray wall316may include one or more cutouts or notches315to similarly facilitate stacking with another vial stopper tray. In some implementations, the tray wall316may extend above the top surface312, thus forming a cavity to further facilitate nesting of stacked stopper trays. Further, each corner317of the vial stopper tray300may be cut off to facilitate insertion of the tray into a primary bag during the packing process. Further, the corners may also help to facilitate stacking, as well as reduce the amount of raw material and associated costs required to manufacture the tray. Furthermore, the tray wall316may include one or more pleats318configured to increase stiffness of the wall in order to provide added stability to the tray.

The receptacle array310includes a plurality of spaced apart rectilinear receptacle rows330. The plurality of receptacle rows330are interconnected by a connection web340formed on the top surface312of the vial stopper tray300. Each receptacle row330includes a plurality of individually spaced apart receptacles320. Further, each receptacle row330defines a shallow channel332connecting each of the plurality of individually spaced apart receptacles320. Each receptacle320is configured to receive a portion of the vial stopper and may be substantially cylindrical in shape. The plurality of rectilinear receptacle rows330are arranged parallel to and spaced apart from each other, whereby the connection web340on the top surface312interconnects the receptacle rows330.

The receptacle array310may include five spaced apart receptacle rows330, with each of the receptacle rows having six receptacles320. Each receptacle320may be sized and shaped to accommodate a 20 mm vial stopper. As such, the receptacle array310may be configured to releasably receive and secure up to thirty vial stoppers per tray. In other implementations, the receptacle array310may be configured to include more or less receptacle rows and associated receptacles. While the vial stopper tray is shown as a box-like rectangular tray, in other implementations it may be made into alternative configurations suitable for its intended use, such as where the outer perimeter of the tray has a shape of a square, a circle, or an oval, among various other shapes.

Each individual receptacle320includes a generally hollow cylindrical cavity322which extends downwardly from the connection web340at the top surface312of the tray to form a sidewall328bounded by a closed lower end324. In some aspects, the cavity322may include a first or top portion and a second or bottom portion, where a diameter of the first or top portion is larger than a diameter of the second or bottom portion. As such, a vial stopper may be secured within the first or top portion while the second or bottom portion remains empty. In some implementations, a narrow central protrusion or region may extend upwardly from a central region of the closed lower end324. The protrusion may include a tip portion configured to provide stiffness and stability to the cavity, as well as support a vial stopper when the vial stopper is received within the receptacle. The tip portion may have a hemispherical or dome shape, among other shapes. Additionally, each receptacle320includes a holding retention or bumper329protruding into the respective cavity322. The bumper329is configured to releasably secure a portion of a corresponding vial stopper within the cavity322.

Accordingly, each bumper329acts as a holding portion provided at an upper end of each respective receptacle. The bumper extends radially inwards into the cavity of the receptacle, thus forming a constricted opening or neck portion of the receptacle for securing the vial stopper. For instance, a vial stopper may be snapped into a respective receptacle by pushing the vial stopper until it engages the corresponding bumper of the receptacle. Further, each receptacle may include one or more bumpers329. For instance, each receptacle may include two bumpers which are diametrically opposite to each other. The bumpers limit the axial mobility of the vial stoppers accommodated in the corresponding receptacles by a positive locking engagement which securely retains the vial stoppers in the receptacles in a generally vertical orientation, while also permitting the user to pull each individual vial stopper with a sufficient force to disengage the bumper and thus remove the stopper from its respective receptacle.

The shallow channel332connecting each receptacle320within a corresponding receptacle row330serves a dual function. Firstly, the channel332provides sufficient clearance or grip space to facilitate manual removal of each individual vial stopper from a corresponding receptacle of the stopper tray. Secondly, the channel332allows for steam sterilization of any vial stoppers disposed in the stopper tray.

In particular, channel332provides sufficient clearance or grip space334between each adjacent receptacle within the row, as well as sufficient clearance or grip space335at each end of the row next to a respective receptacle. For instance, the grip spaces334,335allow a user to manually grasp opposing sides of a vial stopper disposed in a corresponding receptacle320in order to easily remove each individual vial stopper from the tray by using either the user's fingers or a gripping tool. Further, these grip spaces334,335also allow adjacent vial stoppers within a corresponding receptacle row to be spaced apart in order to prevent or minimize contamination between the vial stoppers.

For instance, the grip spaces334,335provide sufficient clearance that allows a user to remove a single vial stopper from an individual receptacle320in the vial stopper tray by gripping opposing sides of the vial stopper by way of the respective grip spaces without touching or contaminating other vial stoppers disposed in the vial stopper tray, such as a vial stopper disposed in an adjacent receptacle320in the shared receptacle row330. Such a tray configuration makes it easier for a user working at a small work space, such as a biosafety cabinet, to remove the individual vial stoppers from the tray. Directly adjacent receptacles320in each receptacle row330are spaced apart by the shallow channel332, whereas adjacent receptacles320in adjacent receptacle rows330are separated by the connection web340.

Further, the shallow channels332permit steam sterilization of the individual vial stoppers disposed in the stopper tray. In particular, as sterilizing steam is introduced into each channel332, the steam is allowed to flow into contact with each individual vial stopper (e.g., by flowing up and around the vial stopper) as the steam travels along the length of the respective channel. The empty second or bottom portion of the receptacle helps the steam sterilization flow along the channel and into contact with an underside of the vial stopper secured within the first or top portion of the receptacle. The vial stopper tray300also includes one or more reinforcement ribs350configured to provide stability to the tray. Each reinforcement rib350is disposed on the top surface of the312of the stopper tray and extends across the top surface substantially perpendicular to the receptacle rows330. With this arrangement, each reinforcement rib350adds stiffness to the top surface of the tray to prevent undesirable flexing of the tray. For instance, the vial stopper tray300may include five reinforcement ribs350, wherein each reinforcement rib is disposed between adjacent receptacles of a corresponding receptacle row, and furthermore, wherein each reinforcement rib perpendicularly extends across all five receptacle rows.

Referring toFIGS.13-16, another implementation of a vial stopper tray400is shown. While vial stopper tray400shares various features of the vial stopper tray300previously discussed. More particularly, the vial stopper tray400comprises a receptacle array410having a plurality of individual receptacles420. For instance, the vial stopper tray400may include a receptacle array410including seven spaced apart receptacle rows430, with five of the receptacle rows having six receptacles420each, and the remaining two receptacle rows having five receptacles each. Each receptacle420may be sized and shaped to accommodate a 13 mm vial stopper. As such, the receptacle array410may be configured to releasably receive and secure up to forty vial stoppers per tray. In other implementations, the receptacle array410may be configured to include more or less receptacle rows and associated receptacles. Further, the vial stopper tray400may include a plurality of reinforcement ribs450, such as seven reinforcement ribs, wherein each reinforcement rib is perpendicularly disposed on the top surface of the tray adjacent to, and spaced apart from, opposite sides of each receptacle of the respective receptacle rows.

Each individual receptacle420of the receptacle array410is configured to releasably receive and secure a vial stopper. The vial stopper tray400may be disposed within a container for protecting the vial stoppers from contamination. Such a container may include one or more sterile bags sized and shaped to accommodate the vial stopper tray. In some aspects, the sterile bag may be heat-sealed once the stopper tray is contained therein. The vial stopper tray400may be formed from one or more rigid or semi-rigid polymeric materials, including, but not limited to, polyethylene, polycarbonate, polypropylene and/or a composite combination of materials chosen to maintain the integrity of the stored vial stoppers.

The vial stopper tray400comprises a box-like body having a top surface412which is substantially rectangular in shape, and a base414defining a stabilization flange protruding outwardly along a perimeter of the stopper tray. A tray wall416extends between the top surface412and the base414along the perimeter of the stopper tray. The top surface412of the stopper tray may include a chamfered edge413along its perimeter to facilitate stacking with another vial stopper tray. The tray wall416may include one or more cutouts or notches415to similarly facilitate stacking with another vial stopper tray. In some implementations, the tray wall416may extend above the top surface412, thus forming a cavity to further facilitate nesting of stacked stopper trays. Further, each corner417of the vial stopper tray400may be cut off to facilitate insertion of the tray into a primary bag during the packing process. Further, the corners may also help to facilitate stacking, as well as reduce the amount of raw material and associated costs required to manufacture the tray. Furthermore, the tray wall416may include one or more pleats418configured to increase stiffness of the wall in order to provide added stability to the tray.

The receptacle array410includes a plurality of spaced apart rectilinear receptacle rows430. The plurality of receptacle rows430are interconnected by a connection web440formed on the top surface412of the vial stopper tray400. Each receptacle row430includes a plurality of individually spaced apart receptacles420. Further, each receptacle row430defines a shallow channel432connecting each of the plurality of individually spaced apart receptacles420. Each receptacle420is configured to receive a portion of the vial stopper and may be substantially cylindrical in shape. The plurality of rectilinear receptacle rows430are arranged parallel to and spaced apart from each other, whereby the connection web440on the top surface412interconnects the receptacle rows430.

Each individual receptacle420includes a generally hollow cylindrical cavity422which extends downwardly from the connection web440at the top surface412of the tray to form a sidewall428bounded by a closed lower end424. In some aspects, the cavity422may include a first or top portion and a second or bottom portion, where a diameter of the first or top portion is larger than a diameter of the second or bottom portion. In some aspects, a narrow central protrusion or region may extend upwardly from a central region of the closed lower end424. The protrusion may include a tip portion configured to provide stiffness and stability to the tray, as well as support a vial stopper when the vial stopper is received within the receptacle. The tip portion may have a hemispherical or dome shape, among other shapes. Additionally, each receptacle420includes a holding retention or bumper429protruding into the respective cavity422. The bumper429is configured to releasably secure a portion of a corresponding vial stopper within the cavity422.

Each bumper429acts as a holding portion provided at an upper end of each respective receptacle. The bumper extends radially inwards into the cavity of the receptacle, thus forming a constricted opening or neck portion of the receptacle for securing the vial stopper. For instance, a vial stopper may be snapped into a respective receptacle by pushing the vial stopper until it engages the corresponding bumper of the receptacle. Further, each receptacle may include one or more bumpers429. For instance, each receptacle may include two bumpers which are diametrically opposite to each other. The bumpers limit the axial mobility of the vial stoppers accommodated in the corresponding receptacles by a positive locking engagement which securely retains the vial stoppers in the receptacles in a generally vertical orientation, while also permitting the user to pull each individual vial stopper with a sufficient force to disengage the bumper and thus remove the stopper from its respective receptacle.

The shallow channel432connecting each receptacle420within a corresponding receptacle row430serves a dual function. Firstly, the channel432provides sufficient clearance or grip space to facilitate manual removal of each individual vial stopper from a corresponding receptacle of the stopper tray. Secondly, the channel432allows for steam sterilization of any vial stoppers disposed in the stopper tray.

In particular, channel432provides sufficient clearance or grip space434between each adjacent receptacle within the row, as well as sufficient clearance or grip space435at each end of the row next to a respective receptacle. For instance, the grip spaces434,435allow a user to manually grasp opposing sides of a vial stopper disposed in a corresponding receptacle420in order to easily remove each individual vial stopper from the tray by using either the user's fingers or a gripping tool. Further, these grip spaces434,435also allow adjacent vial stoppers within a corresponding receptacle row to be spaced apart in order to prevent or minimize contamination between the vial stoppers.

For instance, the grip spaces434,435provide sufficient clearance that allows a user to remove a single vial stopper from an individual receptacle420in the vial stopper tray by gripping opposing sides of the vial stopper by way of the respective grip spaces without touching or contaminating other vial stoppers disposed in the vial stopper tray, such as a vial stopper disposed in an adjacent receptacle420in the shared receptacle row430. Such a tray configuration makes it easier for a user working at a small work space, such as a biosafety cabinet, to remove the individual vial stoppers from the tray. Directly adjacent receptacles420in each receptacle row430are spaced apart by the shallow channel432, whereas adjacent receptacles420in adjacent receptacle rows430are separated by the connection web440.

Further, the shallow channels432permit steam sterilization of the individual vial stoppers disposed in the stopper tray. In particular, as sterilizing steam is introduced into each channel432, the steam is allowed to flow into contact with each individual vial stopper (e.g., by flowing up and around the vial stopper) as the steam travels along the length of the respective channel. The vial stopper tray400also includes one or more reinforcement ribs450configured to provide stability to the tray. Each reinforcement rib450is disposed on the top surface of the412of the stopper tray and extends across the top surface substantially perpendicular to the receptacle rows430. With this arrangement, each reinforcement rib450adds stiffness to the top surface of the tray to prevent undesirable flexing of the tray. For instance, the vial stopper tray400may include five reinforcement ribs450, wherein each reinforcement rib is disposed between adjacent receptacles of a corresponding receptacle row, and furthermore, wherein each reinforcement rib perpendicularly extends across all five receptacle rows.

Referring toFIGS.17-21, another implementation of a vial stopper tray400ais shown, which shares various features of the vial stopper tray400previously discussed. A stopper tray lid or cover460is configured to removably attach to the vial stopper tray400ato both secure and protect the vial stoppers disposed in the vial stopper tray400a. The vial stopper tray400acomprises a receptacle array410ahaving a plurality of individual receptacles420a. For instance, the vial stopper tray400amay include a receptacle array410aincluding seven spaced apart receptacle rows430a, with five of the receptacle rows having six receptacles each, and the remaining two receptacle rows having five receptacles each. Each receptacle420amay be sized and shaped to accommodate a 13 mm vial stopper. As such, the receptacle array410amay be configured to releasably receive and secure up to forty vial stoppers per tray. In other implementations, the receptacle array410amay be configured to include more or less receptacle rows and associated receptacles. Further, the vial stopper tray400amay include a plurality of reinforcement ribs450a, such as seven reinforcement ribs, wherein each reinforcement rib is perpendicularly disposed on the top surface of the tray adjacent to, and spaced apart from, opposite sides of each receptacle of the respective receptacle rows.

Each individual receptacle420aof the receptacle array410ais configured to releasably receive a respective vial stopper. The vial stopper tray400acomprises a box-like body having a top surface412awhich is substantially rectangular in shape, and a base414adefining a stabilization flange protruding outwardly along a perimeter of the stopper tray. A tray wall416aextends between the top surface412aand the base414aalong the perimeter of the vial stopper tray. One or more cutouts or notches415amay be provided on an interior side of the tray wall416afor receiving a corresponding protrusion462aof the lid460. In some implementations, the tray wall416amay extend above the top surface412a, thus forming a cavity to facilitate nesting of the lid460on top of the vial stopper tray.

The receptacle array410aincludes a plurality of spaced apart rectilinear receptacle rows430a. The plurality of receptacle rows430aare interconnected by a connection web440aformed on the top surface412aof the vial stopper tray400a. Each receptacle row430aincludes a plurality of individually spaced apart receptacles420a. Further, each receptacle row430adefines a shallow channel432aconnecting each of the plurality of individually spaced apart receptacles420a. Each receptacle420ais configured to receive a portion of the vial stopper and may be substantially cylindrical in shape. The plurality of rectilinear receptacle rows430aare arranged parallel to and spaced apart from each other, whereby the connection web440aon the top surface412ainterconnects the plurality of receptacle rows430a.

Each individual receptacle420aincludes a generally hollow cylindrical cavity422awhich extends downwardly from the connection web440aat the top surface412aof the tray to form a sidewall428abounded by a closed lower end424a. In some aspects, the cavity422amay include a first or top portion and a second or bottom portion, where a diameter of the first or top portion is larger than a diameter of the second or bottom portion. As such, a vial stopper may be secured within the first or top portion while the second or bottom portion remains empty.

The shallow channel432aconnecting each receptacle420awithin a corresponding receptacle row430aserves a dual function. Firstly, the channel432aprovides sufficient clearance or grip space to facilitate manual removal of each individual vial stopper from a corresponding receptacle of the stopper tray. Secondly, the channel432aallows for steam sterilization of any vial stoppers disposed in the stopper tray.

In particular, channel432aprovides sufficient clearance or grip space434abetween each adjacent receptacle within the row, as well as sufficient clearance or grip space435aat each end of the row next to a respective receptacle. For instance, the grip spaces434a,435aallow a user to manually grasp opposing sides of a vial stopper disposed in a corresponding receptacle420ain order to easily remove each individual vial stopper from the tray by using either the user's fingers or a gripping tool. Further, these grip spaces434a,435aalso allow adjacent vial stoppers within a corresponding receptacle row to be spaced apart in order to prevent or minimize contamination between the vial stoppers.

For instance, the grip spaces434a,435aprovide sufficient clearance that allows a user to remove a single vial stopper from an individual receptacle420ain the vial stopper tray by gripping opposing sides of the vial stopper by way of the respective grip spaces without touching or contaminating other vial stoppers disposed in the vial stopper tray, such as a vial stopper disposed in an adjacent receptacle420ain the shared receptacle row430a. Such a tray configuration makes it easier for a user working at a small work space, such as a biosafety cabinet, to remove the individual vial stoppers from the tray. Directly adjacent receptacles420ain each receptacle row430aare spaced apart by the shallow channel432a, whereas adjacent receptacles420ain adjacent receptacle rows430aare separated by the connection web440a. Further, the shallow channels432apermit steam sterilization of the individual vial stoppers disposed in the stopper tray. In particular, as sterilizing steam is introduced into each channel432a, the steam is allowed to flow into contact with each individual vial stopper (e.g., by flowing up and around the vial stopper) as the steam travels along the length of the respective channel. The empty second or bottom portion of the receptacle helps the steam sterilization flow along the channel and into contact with an underside of the vial stopper secured within the first or top portion of the receptacle

The vial stopper tray400aalso includes one or more reinforcement ribs450aconfigured to provide stability to the tray. Each reinforcement rib450ais disposed on the top surface of the412aof the stopper tray and extends across the top surface substantially perpendicular to the receptacle rows430a. With this arrangement, each reinforcement rib450aadds stiffness to the top surface of the tray to prevent undesirable flexing of the tray. For instance, the vial stopper tray400amay include five reinforcement ribs450a, wherein each reinforcement rib is disposed between adjacent receptacles of a corresponding receptacle row. Each reinforcement rib450amay also perpendicularly extend across all five receptacle rows.

The stopper tray lid460is configured to removably attach to the vial stopper tray400afor both securing and protecting the vial stoppers disposed in the respective receptacles420aof the stopper tray. The stopper tray lid460includes a lid base461having a side wall462extending along a perimeter of the lid base. One or more of the locking protrusions462aextend from a portion of the side wall462for matingly engaging a respective cutout or notch415aprovided on the interior side of the tray side wall416afor releasably securing the stopper tray lid to the stopper tray. For instance, an interference fit may be formed between the locking protrusion462aand the cutout415a. A lid flange464protrudes outwardly from the sidewall462along the perimeter of the tray lid. The lid flange464may include an enlarged grip portion464ato assist a user with detaching the stopper tray lid from the stopper tray.

A bottom surface of the lid base461includes a plurality of retention regions466protruding therefrom, with each retention region corresponding to a respective receptacle420aof the stopper tray400a. Each retention region466is sized and shaped to fit within a corresponding receptacle420awhen the stopper tray lid is attached to the stopper tray. Further, each retention region466includes a tip portion467configured to hold a vial stopper in place within a corresponding receptacle420aof the stopper tray when the stopper tray lid is attached to the stopper tray. Each tip portion467may be substantially flat so as to maximize surface area contact with a respective vial stopper.

One or more lid reinforcement ribs468may be provided on the lid base461for providing stability to the tray lid. Each lid reinforcement rib468may protrude from the bottom surface of the lid base. Additionally, each lid reinforcement rib468may extend across the lid base in a direction substantially perpendicular to the receptacle rows430a. For instance, the lid reinforcement ribs468may extend in the same direction as the reinforcement ribs450aof the stopper tray. With this arrangement, each lid reinforcement rib468adds stiffness to the lid base to prevent undesirable flexing thereof. In some implementations, for instance, the tray lid may include a number of lid reinforcement ribs468corresponding to the number of reinforcement ribs450aof the stopper tray.

After the tray lid460is attached to the vial stopper tray400a, they may be stored within a container, such a sterile bag. In some aspects, the sterile bag may be heat-sealed once the stopper tray assembly is contained therein. Additionally, the vial stopper tray400and the tray lid460may both be formed from one or more rigid or semi-rigid polymeric materials, including, but not limited to, polyethylene, polycarbonate, polypropylene and/or a composite combination of materials chosen to maintain the integrity of the stored vial stoppers.

In further implementations, a kit may be provided which includes various combinations of the aforementioned vial seal trays and vial stopper trays, as well as a vial tray containing a corresponding number of pharmaceutical vials. For instance, such a collection of trays may form a small quantity kit suitable for bio-fillings or the like. Thus, such a kit allows a user to easily access individual vial seals and vial stoppers from their respective trays while working at a small work space, such as a biosafety cabinet or a laboratory desk with hood. Such a kit arrangement makes it much easier for the user to assemble the seals and stoppers on a corresponding vial when compared to conventional seal and/or stopper packaging methods. Moreover, such a kit advantageously eliminates or minimizes the risk of contamination of the component vial seals and vial stoppers since a user can individually remove each unit from its respective tray. In particular, the various vial seal trays, vial stopper trays, and vial trays permit the respective seals, stoppers and vials to be presented in a space-saving rack-like structure to a biosafety cabinet operator in an efficient orientation for use (i.e., by facilitating grasping, carrying and placing each seal and stopper onto a corresponding vial). For example, the vial seals may be oriented with their plastic button facing up, and the vial stoppers may be oriented with their top flange facing up. In contrast, vial closures dumped onto a work surface from a conventional bulk pack would not be presented in the right orientation since some would land upside down or on their side.

FIGS.22-25show an implementation of a vial tray assembly500that comprises a base510defining a general box-like shape having a bottom wall512and a sidewall514extending along a periphery of the base. An upper surface of the sidewall514is in the form of a generally planar flange516extending laterally outward from the side wall. The bottom wall512defines a vial holder array518including a plurality of receptacles520. Each receptacle520is configured to securely and releasably receive an individual vial so that a plurality of vials600are able to be held in the spaced array. The vial holder array518includes a plurality of spaced apart rectilinear receptacle rows530that are interconnected by a connection web540. Each receptacle row530includes a plurality of individually spaced apart receptacles520. Further, each receptacle row530defines a channel532connecting each of the plurality of individually spaced apart receptacles520.

Each receptacle520is configured to receive a top portion of a corresponding vial. Stated another way, the vials are inserted upside down into the corresponding receptacles. In one implementation, the vial holder array518may include five spaced apart receptacle rows530, with each receptacle row having five spaced-apart receptacles520. Each receptacle520may be sized and shaped to accommodate a correspondingly sized and shaped vial. As such, the vial holder array518may be configured to releasably receive and secure up to twenty five vials per tray. In other implementations, the vial holder array518may be configured to include more or less receptacle rows and associated receptacles. While the vial tray is shown as a box-like square tray, in other implementations it may be made into alternative configurations suitable for its intended use, such as where the outer perimeter of the tray has a shape of a rectangle, a circle, or an oval, among various other shapes.

Each individual receptacle520includes a generally hollow cavity522defined by the connection web540to form a closed lower end524. A centrally located protrusion or region526forming a center post extends upwardly from a central region of the closed lower end524. The region526is configured to support the vial when the vial is received within the receptacle520in a generally vertical orientation. The region526may be generally cross-shaped, among other shapes. Each receptacle has a cross-section configured to securely and releasably hold an individual vial. In some implementations, this may be accomplished via a clearance fit, wherein each center post aids in controlling the respective vial's position. The channel532connecting each receptacle520within a corresponding receptacle row530provides sufficient clearance between each adjacent receptacle within the row. In other implementations, the vials may be secured via an interference fit. In further implementations, the center post may be omitted.

Additionally, the vial tray assembly500may also comprise a vial tray lid or cover550that includes a plurality of downward facing recesses554spaced from one another by the same spacing as the vials in the vial holder array518. Since the vials are inverted within each corresponding receptacle520of the vial tray, each recess554of the lid is arranged to hold a bottom portion of a respective vial. An outer periphery of the vial tray lid550is shaped and dimensioned to fit within an open portion of the base510in order to close the base and accordingly seal the vials therein.

Similar to the vial seal trays and the vial stopper trays previously described, the vial tray assembly500may be formed from one or more rigid or semi-rigid polymeric materials, including, but not limited to, polyethylene, polycarbonate, polypropylene and/or a composite combination of materials chosen to maintain the integrity of the stored vials. Additionally, a material, such as gamma stable polypropylene, which is stable following exposure to gamma radiation sterilization processes, may be used to make the vial tray.

FIGS.26-30show another implementation of a vial tray assembly500athat comprises a base tray510ahaving a generally planar flange516aextending laterally outward along a periphery of the base tray. A bottom portion512adefines a vial holder array518aincluding a plurality of receptacles520a. Each receptacle520ais configured to securely and releasably receive an individual vial so that a plurality of vials600are able to be held in the spaced array. The vial holder array518aincludes a plurality of spaced apart rectilinear receptacle rows530athat are interconnected by a connection web540a. Each receptacle row530aincludes a plurality of individually spaced apart receptacles520a. Further, each receptacle row530adefines a channel532aconnecting each of the plurality of individually spaced apart receptacles520a.

Each receptacle520ais configured to receive a top portion of a corresponding vial. As such, the vials are inserted upside down into the corresponding receptacles520a. In one implementation, the vial holder array518amay include five spaced apart receptacle rows530a, with each receptacle row having five spaced-apart receptacles520a. Each receptacle520amay be sized and shaped to accommodate a correspondingly sized and shaped vial. Thus, the vial holder array518amay be configured to releasably receive and secure up to twenty five vials per tray. In other implementations, the vial holder array518amay be configured to include more or less receptacle rows and associated receptacles.

Each individual receptacle520aincludes a generally hollow cavity522adefined by the connection web540ato form a closed lower end524a. A bottom surface of the cavity522amay be planar to ensure a sufficient contact area with the top portion of the vial. In some implementations, each receptacle may be configured to securely and releasably hold an individual vial via an interference fit. The channel532aconnecting each receptacle520awithin a corresponding receptacle row530aprovides sufficient clearance between each adjacent receptacle within the row.

Additionally, the vial tray assembly500amay also comprise a vial tray lid or cover550athat is configured to releasably attach to the base tray510a, such as via a snap fit in some implementations. In other implementations, a vacuum bag may hold the tray and lid together, wherein the relative position of the tray and lid are controlled in the lateral directions (i.e., the x & y directions; where the z direction has no interference since it is a free release) by a segmented wall extending around an edge of the lid. This segmented wall is broken in the middle of each edge by a cut out portion. The vial tray lid550afurther includes a plurality of lid receptacles560athat correspond to the respective receptacles520aof the base tray510a. Each lid receptacle560aincludes a generally hollow cavity562adefined by a connection web564aand forms a closed upper end566ahaving a planar surface that ensures a sufficient contact area with the bottom portion of the vial. In some implementations, each lid receptacle may be configured to securely and releasably hold an individual vial via an interference fit. A channel568aconnecting each lid receptacle560aprovides sufficient clearance between each adjacent receptacle within the row. Accordingly, when a top portion of a vial is placed into a receptacle520aof the base tray510a, the tray lid550acan be attached to the base tray510ain such a manner that a bottom portion of the vial is received within a corresponding receptacle560aof the tray lid. The closed upper end566aof the tray lid contacts the bottom portion of the respective vial to secure it in place. As a result, the vial tray assembly, when closed, is able to present the vials in different orientations, such as a vial oriented with its top portion facing upward, or its top portion facing downward. This also allows the vial tray or vial tray lid to be removed without contacting each other.

While certain implementations of a vial seal tray, a vial stopper tray, a vial tray, and an associated kit have been described in terms of what may be considered to be specific aspects, the present disclosure is not limited to the disclosed aspects. Additional modifications and improvements to the aforementioned trays and kits may be apparent to those skilled in the art. Moreover, the many features and advantages of the disclosure are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the present disclosure which fall within the spirit and scope of the disclosure.