Extractables and leachables testing (E&L)
Would you like to carry out a study of the Extractables and Relargables of your products?
What do we mean by “Extractable and Leachable” ?
In materials science, “extractables and leachables” designates the migration of atoms, ions or molecules in matter whether it be in solids (crystalline or amorphous), liquids or gasses. This phenomenon is irreversible and is therefore a macroscopic concept, referring to notions of chemical concentrations of the different compounds in a material which can change during its use. This natural process designates a diffusion of matter tending to make chemical concentrations of substances homogeneous in any given medium.
What are manufacturers' obligations with regard to extractables and releasables?
In general, the material manufacturer knows the type of compounds that can be extracted and ideally provides the user with a list of extractable chemical species. By analogy, extractables are therefore compounds that migrate from a material in the presence of a formulation under normal conditions of use. Information on extractables can be useful when testing for specific salts.
As a specific formulation can have an effect on the type and amount of salts, it is the manufacturer’s responsibility to demonstrate that the level of salts does not contribute to adverse toxicological effects. Current guidelines (e.g. “Container Closure Systems for Packaging Human Drugs and Biologics” from the Food and Drug Administration (FDA)) and the “Guideline on Plastic Immediate Packaging Materials” from the European Medicines Agency (EMA) clearly state that it is preferable to test for leachables with the final formulation.
Your needs : to analyze extractables and leachables present in your materials to evaluate the conformity of health products with standards
Analysis of extractables and leachables (E&Ls) allows for the risk of a substance migrating from a container to its contents to be assessed. This mostly applies to the pharmaceutical, cosmetics and medical device industries.
Studies of extractables or leachables can be done on different types of materials or compounds : polymer additives, plasticizers, stabilizers, colorings, metallic catalysts and other chemical substances posing a contamination risk to a product.
Any substance susceptible of comping into contact with a product during the production process or at any point all the way till the implementation of the finished product must be subject to rigorous analysis and inspections to confirm that said substance has not contaminated the product.
Our solution :container/content compatibility tests and analysis of potential migration of extractables and releargables.
With a varied analytical fleet and dual expertise in chemistry and materials science, the FILAB laboratory can assist you at each step of the evaluation process of extractables and of leachables in health products (medical devices, pharmaceutical products, cosmetic products) by providing the following services :
- Chemical analysis
- Literature reviews and drafting of a custom study schedule for analyzing extractable and leachable substances
- Heavy metal analysis
- Analysis of additives
- Qualitative and quantitative analysis of extractables in Medical devices – material characterization in accordance with ISO 10993-12 and 10993-18
- Qualitative and quantitative analysis of leachable substances (organic and inorganic analysis : volatile, semi-volatile and non-volatile substances)
- Degradation product and leachable substance analysis of medical devices
- Chemical characterization of materials in Medical devices in accordance with ISO 10993-18 : polymers, ceramics, metallic parts
- Analytical development and validation of a new technique
- Stability and compatibility analysis of extractables and leachables
- Interaction testing between a container and its contents (Migration testing)
- Packaging analysis
With three levels of services – analysis, expertise and R&D support – FILAB assists companies from all sectors and of all sizes in overcoming their industrial challenges by sharing its technical know-how and the wealth of experience of its team with its clients.
The FILAB laboratory assists manufacturers in the study of extractables and leachables
What are the analysis techniques for extractables and releargables?
- GC-MS, HPLC or UHPLC/MS/MS for detecting, identifying and quantifying organic compounds present in solvents, anti-UV additives, antioxidants, dyes, inks, detergent residues, sterilization residues, polymer residues, … that have been extracted and/or released from the material by a standardized simulant
- UV-Vis spectrophotometry for dosing Chromium VI leached out of metallic alloys
- ICP-AES and ICP-MS particularly adapted for pollutants, inorganic and metallic additives such as heavy metals, mineral or metallic fillers, dyes…
- SEM-EDX microscopy is a quick and reliable tool for diagnosing the state of the surface of a material after an ageing process, the observation of particulates or deposits…
How FILAB supports its customers in the analysis of extractables and leachables
In this context, FILAB has managed to implement extraction and leaching techniques described in standards and guidelines (USP 1663, USP 1664, EN 1186, EN 1388-2, ISO 10993-12…) and in accordance with relevant national or European standards. Moreover, FILAB develops protocols specific to clients’ challenges with the aim of simulating real conditions of contact between a container and its contents to be able to analytically determine their chemical compatibility and to evaluate their level of chemical inertia. Testing chemical inertia consists of demonstrating a containers ability to resist the invasive effects of its contents which are susceptible of extracting and/or leaching chemical compounds.
With extensive experience in implementing these techniques and in developing specific analytical techniques, FILAB can assist you in the context of a study into E&Ls and studies of ageing materials.
The European legislation provides specific guidelines for E&L testing on polymer materials used in medical devices, pharmaceutical products, and other applications.
The guidelines for E&L testing on polymer materials according to European legislation include:
- European Pharmacopoeia (Ph. Eur.) General Chapters 3.1 and 3.2: The Ph. Eur. provides general guidelines for E&L testing of plastic materials and elastomers used in pharmaceutical products and packaging. These chapters outline the general principles for extractables and leachables testing and recommend that manufacturers perform a risk assessment to determine the appropriate testing approach.
- European Medicines Agency (EMA) Guideline on Plastic Immediate Packaging Materials: This EMA guideline provides specific guidelines for E&L testing of plastic materials used in pharmaceutical packaging. The guideline recommends that manufacturers perform a risk assessment to determine the appropriate testing approach and provides specific requirements for extractables and leachables testing based on the intended use and duration of contact between the packaging material and the product.
- ISO 10993-12 and ISO 10993-18: The International Organization for Standardization (ISO) provides guidelines for E&L testing of polymer materials used in medical devices. ISO 10993-12 focuses on sample preparation and reference materials, while ISO 10993-18 outlines the general principles for extractables and leachables testing and recommends that manufacturers perform a risk assessment to determine the appropriate testing approach.
- European Union Regulation on Cosmetic Products (EC) No. 1223/2009: This regulation requires cosmetic companies to conduct extractables and leachables testing on packaging materials and applicators to ensure that they do not introduce any harmful substances into the product.
These guidelines provide general principles and specific requirements for E&L testing of plastic materials and elastomers used in medical devices, pharmaceutical products, and packaging. Manufacturers are recommended to perform a risk assessment to determine the appropriate testing approach.
An extractables and leachables (E&L) testing study typically involves several steps to ensure thorough analysis and accurate results. These steps include:
- Risk assessment: Conduct a risk assessment to identify potential sources of extractables and leachables, taking into consideration the materials used, manufacturing processes, storage conditions, and intended use of the product.
- Study design: Develop a study plan outlining the scope, objectives, and testing strategy for the E&L study. This includes selecting the appropriate extraction methods, analytical techniques, and acceptance criteria based on the risk assessment and regulatory requirements.
- Sample preparation: Collect samples of the materials or products to be tested, ensuring proper handling and storage to prevent contamination. Prepare samples for analysis by applying appropriate extraction methods, such as solvent extraction, accelerated aging, or simulated use conditions, depending on the study objectives.
- Analytical testing: Perform qualitative and quantitative analysis of the extracted samples using various analytical techniques, such as gas chromatography-mass spectrometry (GC-MS), liquid chromatography-mass spectrometry (LC-MS), inductively coupled plasma-mass spectrometry (ICP-MS), or other suitable methods, to identify and quantify extractables and leachables.
- Data analysis and interpretation: Analyze the data obtained from the analytical testing to identify and quantify the extractables and leachables present in the samples. Compare the results with established acceptance criteria or toxicological limits to assess the potential risk associated with the detected compounds.
- Toxicological risk assessment: Conduct a toxicological risk assessment to evaluate the potential health risks associated with the identified extractables and leachables. This may involve comparing the concentrations of the detected compounds with established safety thresholds or performing additional toxicological studies if necessary.
- Reporting and documentation: Prepare a comprehensive report detailing the E&L study's findings, including the testing methods, results, data analysis, and toxicological risk assessment. Maintain thorough documentation of the study to ensure traceability and transparency.
- Review and follow-up actions: Review the results of the E&L study and determine if any follow-up actions are required, such as modifying the materials or manufacturing processes, implementing additional quality control measures, or conducting further testing.
By following these steps in an E&L testing study, laboratories can effectively identify and assess the potential risks associated with extractables and leachables in the products, ensuring compliance with regulatory requirements and safeguarding patient safety.
To confirm the accuracy and reliability of an extractables and leachables (E&L) testing study, several quality control measures can be implemented. These measures help ensure that the study is conducted according to established guidelines and industry best practices:
- Method validation: Before starting the E&L study, validate the analytical methods used to identify and quantify extractables and leachables. Method validation should include parameters such as specificity, linearity, accuracy, precision, limit of detection (LOD), and limit of quantitation (LOQ).
- Use of reference standards: Utilize reference standards when available to confirm the identity and concentration of the detected compounds. Reference standards can help to ensure that the results are accurate and reliable.
- Sample preparation controls: Implement proper controls during sample preparation, such as using blanks, matrix spikes, and duplicate samples. These controls can help to identify any contamination or matrix interference that may affect the accuracy and reliability of the study.
- Instrument calibration and maintenance: Regularly calibrate and maintain the analytical instruments used in the study. This helps to ensure that the instruments are functioning properly and providing accurate and reliable results.
- Analyst training and proficiency: Ensure that the analysts conducting the E&L testing study are well-trained and proficient in the techniques used. This helps to minimize human errors and ensure the accuracy and reliability of the results.
- Data review and quality assurance: Implement a thorough data review process, including quality assurance checks, to identify any inconsistencies or potential errors in the data. This helps to ensure that the data is accurate and reliable before reporting the results.
- Adherence to guidelines and best practices: Conduct the E&L testing study according to established guidelines (such as ISO 10993-18, USP , and Ph. Eur. 3.2) and industry best practices. This ensures that the study is conducted according to the highest quality standards and can be considered reliable.
- Documentation and traceability: Maintain detailed documentation of the E&L testing study, including sample preparation, analytical methods, instrument settings, and data analysis. This helps to ensure traceability and transparency, which are essential for confirming the accuracy and reliability of the study.
The FDA (Food and Drug Administration) is a U.S. federal agency responsible for regulating food, drugs, medical devices,
The FDA's guidance on Extractables and Leachables (E&L) for medical devices refers to the evaluation and testing of potential chemical substances that can be extracted from a medical device into the body or leached out under normal conditions of use.
The FDA requires manufacturers to assess the risk of E&L to ensure that medical devices are safe and effective for their intended use. This involves identifying the chemicals that could potentially be released, understanding the conditions under which extraction or leaching could occur, and evaluating the potential impact on patient safety.
The FDA provides guidelines and recommendations on how to conduct E&L studies, including analytical methods, toxicity assessments, and risk management strategies. cosmetics, and other products related to public health.
