Storing live viral vaccines at -80 °C in glass vials with rubber stoppers can lead to overpressure, posing risks for both medical personnel and product quality. This occurs when the rubber stoppers lose elasticity below their glass transition temperature (-55°C to -70°C), allowing gas to enter the vial, which becomes trapped upon thawing.

Using non-destructive headspace analysis, this study investigates changes in headspace pressure and gas composition, identifying vials with compromised integrity. Explore how proper vial and stopper selection can prevent these issues and ensure safe low-temperature storage.