Tray-based sterile packaging of pharmaceutical vials and vial closures

A vial stopper 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 stopper;
• a stopper tray lid configured to removably attach to the body of the vial stopper tray, wherein 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;
• 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.

A kit comprising:

• 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 arranged parallel to each other along parallel lateral axes and laterally offset from one another, 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 each receptacle in adjacent receptacle rows being laterally offset from one another, and
• a seal channel extending along each parallel lateral axis through the plurality of individually spaced-apart seal 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.