The vaccine vial monitor: the world's smartest sticker

November 6, 2017 by PATH

03761_hr Lab workers in the Bandung BioFarma facility in Indonesia examine vials that have vaccine vial monitor technology incorporated into their labels.

Lab workers in the Bandung BioFarma facility in Indonesia examine vials that have vaccine vial monitor technology incorporated into their labels. Photo: Umit Kartoglu.

Vaccine vial monitors are small stickers with a big impact: alerting health workers to heat-damaged vaccines before they are accidentally used.

Vaccine vial monitors flag heat-damaged vaccine

Imagine the challenge of getting the heat-sensitive polio vaccine from a high-tech pharmaceutical company in Belgium to a remote village in Ghana. The vaccine leaves by truck, is flown to Africa, and then is carried across dirt roads by truck or bicycle to eventually reach a refrigerator in a rural clinic that has sporadic electricity. The journey may take days or weeks, during which the vaccine is constantly at risk of being exposed to too much heat, sapping its potency.

Too often in the past, heat-exposed vaccines were used because the problem wasn’t recognized. Or health workers tossed out viable vaccines because they suspected damage from overheating.

To help, PATH found a technology originally used by the food industry to monitor perishable products and worked with its owners to adapt it for vaccines. The vaccine vial monitor (VVM) is a small circle, no bigger than a dime, that is placed or printed on a vaccine vial and changes color as it is exposed to heat.

Since they were introduced, VVMs have helped health workers around the world know at a glance whether a vaccine has been exposed to too much heat and is damaged or if it can still be used for immunization. In the process, the sticker has saved millions of doses from being discarded unnecessarily.

A small circle with a big impact

Starting in the late 1970s, PATH worked with the World Health Organization (WHO) and a variety of technology developers to find a way to track the heat exposure of individual vaccine vials. In the early 1980s we teamed up with the Temptime Corporation, to develop VVMs. Many donors provided financial support to the project, especially the US Agency for International Development. In 1996, VVMs became commercially available for oral polio vaccine, adding only a few cents to the price of each vial.

Today, WHO requires that all vaccines purchased through the United Nations Children’s Fund (UNICEF) use VVMs. And together, WHO and UNICEF have urged other groups that procure vaccines—including donor agencies, international organizations, and country leaders—to make sure VVMs are required in all of their vaccine purchase agreements and donations. PATH and WHO have also developed and tested training materials for health workers that help them learn how to handle vaccines and use VVMs effectively.

In the years since introduction, the VVM has demonstrated its value again and again. In one example, electricity went out at health facilities in Yogyakarta, Indonesia, for several days during an earthquake. Vaccine vial monitors showed that most vaccines were undamaged, despite the heat, saving 50,000 doses of vaccine that otherwise would have been thrown away.

Saving lives and resources

Today, many years after the first vaccine vial monitors transformed the transport, storage, and use of vaccines, the circles continue to serve communities worldwide. They are on every vial of the MenAfriVac® vaccine, for example, helping to protect millions of people in sub-Saharan Africa against deadly meningitis A.

Over the next decade, it’s estimated that VVMs will allow workers to recognize and replace more than 200 million doses of damaged vaccine and to confidently deliver more than a billion more doses in remote settings—saving lives and reducing illness for countless people.

In addition, thanks to the presence of the VVMs on vaccines, WHO revised its policies to allow open vials of liquid vaccine to be used for more than a single day. UNICEF and WHO estimate that the use of VVMs on basic vaccines saves the global health community more than $14 million each year by preventing undamaged vaccines from being discarded.

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