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Core Dilution Mathematics and Vial Sizing Protocol Primary capacity formula: Required capacity = (Peptide mass ÷ Target concentration) × 1.20 headspace factor Complete five-step validation workflow: Confirm peptide mass from certificate of analysis (CoA) Establish target concentration : 1-5 mg/mL optimal therapeutic range Calculate diluent requirement : Mass ÷ Target concentration Apply a 20% headspace factor for reconstitution mixing and thermal expansion Select the next larger ISO-standard vial from the capacity table Clinical calculation examples: 10 mg semaglutide powder, target 2 mg/mL: Diluent required = 10 ÷ 2 = 5.0 mL Total capacity needed = 5.0 × 1.20 = 6.0 mL minimum → Select 6R vial (12 mL brimful, 8.0 mL headspace available) 5 mg BPC-157, target 5 mg/mL: Diluent required = 5 ÷ 5 = 1.0 mL Total capacity needed = 1.0 × 1.20 = 1.2 mL minimum → Select 2R vial (4 mL brimful, 2.5 mL headspace available) Syringe Dead Volume and Dose Accuracy Impact U-100 insulin syringe dead space : 0.01-0.03 mL retained per draw Dosage loss calculation : At 2 mg/mL concentration, 0.02 mL dead space = 40 mcg lost per dose Optimal concentration ranges by syringe type: U-100 (0.01 mL increments): 2-5 mg/mL → 0.05-0.25 mL draws (±5% accuracy) TB syringes (0.05 mL increments): 5-10 mg/mL → 0.025-0.05 mL draws Vial dead volume comparison: 2R vials: 0.9% concentration through 28-day BUD (USP 797 Category 2 multi-dose vials)

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