Discover your next big idea at PACK EXPO Las Vegas this September
Experience a breakthrough in packaging & processing and transform your business with solutions from 2,300 suppliers spanning all industries.
REGISTER NOW & SAVE

Plastic prefillable syringe systems

New biopharmaceuticals, rising production costs, at-home convenience, and safety are driving the need for break-resistant, silicone-free prefilled syringes.

West_prefilled_syringes
West_prefilled_syringes

The rise in biopharmaceuticals used to treat diseases and chronic conditions such as multiple sclerosis and rheumatoid arthritis has forced drug and packaging manufacturers to seek improved manufacturing processes and more sophisticated container closure and drug delivery systems. Increased compliance requirements and pressure to achieve higher quality have resulted in a variety of new drug delivery options. Prefillable syringes provide convenient, premixed, sterile, fixed dosages.

To answer demands for higher quality, the drug industry has moved toward ready-to-sterilize and ready-to-use components for prefillable syringe systems. These components reduce the levels of extractables and leachables through wash and sterilization processes that reduce the risk of microbiological contamination in the drug product. Components are also available with films that serve as a barrier between the drug and the closure to reduce leachables. Some provide lubricity, so manufacturers can reduce or eliminate the need for silicone oil, which removes a potential source of contamination.

With the development of novel materials, including cyclic olefin polymers such as Daikyo Crystal Zenith® (CZ) resin, manufacturers can now offer high-quality, transparent, break-resistant material that is more inert than glass, is scratch-resistant and, unlike glass, does not flake, which reduces particulate contamination from the container. These resins can also be stored and shipped at low temperature--a requirement of many biologics.

As the industry trends toward the use of prefillable syringe systems, which are often used in devices or delivery systems to aid with the increased need for injection in the home setting, such resins offer a solution. Because of flexibility in molding these polymers, they can be used in a variety of drug delivery systems such as custom cartridges. Plastic prefillable syringe systems help to reduce costly overfill and enhance patient and caregiver safety.

Economic option

Since biologics tend to be expensive, manufacturers are increasingly looking for ways to maximize production efficiency. Prefillables, with their premeasured dosage, can reduce dosing errors and increase patient compliance while saving manufacturers money. Unlike single- or multi-dose vials that may overfill by as much as 30% to account for potential waste, a prefillable syringe can virtually eliminate the need to overfill. This is important where manufacturing and product costs are high and bulk manufacturing capacity is limited.

Additionally, with a vial there is often a great deal of variability when removing product with a conventional disposable needle and syringe. With a prefillable syringe, the nature of its design cuts out that variability and delivers a more accurate dose of the drug to the patient.

Prefillable syringes also provide for greater safety by reducing the potential for inadvertent needle-stick injuries and exposure to contaminated or adulterated products that can occur while drawing medication from vials.

The plastic advantage

Glass prefilled syringes still dominate the market. Switching from a glass prefill to a plastic-molded prefillable syringe can reduce the variability and breakage issues associated with silicone oil and glass use.

Break out of the ordinary: see what’s new in packaging & processing!
At PACK EXPO Las Vegas, you’ll see machinery in action and new tech from 2,300 suppliers, collaborate with experts and explore transformative solutions. Join us this September to experience a breakthrough in packaging and processing.
REGISTER NOW AND SAVE
Break out of the ordinary: see what’s new in packaging & processing!
2024 PACK EXPO Innovations Reports
Exclusive access: Packaging World editor-curated reports revealing PACK EXPO's most groundbreaking technologies across food, healthcare, and machinery sectors. Each report features truly innovative solutions selected from hundreds of exhibitors by our expert team. Transform your operations with just one click.
Access Now
2024 PACK EXPO Innovations Reports