From prefilled syringes to combined filling

Update:16 Aug 2019

“There is more and more discussion about disposable fil […]

“There is more and more discussion about disposable filling systems associated with prefilled syringes in the pharmaceutical industry.”

Pre-filled needles have become the preferred method of infusion because they are not only easy to handle, but also improve the accuracy of the dose. In addition, the continued prosperity of the biopharmaceutical industry has also contributed to the development of the prefilled syringe market. At the same time, other types of pre-sterilized packaging are also emerging, which poses new challenges for pharmaceutical companies. As a result, machine builders are committed to providing new, more flexible solutions – and achieving groundbreaking results.

Compared to conventional packaging, prefilled syringes are not only easier to use, they are more precise, and modern prefilled syringes are characterized by reduced product losses, which is a major advantage in the expensive biopharmaceutical industry. These highly personalized products, such as those used to treat autoimmune diseases, are examples of the best liquid drug forms for using syringes.

Process flow: highly automated

As manufacturing becomes more automated, bacterial contamination from particulate matter from manual operations by operators will be minimized.

At this point, fully automatic opening of sterile syringe packaging has become a standard requirement for new filling lines. In addition, the use of isolators is becoming more common as it continuously separates the sterile field from its surroundings.

Process control (IPCs) are also an important factor in further improving the quality of the filling process. The current focus is on determining the filling weight and monitoring the presence of the rubber plug. In the future, the following checks may be carried out on the quality of the packaging material directly before filling: Is the silicone seal intact? Is there a safety cover? Is it installed correctly? If not, the problematic syringes can be sorted prior to the filling process to reduce product loss.

The highly automated filling machine is equipped with a flexible robot that accurately removes the syringe from the hive. Finally, a single syringe can be sent to the integrated inspection station. In addition, there is now a way to check the thickness and distribution of the silicone layer in the syringe to ensure smooth sliding of the plug, which is a particularly important factor in self-injection.

In this case, it is worth mentioning that more and more non-silicide systems are used for plastic syringes. It has also been reported that glass syringes use a silicon-free plug, which may open a door for a silicon-free glass system.

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