Making Prefilled Syringes
Find innovative production technology for making pre-filled syringes and connect directly with world-leading specialists
A pre-filled syringe or PFS is a single-dose disposable syringe that is supplied loaded with the substance to be injected. By using a pre-filled syringe filling machine, you can have excellent dosage accuracy due to the exact filling of medications. During administration, safety from potential contaminants is also ensured as they are directly injected after opening. To further minimize the risk of contamination, pre-filled syringes are often filled and sealed in a sterile environment using stainless steel equipment.
Select your pre-filled syringes process
Tell us about your production challenge
Rising demand for sophisticated forms of drug delivery
Pre-filled syringes are gaining popularity over traditional syringes and vials and are considered one of the fastest-growing markets in drug delivery and pharmaceutical packaging industries. Pre-filled syringes address most of the issues from the traditional vial and syringe drug delivery such as less risk of contamination during administration as there is no need to draw out substances from a separate container and elimination of on-site vial cleaning and depyrogenation. Additionally, the exact fill volume of pre-filled syringes ensures that the correct dosage is administered to the patient, thereby minimizing potential dosage errors.
For healthcare providers, prefilled syringes provide the exact dosage for injection, preventing potential dosage error and offering quick and convenient drug administration. For pharmaceutical companies, pre-filled syringes eliminate drug overfill with its correct dosage. This means less waste of drugs and better efficiency in manufacturing since vials are usually overfilled to ensure that the transfer of drugs from vial to syringe is adequate.
Less contamination, safer application, from a material called Cyclo Olefin Polymer
Most prefilled syringes still use glass materials, but in some parts of the world like Japan, plastic-based materials are becoming more common due to their improved break resistance and less surface reaction from chemicals. New materials for syringes have been developed to improve safety from contamination using a material called Cyclo Olefin Polymer (COP) that looks and feels like glass but tougher. The piston in pre-filled syringes made of COP material is resistant to delamination, and its properties are retained at cryogenic temperatures, and it requires no lubricants or processing aids.
It is tungsten-free, which means it has fewer chances of health hazard due to tungsten exposure – tungsten can cause nausea and irritation to the lungs, eyes, and skin. COP is resistant to delamination; its properties are retained at cryogenic temperatures and require no lubricants or processing aids. This material can also be sterilized with gamma, ethylene oxide, and steam.
Administration of vaccines: tried-and-tested or new-and-improved?
Typical delivery methods for vaccines use multi-dose vials especially in mass vaccination programs. However, with the pre-filled syringes gaining market share, there is a shift towards using pre-filled syringes rather than multi-dose vials for vaccines. Based on global data of evaluation of vaccine presentation, pre-filled syringes can save time in mass immunization clinics. A study conducted by Scheifele and colleagues in Canada shows that, for every 1000 vaccine doses, vials took 36 hours while pre-filled syringes only took 27 hours.
This means that man-hours charged for labor costs are significantly lowered by 25 to 33 percent. Other advantages of using pre-filled syringes include the reduction of vaccine waste as it removes the variation inherent in drawing from a vial. There is also an increase in the consistency of administrating medicines across all locations as some healthcare workers are more adept than others in drawing medicines from a vial.
Pre-filled syringe filling machine for bubble-free liquid contents
Pharmaceutical companies that manufacture complex biologics require less headspace by using the bubble-free filling method. This is done by a stoppering technique called vacuum placement. A vacuum is pulled in each syringe that causes a differential pressure. The pressure draws the plunger into the syringe, leaving minimal headspace between the product and the plunger.
Advantages of a bubble-free pre-filled syringe filling machine are dosing accuracy with the removal of air bubbles, assurance of sterility because of fewer chances of plunger movement during shipping, and biologic stability due to less oxygen content that can affect oxygen-sensitive drugs. In addition to the filling machine, a labeling machine can also be used to apply labels to pre-filled syringes. This ensures that the syringes are properly labeled, which is important for tracking and tracing purposes.
Processing steps involved in pre-filled Syringes making
Which pre-filled syringes technology do you need?
Modular assembly line for healthcare products
Assembly setups need to be constantly rethought and reconfigured to adapt qu...
Manual stoppering equipment for pre-filled syringes
Air present in the empty space of pre-filled syringes may prevent you...
R&D bottle washer
When you pack your products in bottles, vials, syringes, and test tubes you need to wash them before fillin...
Aseptic filling machine for liquids and powders
Aseptic filling of containers such as vials, syringes, bottles, and cartri...
Semi-automatic forming and sealing blister machine
As a manufacturer of medical device, the packaging is a critical facto...
Automatic forming and sealing blister machine for packing syringes
Controlling contamination is on every manufacturer&#...
Cold forming aluminum blister machine for capsules
Aluminum blisters are mainly used for packaging products that are sens...
Easy to validate capsule filler
Staying competitive in today’s highly dynamic and highly regulated pharmaceutical prod...
High speed bottle filler with inspection
Medicines in tablet, capsule, or soft gel forms undergo various processes before r...
Contained Visual Inspection System
In the medicine industry, it is important to ensure there are no defects in tablets or c...
Ethylene oxide sterilizer
When medical devices like syringes, catheters, dialysis cartridges, plastic dressings and sutures ...
API powders storage bottle
Users who prefer rigid storage over single-use pharma charge bags, require lightweight solutions ...
High containment closing system
Pharma and biopharma laboratories need fast effective solutions for tightly sealing bags for...
Packaging machine for syringes in trays
Pre-dosed syringes are rapidly becoming the method of choice for the delivery of in...
Entry-level blister packaging machine
Blister packaging is a popular packing method in the pharmaceutical industry thanks t...
Horizontal cartoner for pharmaceutical applications
Automatic cartoning for cosmetic or pharmaceutical products is a requ...
Start-up sterile filling line for injectables
For smaller-scale production of vials and syringes for the injectables marke...
Table top sterile filling line for injectables
Where a compact solution is required for filling vials for the injectables ...
Cleaning and sterilization systems
An increasingly vital part of high quality pharmaceutical production is a dedicated Clea...
Vial sterilization tunnel
Sterilization of vials, ampoules and syringes before filling is a vital step in the production of ...
Syringe tub sterilizer
A common challenge is how to transfer nested syringe tubs to the aseptic filling area without compromi...
Sterile compounding system
Hospitals and compounding centres have traditionally used manual aseptic compounding processes. A...
Flowmeter filler
For larger production runs of food, non-food and cosmetics industries, where accuracy and volume of filling i...
Microencapsulation system for your drug delivery system
Whether you want to improve the stability of nutrients, protect a...
High-capacity horizontal cartoner for pharma and cosmetics appliances
Cartoners take carton blanks which are formed and...
Automatic cartoner for applications in pharma and cosmetics
For high capacity production of cosmetics and pharmaceutical...
Pharmaceutical and cosmetic industry products cartoner
A large number of cosmetic and pharmaceutical products are packed ...
Horizontal cartoner for pharma and cosmetics
Most pharmaceutical and cosmetics products are packed in cardboard cartons fo...
High capacity cartoner for pharmaceutical applications
Many pharmaceutical products are packed in protective and decorati...
Vertical cartoner for pharmaceutical applications
Many pharmaceutical and cosmetic products are sold in protective and de...
Flexible automatic inspection machine for ampoules, vials, cartridges
If you are looking to improve the efficiency of y...
Flexible automatic inspection machine for syringes
Manufacture of pre-filled syringes requires the highest quality inspec...
Small automatic inspector for ampoules, vials, or cartridges
Inspect small batch production of ampoules, vials, or cartr...
Semi-automatic inspection machine for ampoules, vials or cartridges
If you need to increase the efficiency of your manu...
Visual and HVLD inspection for ampoules, vials and cartridges
Do you need to improve the efficiency and capability of yo...
Filling and closing machine for parenterals
Any pre-filled syringe can be filled and closed with this fast and easy machin...
Bellows for pharmaceutical powders
Thermal and mechanical changes can lead to stresses in industrial piping systems. These ...
Sterile filling line for injectables
Sterile filling of liquids and powders for the pharmaceutical and cosmetic industries ...
Ethylene oxide sterilization chamber
Designed for the terminal sterilization of temperature sensitive medical-health produc...
Sterility test isolators
Designed to avoid this risk and protect the product from both the process and externally generated f...
Flexible contained drum transfer system
Transferring powders from drums to process equipment such as reactors or mills can ...