Do You Learn The Packaging For prefilled Syringes?

Patient safety is a concern when discussing prefilled syringes.

Manufacturing prefilled syringes also is a broad consideration, as patient directions and needs for injectable pharmaceuticals are particularly varied, and often even customized. Far-ranging production needs mean that effective, versatile secondary packaging for prefilled syringes and autoinjector pens must be compatible with both automated and manual manufacturing processes. From materials to manufacturing, prefilled syringes, autoinjector pens, vials and ampoules frequently need “just right” solutions suitable for everything from limited clinical trials to full-scale commercialization.

1.The necessary of innovative carton packaging for prefilled syringes

Over recent years, the pharmaceutical industry has increasingly embraced prefilled syringes as a more user-friendly delivery format for parenteral drugs and vaccines, simple to handle and with minimal risk of spillage, contamination or, crucially, dosage error.

This trend has been accelerated by the greater prevalence of biotech products with their greater therapeutic effect but whose active ingredients are frequently too unstable to be incorporated into solid-dose tablets or capsules. More than 90% of these products are therefore packaged as liquids in syringes, vials or ampoules.

Secure packing of these hi-tech liquid products has become a key concern, not only because of their greater fragility and cost, but also because they tend to be temperature-controlled and subject to the added constraints of cold-chain logistics where volume is at a premium.

It follows that innovative carton packaging solutions for prefilled syringes are needed to enhance their marketability, which also means meeting increasingly stringent regulatory guidelines on product protection, security traceability and environmental sustainability.

2.Packaging of prefilled syringes

Innovative carton packaging solutions for prefilled syringes are needed to enhance their marketability, which also means meeting increasingly stringent regulatory guidelines on product protection, security traceability and environmental sustainability.

The most effective packing solutions for prefilled syringes therefore need to support highly flexible packaging schemes that can handle a wide range of different containers and formats while  at the same time providing sensitive handling, optimal product protection and delivering the flexibility for ‘on demand’ manufacturing that includes small, medium and large lot sizes. The ideal modern packaging system must also support vision system automatic item and code checking, integrated labelling, printing and inserts, auto-checking of variable data, minimized machine setup and changeover times and GMP compliance.

A genuinely holistic approach to packaging must also consider the functional requirements of the parenteral package, which are not only to safeguard the product throughout its route from manufacture to final point of use but also to deliver patient information and tracking data to form an end-to-end metadata link between the pharma company and its consumers. In effect, the carton becomes an essential part of the prefilled syringe delivery system, delivering patient benefits like ease of access, reclosability clear instructions and peace of mind.

A monomaterial syringe carton formed on our factory delivers powerful advantages over PVC or PET blister packs and attendant end-load cartons. Not only does this avoid plastics use, now facing consumer resistance but there are also savings in material costs and logistics, with up to 40% reduction in the ratio between product and package volume for disposable filled syringes.

3.Modularity is essential to meet the technical packaging requirements of modern medical products

Modularity is essential to meet the technical parenteral packaging requirements of modern pharmaceutical products, including the growing diversity of prefilled syringes, vials and other types of injection device.

Helps pharma & biotech manufacturers achieve operational and commercial viability through a quality-driven modular packaging platform approach that combines low to high speed packaging machines, compact and economical carton forms, thorough product protection with ease of use, quick set up and reduced total cost of ownership.

4.Prefilled syringe packaging options

The prefilled syringe is normally filled with injectable such as vaccines and anticancer drugs to be readily used. This type of syringe has been increasingly adopted in recent years as it does not require transfer of the drug from a container such as vial to a syringe, which is more convenient and safer for medical practitioners.

This prefilled syringe is generally packaged in a carton after it is set in a plastic tray or a paper inner tray. A paper inner tray has an advantage over a plastic one as it does not have to be separated from the carton in disposal, but its structure is complex and causes trouble when assembled at pharmaceutical companies.

The inner tray is flat before assembling, so it does not take up space for storage at pharmaceutical companies.Simple configuration and easy assembly.

When a tray and syringe are set in the carton.The packaging has high shock-absorbing effect as the prefilled syringe remains and fixed in the air with very few holding points of the packaging. Besides, it is easy to open the carton and take out the prefilled syringe.

The configuration of this inner tray is simplified and has high shock-absorbing effect. It is easy to assemble and will make packaging process efficient.

5.The advantage of modularity

Modular packaging solutions offer safety combined with sustainability, efficiency, economy and user friendliness.

A range of highly modular and therefore flexible and adaptable toploading packaging machines that are combined with 100% monomaterial cardboard, which enables economical and efficient parenteral packaging of the whole range of pharma products, including  prefilled syringe formats.

Modularity can be adapted to the specific requirements of pharmaceutical product manufacturing, making it ideal for the production of small to medium batch sizes.support higher speed production of mid to large size lots also being modular and expandable throughout.