We handle secondary packaging and product handling of vials and syringes.  Assuming the device is prefilled, its critical that the product handling is gentle and positive. For example, vials or syringes might be driven through a timing screw, then tipped into a bucket on a cartoner infeed. Guide rails can limit the ‘fall’ of the vial into the bucket, but there is a point at which the vial isn’t contained positively.

Robotics provide the best, current solution. A high-speed robot can positively pick and place the vials gently. The cost of robotics has fallen in recent years; however, this solution still may be slightly greater than traditional product-handling methods. Frequently, the cost/value of a pharmaceutical or biologic held in a vial is quite high. When considering the cost of a robot, once factoring in the reduction in scrapped product caused by traditional product handling, robotics is often the clear choice.

Ken Himes at Filamatic offers further input on the cost issue:  “There appears to be no standard industry data on this subject, but this comparison might help:

- traditional glass vial injectible system = cost of “1X”
- a glass syringe system = cost of “2X”
- a plastic syringe system = cost of “2.5X”

Himes adds that “the prefilled syringe market is growing 10-15% per year for the foreseeable future. Vial usage appears to be flat.”

This is a very difficult area. Every hospital and physician has very different guidelines and procedures for handling vial and syringe medication storage and administration.

There is a Pharma industry trend that is moving toward prefilled syringes and pens. Although this type of delivery system is more costly than the vial and syringe method, it will better address the tamper-evidence issues.

Also, there are many overt, covert, and tamper-evident scenarios that can be employed on the package.