Packaging Resource Center: The Latest in Drug Deliver & Parenteral Packaging

Swab Applicator

A manufacturer offers large-surface-area applicator tips for its plastic ampules. The tip is available for both the 2- and 5-ml ampules. The tip is a molded plastic component with a specially designed foam applicator adhered to the plastic. Different types of foam are available, depending on the composition of the customer’s formula and application needs. Many of the foam tips offered by the manufacturer can be reconfigured for specific applications. The user activates the package with a gentle squeeze of one hand, which ruptures the internal membrane; another squeeze then dispenses the contents onto the applicator tip. The company’s standard applicator tips include a cylindrical tip with a centered hole for product flow, tapered tips for topical applications, and brush applicator tips in a variety of styles. The company also offers three-color print capability. James Alexander Corp., Blairstown, NJ; 908/362-9266;

Glass Vials

A glass vial has been redesigned to increase durability and protection against contamination during manufacture and transportation. The NextGen V Vial features a fire-glazed bottom. Previously, the bottom of the vial was ground in a secondary process after the vial was formed. The change in the forming process to produce the redesign eliminates possible sources of contamination from glass particles and residue from the post-grind washing step. The vial’s completely conical interior bottom provides total downward drainage for maximum retrieval of contents by syringe. The manufacturer offers bulk packs of 100 vials that are shrink-wrapped in four low-particulate cellular trays per carton. Low-particulate dividers used to separate the vials protect the finish by preventing glass-to-glass scratching. Wheaton Science Products, a member of Alcan Packaging, Millville, NJ; 856/825-1100; www.


A contract packager has installed blow-fill-seal systems for high-volume production of liquid unit-dose products. The custom-built Weiler 624 machines enable the company to manufacture vials in mold sizes from 0.5 to 20 ml at high speeds. Sizes from 0.5 to 5.5 ml include a proprietary offset dispensing tip so that the user can accurately place the product. Standard resins include a full range of polyethylene and a flexible polypropylene with glass-like clarity. Custom colors and shapes are available. Unicep Packaging, Sandpoint, ID; 208/265-9696;


Disposable Syringe Filler

A fully automatic filling and closing machine for disposable, nested syringes accommodates fill volumes from 0.5 to 20 ml. The five-lane version of the machine can reach speeds up to 10,500 syringes/hr. The 10-lane model reaches speeds up to 18,000 syringes/hr. The H310 machine is equipped with infeed and discharge conveyor belts. It also features linear and vertical processing of tubs and a slim structure design, and it is compatible with an isolator. Optima Machinery Corp., Green Bay, WI; 920/339-2222;


An autoinjector for liquid medications is a prefilled drug-delivery system designed to combine the safety benefits of a sterile container with a user-friendly, simple design that is easy to use in emergencies. The PC-II-M autoinjector is composed of an activator unit and an injection unit, which protects the prefilled glass carpule. The device was originally developed with USP/EUP-compliant materials for the Army for fighting nerve gas attacks. The manufacturer’s plants are equipped and certified for loading pharmaceutical drugs into the injectors. Rexam Pharma, Suresnes, France; +33 1 41 38 98 00;

Dissipative Compound

A static dissipative acrylic multipolymer compound developed for injection-molding applications is designed to improve efficiency in drug delivery. The Vu-Stat Y-20 compound provides permanent electrostatic dissipative protection for medical devices where static attraction is a concern, such as with needle hubs for bracheotherapy and spacers for dry powder pharmaceutical inhalation. The compound is designed to combat potential static charges that may weaken the performance of drug-delivery devices by impeding the passage of drug particles. It is not dependent on moisture or humidity for its effectiveness, so it retains its ESD properties even after repeated washing cycles. Cyro Industries, Rockaway, NJ; 800/631-5384;

Needle Protection

A company offers a syringe label with integrated needle protection. It can be adapted to all standard syringe dimensions. It can also be processed on conventional labeling equipment. The safety mechanism can be activated using only one hand. After performing the injection, the user presses the needle protector against the edge of a table to make it click into place. This mechanism was designed for large-scale use to minimize the risk of needle injuries. Schreiner Medi-Pharm, Oberschleissheim, Germany; +49 89 31584-5400;


Drug Reconstitution

A system is designed to enable the safe, rapid, and easy preparation of lyophilized drugs. MixJect is a single unit for reconstituting a powder drug with a prefilled diluent syringe. Upon reconstitution, the drug is available for immediate injection with a dry integral needle. The body and vial adapters of the MixJect system are molded from medical-grade polycarbonate, and the valves are molded from polyethylene. The low-profile lock is designed to minimize fluid path dead space. The unit is preassembled and fits standard vials. Customers can specify the type of syringe needle to be used. The unit fits syringes and needles that are luer compatible. It is also compatible with autoinjector devices. West Pharmaceutical Services Inc., Lionville, PA; 610/594-2900;

Pressure-Sensitive Components

A printing and manufacturing company offers pressure-sensitive components for drug-delivery applications, including conductive traces for iontophoretic devices. In addition to this line of SmartParts for drug delivery, the company also prints on flexible, rotary units. The company’s circuits can be manufactured to fine line traces of 0.006 in. in a variety of configurations. Configurations available include silver, carbon, silver/silver chloride, copper etching, and a proprietary silver/copper structure. The company also offers skin-friendly, self-adhesive patches and double-sided adhesive fixation devices. TopFlight Corp., Glen Rock, PA; 800/233-9386;

Prefilled Syringes

Prefilled syringe technology features a specially designed plastic tip cap with a twist-off mechanism familiar to healthcare professionals. The innovative tip cap design of the BD Hypak PRTC, which is used for GlaxoSmithKline’s recently approved prefilled flu vaccine, facilitates aseptic technique during tip cap removal. The securely attached tip cap promotes integrity of the syringe tip and contents; it is also easy and convenient to open. A transparent BD Luer-Lok adaptor allows visual inspection of the needle hub connection and is compatible with conventional and safety-engineered needles. BD Hypak prefills require minimal overfill over the desired dose and minimize medication errors; as a result, they can contribute to reductions in the cost of care and drug deliveries. In the United States, the BD Hypak SCF is the medication delivery system selected and used for a prefilled flu vaccine. BD Medical Pharmaceutical Systems, Franklin Lakes, NJ; 800/225-3310;

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