Optimizing Autoinjector Performance for Drug Development

Sebastian Cordier from Aptar Pharma delivered an insightful presentation, in collaboration with Lucy Lee from SHL Medical and Christian Redeker from Gerresheimer. This presentation brought together leading experts from the pharmaceutical packaging industry to discuss how collaboration between component manufacturers, Pre-Filled Syringe (PFS) and autoinjector manufacturers can derisk drug development and delivery for pharmaceutical companies. The experts focused on addressing how autoinjectors are addressing the evolving market demand for biologic drug delivery, the interplay between each component of these injection systems and how it can contribute to facilitating the drug development process.  

In the growing biotech and GLP-1 market, autoinjectors provide a convenient way for patients to self-administer medication at home, reducing hospital visits. This improves treatment adherence and quality of life. Christian explained that an autoinjector includes a pre-filled syringe with a staked needle, a rigid needle shield, a syringe plunger, and the autoinjector itself. He also discussed regulatory requirements and the importance of understanding these components to speed up time to market while minimizing development risks. 

Although pharmaceutical companies are responsible for the functionality and efficiency of combination products, packaging manufacturers can provide valuable data to mitigate risks and support the development of injection systems. It is important to recognize that suppliers may not have access to the drug formulation, final user requirements, or intended use; therefore, the data they provide are “drug agnostic” and represent typical case scenarios.  

Sebastien, Lucy, and Christian discussed the essential functions of an autoinjector and the role of each component in ensuring functionality and reducing risks for drug developers: 

• Consistent injection activation and speed 

• PFS flange resistance to prevent breakage upon autoinjector activation 

• Proper removal of the Rigid Needle Shield 

• Acceptable duration of the dose delivery 

Sebastien described the interaction between the pre-filled syringe barrel and the syringe plunger, focusing on their impact on break-loose and gliding forces needed for dose administration. He shared data showing the performance of PremiumCoat® 1-3mL plunger when used with Gerresheimer’s glass or COP pre-filled syringes.  

Sebastien and Christian emphasized the Rigid Needle Shield’s (RNS) crucial role in consistent system decapping, which supports easy dose delivery. The RNS works with the AI cap for proper decapping and connects to the PFS tip to prevent spontaneous deshielding while maintaining needle sterility. 

Finally, Lucy covered all the key dimensional considerations necessary to ensure that the pre-filled syringe fits into the autoinjector appropriately, which is essential to ensure the alignment of the needle, depth of injection, as well as ensuring proper decapping of the system. 

Aptar Pharma, SHL Medical, and Gerresheimer have joined their expertise to provide integrated solutions for autoinjector development products. They demonstrated how collaboration between suppliers can help minimize development risk for pharmaceutical companies, shorten time to market, and reduce costs, thereby providing improved therapeutic solutions to patients globally.