The pharmaceutical sphere is leveraging the intensifying wave of innovation as medical professionals across the globe hunt for user-centric injectors aiding in accurate dosage of drugs. Double chamber prefilled syringes – a product of such innovation – are garnering huge prominence in the medical sector thanks to straightforward re-formation and drug infusion, enhancing user experience.

Coupled with passive needle-safety technology double chamber prefilled syringes protect users from needlestick, and avoids re-use. Post injection, users get an end-of-dose click indication in sync the retraction of needle into the barrel of the syringe and plunger rod, keeping the syringe needle unusable. As such, double chamber prefilled syringes prevent re-use of the needles, achieving compliance with mandates associated with needlestick and re-use prevention.

Patients are shifting towards self-medication at home in a bid to reduce the need of visiting healthcare centers on a frequent basis. With online training lessons, users can employ double chamber prefilled syringes under restricted conditions. Time is a factor in the fast-paced lifestyles of customers while money tops the list when it comes to cost prohibitive biologics. As such, the demand for innovation-driven double chamber prefilled syringes is set to face an upward trajectory in near future.

‘Glass’ and ‘Plastics’ – The Battle Between High Chemical Resistance and Low O2 and UV Barrier

Bulk glass double chamber prefilled syringes allows injection of highly sensitive fluids into patients with great accuracy. In addition, absence of glue from the syringes eliminate the risk of unwanted mixing with the therapeutic drug, allowing alternative siliconization methods. However, the glass material in the syringes proves inefficient while infusing high viscous liquids, resulting in potential contamination. Further, glass poses the challenges of delamination and insufficient UV barrier.

Although traditional plastic alternatives act as better alternative, double chamber prefilled syringes made of plastics exhibit the problem of inept oxygen and ultraviolet light (UV) barrier – ~70% permeation. The US FDA has highlighted the issues related to bulk glass and plastic double chamber prefilled syringes, instituting significant incidents of recalls.

COP Polymer Fills the Gaps; Injection Molding Complements the Performance

Proliferation of plastic composites is evident in pharmaceutical sectors, with manufacturers relying on high performance polymer – COP (Cyclic Olefin Polymer) – for developing double chamber prefilled syringes. COP syringes are characterized by high degree of break resistance and a transparency akin to glass. The COP material does not result in the formation of alkali ions, dismissing the risk of changes in pH value.

The COP material offers a wide spectrum of design options – a great fit for customer-specific demands. The polymer is directly utilized for aseptic filling owing to low oxygen permeation – ~1.7% – as compared to fellow plastics. High UV shield aspect complements the stability of biologics. In addition, the robustness and accuracy of COP double chamber prefilled syringes make them suitable for application in autoinjectors. Further, the entire syringe is manufactured in a single process – free of tungsten and adhesives.

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Development of COP double chamber prefilled syringes via injection molding process ensures exact dimensions. As such, the dead volume in the polymer syringe is reduced, minimizing overall wastage of expensive therapeutic drugs, such as hyaluronic acid. The cannula is insert-molded during the injection molding process in lieu of glued in, decreasing the risk of contamination of the injecting fluid.

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