Pre-filled Syringes and Aseptic Processing

By Ian Bruce

Pre-Filled Syringes and Aseptic Processing is a comprehensive technical guide for pharmaceutical professionals, engineers, and quality experts involved in the development, manufacturing, and regulation of injectable drug delivery systems. With the increasing shift toward patient-centric therapies and biologics, pre-filled syringes (PFS) have become a cornerstone in modern parenteral drug delivery-offering convenience, safety, and dose accuracy.
This book dives deeply into the science, engineering, and regulatory landscape that underpins the lifecycle of pre-filled syringe systems. From raw materials and component design to aseptic processing and advanced barrier technologies, each chapter builds a rich understanding of how PFS systems are conceptualized, validated, and brought to market in compliance with global standards such as ISO 11040, ISO 15378, and cGMP.
Readers will explore intricate aspects of glass and elastomer selection, plunger-syringe compatibility, and the nuanced mechanical forces (like glide and breakloose) that affect performance. With discussions on protein aggregation, lifecycle testing, container closure integrity, and automation through SCADA-integrated isolator lines, the book spans both the micro-level chemical interactions and the macro-level facility and regulatory considerations.
Special attention is paid to isolator technologies and ready-to-use (RTU) components that have redefined aseptic processing, enabling cleaner, more efficient, and scalable sterile filling lines. The integration of clean utilities, sterility assurance strategies, and automated inspection systems is also covered in depth, with practical examples and visual illustrations that enhance understanding.
Key Topics

ISO 15378 and QMS for Primary Packaging MaterialsISO 11040 Series - Glass and Plastic Syringe StandardsPlunger Materials and Elastomeric ClosuresContainer Closure Integrity (CCI) TestingGlide Force and Breakloose Force TestingFunctional Testing for Needle Shields and Tip CapsSiliconization Techniques and Lubrication ChallengesProtein Aggregation and Drug-Container InteractionMaterial Compatibility and Extractables/LeachablesFluoropolymer Coatings in PlungersDesign Control and Quality by Design (QbD) ApproachesLifecycle and Fluid Leakage TestingAutomation and Robotic Integration in PFS LinesAseptic Filling with RTU Syringe TubsIsolator Technology and VPHP DecontaminationVision Inspection Systems and Data Integrity (21 CFR Part 11)Sterility Assurance and Environmental MonitoringClean Utilities - WFI, Compressed Air, Clean SteamRegulatory Standards - ISO 13408, EU GMP Annex 1Device Development and Design Verification for PFS

• Format: Paperback
• Language: English
• ISBN: B0F2TCRFG6
• ISBN13: 9798315610786
• Release Date: March 2025
• Publisher: Independently Published
• Length: 248 Pages
• Weight: 0.74 lbs.
• Dimensions: 0.5" x 6.0" x 9.0"