The advantages of COC/COP-based containers in the production of staked-needle syringes

Pharmaceutical primary products with sterile needles - such as disposable needles, staked needle syringes (pre-filled syringes) and insulin pen adapters - are used in a variety of applications every day. In all cases, products made of plastic are clearly superior to their glass counterparts in terms of practical handling and unproblematic storage. We present the advantages of COC/COP based containers.

Advantages of Vials & Pre-filled Syringes of COC/COP

• pH neutral surface

• Lower heavy metal content than glass

• Freezer compatibility increases shelf life, especially for highly sensitive medication

• No risk of breakage and, compared to glass, easier and safer handling for self-medication

• More freedom in product design and in cannula-position and shape

Production lines for any requirement

Based on customer-specific product designs, a cycle time of 15 to 17 seconds can be achieved on the three currently available PRIMA Z production lines using the no-human-touch process. Ready-to-use syringes (Pre-Filled Syringes, PFS) according to ISO11040-6 with filling quantities of 0.5 to 5 ml, cannula sizes of 19 G to 32 G and cannula lengths of 12 to 45 mm can be manufactured for immediate filling. Our PRIMA Z lines produce up to 3,400 parts per hour.

Cost savings through continuous aseptic production of plastic vaccine containers

A medication container for a liquid vaccine can use plastic instead of glass thanks to ZAHORANSKY's advanced injection mold tooling and manufacturing equipment. This is accompanied - due to the elimination of the risk of breakage - by advantages in storage and handling in doctors' offices, laboratories, hospitals, as well as in emer[1]gency medical services. The special feature: In this special application, sterilization could be completely dispensed, since the product runs directly into aseptic filling after production via injection stretch blow molding - a novelty in this area.

Continuous aseptic production

To ensure the aseptic production of this special product, the injection stretch blow molding tool and the assembly unit work together in a class 6 clean room cell. The vial is removed directly from the injection molding chamber and sealed without leaving the sterile environment.
In the next steps, the pre-assembled container is ejected from the system, transported to the filling system via a transport unit, filled and finally fed to the packaging machine.
The continuous aseptic production of the main components eliminates the washing, drying, testing and sterilization processes otherwise required for glass, resulting in considerable cost savings.

Integrated Rotation Inside the Closed Mold

Z.SONIC turn is based on an advanced index plate solution with a servo-driven rotary unit. An eccentrically positioned index plate enables the rotation of components within the closed mold from the injection to the ejection position. Part removal takes place in parallel with the ongoing injection cycle and requires no additional process time.

Efficient Cooling Through Process Relocation

A key efficiency factor is the relocation of residual cooling: after injection, the parts continue cooling on the cores outside the cavity. Combined with conformal cooling, this accelerates heat removal and reduces cycle time.

Simplified Automation and Stable Processes

The concept integrates a stripping function and avoids complex relative movements. This simplifies automation integration and improves overall process stability.

Key Performance Data

• Cycle time reduction

• Increased output

• Significally educed mold weight compared to conventional solutions

Scalable and Compact System Design

Z.SONIC turn is scalable across different cavity configurations and, thanks to its compact design, enables space-efficient integration into existing production environments.