Syringe nest for improved aseptic filling and stoppering

Abstract

The syringe nest includes a substantially planar base and a plurality of syringe receptacles. Each receptacle includes a cylindrical wall defining an upper opening. The inner surface of the cylindrical wall has a diameter greater than the diameter of the body portion but less than the diameter of the rear flange of the syringe barrel. One or more upwardly extending ribs are positioned around the upper opening of each receptacle and limit radial movement of the syringe barrel within the receptacle through contact with the rear flange. Centering the syringe barrel within the receptacle in this manner results in an improved process for preparing prefilled syringes, particularly improved filling and stoppering steps.

Description

[Technical Field]

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 411,381, filed September 29, 2022, which is incorporated herein by reference in its entirety.

[0002] Embodiments of the present disclosure relate to syringe nests, particularly those configured to hold multiple syringe barrels during preparation of pre-filled syringes, particularly during the filling and / or stoppering steps. Summary of the Invention

[0003] Pre-filled syringes have become increasingly important in the pharmaceutical industry. To fill and seal or stopper the filled syringes, syringe barrels having a body portion, a front dispensing portion, and a rear flange are typically provided in a tray commonly known as a "syringe nest." The syringe nest is configured to hold multiple syringe barrels. For example, some syringe nests may be configured to hold 100 syringes, e.g., including 10 rows of 10 syringe barrel receptacles.

[0004] The forward dispensing portion of the syringe barrel most commonly includes either a staked needle or a luer tip configured to receive a needle attachment via a luer connection, but is sealed by a removable tip cap, e.g., a rigid needle shield in the case of a staked needle, or a tip cover in the case of a luer tip. Conventionally, the diameter of the tip cap may be similar to the diameter of the main body portion of the syringe barrel. The rear flange, which is often (but not always) circular in cross section, has a diameter larger than the diameter of the main body portion of the syringe barrel.

[0005] The syringe nest includes a substantially planar base and a plurality of syringe receptacles, or wells, defined within the base. Each receptacle includes a cylindrical wall defining an upper and lower opening. The inner diameter of the cylindrical wall is larger than the diameter of the syringe barrel's body (and the diameter of the tip cap) but smaller than the diameter of the rear flange, such that the syringe barrel can be inserted downward into the upper opening until the rear flange seats on the top surface of the cylindrical wall. Typically, a forward dispensing portion sealed by a removable tip cap and some portion of the syringe barrel's body extend from the receptacle's lower opening. Because removable tip caps conventionally have a diameter similar to that of the syringe barrel's body, each receptacle can be configured such that the inner diameter of the cylindrical wall is slightly larger than the diameter of the syringe barrel's body. Thus, radial, or lateral, movement of the syringe barrel within the receptacle is restricted.

[0006] Syringe barrels are typically filled using an aseptic filling machine. During the aseptic filling process, a syringe nest containing multiple syringe barrels is aligned with a fixture containing multiple filling needles (the number of filling needles corresponds to the number of syringe barrels held by the syringe nest, i.e., the number of receptacles in the nest). The filling needles are then inserted into the lumen of the syringe barrel through the rear opening. A predetermined volume of injectable medical solution is deposited in the lumen, and the filling needles are then removed.

[0007] After the syringe barrel is filled and before the filled syringe barrel leaves the aseptic environment, the rear opening of the lumen is stoppered to seal the fluid-containing lumen. For this purpose, the syringe nest aligns with the plunger nest, which is also called the stopper nest. The plunger nest includes a plurality of plungers, that is, the number of plungers corresponding to the number of syringe barrels held by the syringe nest, that is, the number of receptacles in the syringe nest. Both the syringe nest and the plunger nest align with a fixture including a plurality of plunger insertion rods, and the plunger nest is positioned directly between the syringe nest and the plunger insertion rods. A vacuum is achieved within the aseptic chamber to remove air that could prevent the installation of the plungers, that is, the stoppers. Next, the plunger insertion rods, which may also be called needles, are arranged to contact the plurality of plungers so as to push the plungers out of the plunger nest and push them into the lumen of the syringe barrel until they reach a predetermined position along the axis of the syringe barrel.

[0008] The filling and stoppering processes are typically fully automated, and the movement of the components is controlled through one or more central processors.

[0009] Once the syringe barrel is filled and stoppered, it can be referred to as a pre-filled syringe. A syringe nest containing a plurality of pre-filled syringes is typically inserted into a barrel. The barrel typically includes a shoulder portion where the substantially planar base of the syringe nest seats, thereby placing the plurality of pre-filled syringes within an internal space defined by the sidewall of the barrel. Next, a cover is sealed to the barrel to enclose the syringe nest and the pre-filled syringes therein.

[0010] In embodiments of the present invention, it may be desirable to utilize tamper-evident tip caps. In this way, the pre-filled syringe will immediately indicate to the medical professional whether the tip cap has been removed previously.

[0011] However, the tamper-evident tip cap may have a diameter significantly larger than the diameter of the syringe barrel's body portion. Because the syringe barrel is first inserted into the receptacle at the syringe nest's dispensing end, the inner diameter of the cylindrical wall of each receptacle must be large enough to accommodate the increased diameter of the tip cap, i.e., the inner diameter of the cylindrical wall of each receptacle must be at least slightly larger than the diameter of the tip cap. This results in a gap between the syringe barrel's body portion and the inner surface of the cylindrical wall, which allows radial movement of the syringe barrel within the receptacle.

[0012] During filling of the syringe barrel, the fill needle must be aligned with the rear opening of the syringe barrel held by the syringe nest. Similarly, during subsequent stoppering of the syringe barrel, the plunger must be aligned with the rear opening of the syringe barrel held by the syringe nest. To prevent complications arising from improper alignment, it has now been determined that radial movement of the syringe barrel within the syringe nest should be reduced.

[0013] Embodiments of the present disclosure are directed to a syringe nest that includes one or more ribs positioned around the top opening of each receptacle, the one or more ribs configured to limit radial movement of the syringe barrel within the receptacle through contact between the one or more ribs and an outer surface of the rear flange of the syringe barrel.

[0014] Some embodiments of the present disclosure are directed to a syringe nest including a substantially planar base and a plurality of receptacles, each sized and configured to receive a syringe barrel having a body portion, a front dispensing portion, and a rear flange. Each receptacle includes a cylindrical wall defining an upper opening. The diameter of each receptacle, measured from the inner surface of the cylindrical wall, is greater than the diameter of the body portion of the syringe barrel but less than the diameter of the rear flange of the syringe barrel it is configured to receive. One or more upwardly extending ribs are positioned around the upper opening of each receptacle. The one or more ribs are configured to limit radial movement of the syringe barrel within the receptacle through contact between the inner surface of the one or more ribs and the outer surface of the syringe flange. By limiting radial movement, the one or more ribs are configured to maintain each of the plurality of syringe barrels substantially centered within the receptacle.

[0015] Embodiments of the present disclosure are also directed to a syringe nest, such as those described above, and a plurality of syringe barrels positioned within a plurality of receptacles. Some embodiments, for example, are directed to (a) a syringe nest including a substantially planar base and a plurality of receptacles, and (b) a plurality of syringe barrels, each of which is removably positioned within one of the plurality of receptacles. Each syringe barrel includes a body portion, a front dispensing portion, and a rear flange. The diameter of each receptacle, measured from the inner surface of the cylindrical wall, is greater than the diameter of the body portion of the syringe barrel but less than the diameter of the rear flange of the syringe barrel located therein. The syringe nest further includes one or more upwardly extending ribs positioned around the top opening of each of the plurality of receptacles. The one or more ribs limit radial movement of the syringe barrel positioned within the receptacle through contact between the inner surface of the one or more ribs and the outer surface of the syringe flange. By limiting radial movement in this manner, the one or more ribs maintain each of the plurality of syringe barrels substantially centered within the receptacle.

[0016] In some embodiments, the one or more ribs may be a single rib that extends around the perimeter of the top opening of the receptacle. Alternatively, in some embodiments, the one or more ribs may include two or more ribs, each of which extends around a portion of the perimeter of the top opening of the receptacle.

[0017] In some embodiments, at least a portion of the cylindrical wall of each of the receptacles may extend upwardly from a substantially planar base. In such embodiments, one or more ribs may extend upwardly from a top surface of the cylindrical wall. Alternatively, in some embodiments, the top opening of each of the receptacles may be substantially planar with the top surface of the substantially planar base. In such embodiments, one or more ribs may extend upwardly from the top surface of the substantially planar base.

[0018] In some embodiments, the cylindrical wall of each receptacle may also define a lower opening.

[0019] In some embodiments, the one or more ribs may have an inner surface configured to be positioned 1.5 mm or less, alternatively 1.25 mm or less, alternatively 1.0 mm or less, alternatively 0.75 mm or less, or alternatively 0.50 mm or less, from an outer surface of a flange of a syringe barrel that an associated receptacle is configured to receive, when the syringe barrel is centered within the receptacle. In some embodiments including multiple syringe barrels, the one or more ribs may have an inner surface that is positioned 1.5 mm or less, alternatively 1.25 mm or less, alternatively 1.0 mm or less, alternatively 0.75 mm or less, or alternatively 0.50 mm or less, from a flange of a syringe barrel positioned within an associated receptacle, when the syringe barrel is centered within the receptacle.

[0020] In any embodiment, the one or more ribs may be positioned at a radial distance from the inner surface of the cylindrical wall, i.e., from the periphery of the top opening of the receptacle, selected to provide a desired restriction on movement of the syringe barrel that the receptacle is configured to receive. In some embodiments, the inner surface of the one or more ribs may be positioned about 0.50 mm to about 2.0 mm from the top opening of the receptacle (i.e., the inner surface of the cylindrical wall), alternatively about 0.75 mm to about 1.75 mm from the top opening of the receptacle, alternatively about 1.0 mm to about 1.5 mm from the top opening of the receptacle.

[0021] In some embodiments, each of the one or more ribs may have a chamfered surface configured to direct a flange of the syringe barrel toward the top opening of the receptacle during insertion of the syringe barrel into the receptacle.

[0022] In some embodiments, the diameter of the inner surface of the cylindrical wall may be at least 3 mm larger than the diameter of the body portion of the syringe barrel that the associated receptacle receives, alternatively, may be at least 4 mm larger than the diameter of the body portion of the syringe barrel, or alternatively, may be at least 5 mm larger than the diameter of the body portion of the syringe barrel.

[0023] In some embodiments, the syringe barrel may include a fixed needle and a removable needle shield. In some embodiments, the needle shield may be a tamper-evident needle shield. In some embodiments, the needle shield may have a diameter larger than the diameter of the body portion of the syringe barrel and smaller than the diameter of the rear flange of the syringe barrel. Alternatively, in some embodiments, the syringe barrel may include a luer tip and a removable tip cover. In some embodiments, the tip cover may be a tamper-evident tip cover. In some embodiments, the tip cover may have a diameter larger than the diameter of the body portion of the syringe barrel and smaller than the diameter of the rear flange of the syringe barrel.

[0024] In some embodiments, each of the plurality of syringe barrels may have a volume of 1 mL or less, optionally less than 1 mL, optionally 0.75 mL or less, optionally less than 0.75 mL, optionally 0.5 mL or less, and optionally a syringe barrel may have a volume of about 0.5 mL.

[0025] The syringe nest of any embodiment can be made of any desired material. In some embodiments, the syringe nest can be made of plastic. For example, the syringe nest can be made of polypropylene. In any embodiment, the syringe nest can also be injection molded.

[0026] The syringe nest of any embodiment may have any desired number of receptacles, in some embodiments, the syringe nest may have 50 to 100 receptacles.

[0027] Embodiments of the present disclosure are also directed to a nested set of syringe barrels including: (a) a syringe nest of any embodiment described herein; and (b) a plurality of syringe barrels, each of which is received within one of a plurality of receptacles of the syringe nest. Each of the syringe barrels may include a removable needle shield or removable tip cap sealing a dispensing opening, and optionally a tamper-evident removable needle shield or removable tip cap.

[0028] Embodiments of the present disclosure are also directed to a nested set of pre-filled syringes including (a) a syringe nest of any embodiment described herein, and (b) a plurality of pre-filled syringes, each having a syringe barrel received in one of the plurality of receptacles of the syringe nest. Each of the pre-filled syringes may include a removable needle shield or removable tip cap sealing a dispensing opening, an optional tamper-evident removable needle shield or removable tip cap, an injectable medical solution within the lumen of the syringe barrel, and a plunger sealing a rear opening of the lumen.

[0029] Embodiments of the present disclosure are also directed to a package of prefilled syringes, including: (a) a syringe nest of any of the embodiments described herein; (b) a plurality of prefilled syringes, each having a syringe barrel received in one of the receptacles of the syringe nest; (c) a tub including a shoulder on which the syringe nest seats such that the prefilled syringes are positioned within an interior of the tub defined by the tub sidewalls; and (d) a cover sealed to the tub and enclosing the prefilled syringes. Each of the prefilled syringes may include a removable needle shield or removable tip cap that seals the dispensing opening, an optional tamper-evident removable needle shield or removable tip cap, an injectable medical solution within the lumen of the syringe barrel, and a plunger that seals the rear opening of the lumen. In some embodiments, the cover may be a flexible membrane.

[0030]

[0006] Embodiments of the present disclosure are also directed to a method for preparing a plurality of pre-filled syringes, including a stoppering step in which a plurality of plungers are inserted into the lumens of a plurality of syringe barrels. In the stoppering step, the plurality of syringe barrels are held within a syringe nest of any embodiment described herein, and a plurality of plungers are held within the plunger nest. The plunger nest is then aligned with the syringe nest, and a fixture including a plurality of plunger insertion rods pushes the plurality of plungers out of the plunger nest and into the lumens of the syringe barrels a desired distance. Ribs on the syringe nest can ensure that each of the plurality of syringe barrels is substantially centered within a receptacle of the syringe nest during the stoppering step.

[0031]

[0006] Embodiments of the present disclosure are also directed to a method for preparing a plurality of pre-filled syringes, including a filling step in which a medical solution is injected into the lumens of a plurality of syringe barrels. In the filling step, the plurality of syringe barrels are held within a syringe nest of any embodiment described herein. Then, a plurality of filling needles are inserted into the lumens of the syringe barrels, and the injectable medical solution is injected from the filling needles into the lumens of the plurality of syringe barrels. Ribs on the syringe nest can ensure that each of the plurality of syringe barrels is substantially centered within a receptacle of the syringe nest during the filling step.

[0032] Embodiments of the present disclosure are also directed to a method of preparing a plurality of pre-filled syringes, the method including a stoppering step such as that described above and a filling step such as that described above. The ribs of the syringe nest may ensure that each of the plurality of syringe barrels is substantially centered within the receptacle of the syringe nest during both the stoppering step and the filling step.

[0033] As used herein, a syringe barrel that is substantially centered within a receptacle means that the syringe barrel is positioned within the receptacle such that the fill needle and / or plunger, aligned with the center of the receptacle, enters the rear opening of the syringe barrel.

[0034] For purposes of this disclosure, the syringe barrels are shown and described as having rear flanges that are circular in cross section, however, it should be understood that the concepts described herein are equally applicable to syringe barrels having rear flanges that are not circular in cross section.

[0035] While the present disclosure refers to tamper-resistant tip caps as having a diameter significantly larger than the body portion of the syringe barrel to which they are attached, it should be recognized that any tip cap, whether tamper-resistant or not, may have a diameter significantly larger than the body portion of the syringe barrel to benefit from the use of the syringe nest embodiments described herein to reduce radial movement of the syringe barrel within the nest. [Brief explanation of the drawings]

[0036] [Figure 1] FIG. 1 is a perspective view of one embodiment of a syringe nest having a plurality of pre-filled syringes received therein and a tub configured to hold the syringe nest. [Figure 2] FIG. 2 is a perspective cross-sectional view of a portion of a syringe nest according to an embodiment disclosed herein. [Figure 3] FIG. 3 is a cross-sectional side view of a well (ie, receptacle) of a syringe nest according to an embodiment disclosed herein, showing an exemplary syringe barrel received therein. [Figure 4] FIG. 4 is a perspective view of a system for stoppering multiple syringe barrels according to an embodiment disclosed herein. [Figure 5] FIG. 5 is a side cross-sectional view of a system for stoppering multiple syringe barrels according to an embodiment disclosed herein. [Figure 6] FIG. 6 is a top view of a syringe nest according to an embodiment disclosed herein. [Figure 7]FIG. 7 is a cross-sectional side view of a well (ie, receptacle) of a syringe nest according to an embodiment disclosed herein. [Figure 8] FIG. 8 is a top view of an embodiment of a receptacle illustrating the radial movement of a syringe barrel within the receptacle that may be tolerated without the presence of one or more ribs disclosed herein. [Figure 9] FIG. 9 is a perspective view of one embodiment of a 0.5 mL syringe barrel with a tamper-evident tip cap. [Figure 10] FIG. 10 is a cross-sectional side view of a well (i.e., receptacle) of a syringe nest according to an embodiment disclosed herein, showing the gap between the body portion of the syringe barrel and the inner surface of the cylindrical wall of the receptacle when the syringe barrel is centered in the receptacle. [Figure 11] FIG. 11 is a cross-sectional side elevation view of a portion of a well (i.e., receptacle) of a syringe nest according to an embodiment disclosed herein, showing the distance between the outer surface of the flange of the syringe barrel and the inner surface of one or more ribs when the syringe barrel is centered in the receptacle. [Figure 12] FIG. 12 is a side cross-sectional view of a portion of a system for stoppering multiple syringe barrels according to embodiments disclosed herein, showing alignment of the wells of the plunger nest with the wells of the syringe nest according to embodiments disclosed herein and prior to insertion of the plungers into the lumens of the syringe barrels. DETAILED DESCRIPTION OF THE INVENTION

[0037] The present disclosure will now be more fully described with reference to the accompanying drawings, which illustrate several embodiments. However, the present invention may be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein. Rather, these embodiments are examples of the present invention, which has full scope as indicated by the language of the claims. Like reference numerals refer to like or corresponding elements throughout. The following disclosure relates to all embodiments unless specifically limited to a particular embodiment.

[0038] Embodiments of the present disclosure are directed to syringe nests (either by themselves or in combination with multiple syringe barrels or pre-filled syringes contained therein) that are configured to limit radial movement of syringe barrels received within the wells of the syringe nest. An example of such a syringe nest 10 is shown in Figures 2-3.

[0039] However, before describing syringe nest 10, a brief description of a syringe barrel is necessary, an example of which is also shown in Figures 2-3. Syringe barrel 100 includes a body portion 101, a front dispensing portion 102, and a rear flange 103. The cylindrical sidewall of syringe barrel 100 defines a central lumen 104, which is accessible through a rear opening 105 prior to stoppering. Prior to placement within syringe nest 10, front dispensing portion 102 is provided with a removable tip cap 120.

[0040] The removable tip cap 120 may take any of several configurations, including, for example, a rigid needle shield (e.g., if the syringe is a fixed needle syringe) or a tip cover (e.g., if the syringe has a Luer-fit tip). Additionally, in some embodiments, the removable tip cap 120 may include a tamper-evident component.

[0041] The body portion 101 of the syringe barrel has a first diameter, identified as D1 in Figure 3. The front dispensing portion 102, with the attached tip cap 120, has a second diameter, identified as D2 in Figure 3. The rear flange 103 has a third diameter, identified as D3 in Figure 3. As shown in Figure 3, the diameter D3 of the rear flange is larger than the diameter of the body portion D1, and the diameter of the front dispensing portion with the attached tip cap D2 may be smaller than the diameter D3 of the rear flange, but may be significantly larger than the diameter of the body portion D1 (to the extent that the radial movement problems described herein arise).

[0042] In some embodiments, the syringe barrel may include a small-volume lumen. For example, in some embodiments, the syringe barrel may have a volume of 1 mL or less, alternatively less than 1 mL, alternatively 0.75 mL or less, alternatively less than 0.75 mL, alternatively 0.5 mL or less, alternatively 1 mL or 0.5 mL, or alternatively 0.5 mL. In some embodiments, the pre-filled syringe may have a fill volume of approximately 300 microliters (0.3 mL) of injection solution. An example of a 0.5 mL syringe barrel 100 with a relatively high-diameter tamper-evident tip cap 120 is shown in FIG. 9.

[0043] In some embodiments, syringe barrel 100 may have a diameter D1 of body portion 101 that is about 7 to about 9 millimeters, alternatively about 7 to about 8 millimeters. In some embodiments, syringe barrel 100 may have a diameter D2 of tip cap 120 that is about 10 to about 13 millimeters, alternatively about 11 to about 12 millimeters. In some embodiments, syringe barrel 100 may have a diameter D3 of flange 103 that is about 12 to about 15 millimeters, alternatively about 13 to about 14 millimeters.

[0044] Returning to the syringe nest, embodiments of the syringe nest 10 disclosed herein may include a planar or substantially planar base 11 and a plurality of syringe receptacles 12, i.e., wells, defined within the base. Each syringe receptacle 12 includes a cylindrical wall 13 having an inner surface 14 spanning and defining an upper opening 15 and a lower opening 17. Each syringe receptacle 12 is sized and configured to receive a syringe barrel 100.

[0045] For example, cylindrical wall 13 has an inner surface 14 with a diameter identified as D4 in Figure 3, which is large enough to receive a tip cap 120 attached to syringe barrel body portion 101 and syringe barrel forward dispensing portion 102. When the diameter of the syringe barrel forward dispensing portion with attached tip cap D2 is larger than the diameter D1 of the syringe barrel body portion, as in the illustrated embodiment, the result is a gap G between syringe barrel body portion 101 and inner surface 14 of cylindrical wall 13.

[0046] However, inner surface 14 of cylindrical wall 13 has a diameter D4 that is smaller than diameter D3 of rear flange 103 of the syringe barrel. In this manner, rear flange 103 of the syringe barrel seats on top surface 16 of the cylindrical wall, thereby preventing syringe barrel 100 from sliding completely through receptacle 12. In the illustrated embodiment, cylindrical wall 12 extends upward from base 11 to top surface 16. However, in other (not shown) embodiments, cylindrical wall 12 may extend downward from base 11 such that top surface 16 of cylindrical wall 12 is part of the upper surface of the base. In some embodiments, syringe nest 10 may be configured to hold syringe barrels having a volume of 1 mL or more, for example, syringe barrels having a volume of 1 mL to 3 mL.

[0047] Syringe nest 10 also includes one or more ribs 20 positioned around the top opening 15 of each receptacle 12, for example, on the top surface 16 of cylindrical wall 12. As shown in FIGS. 2-3 , one or more ribs 20 extend upwardly from the top surface 16 of cylindrical wall 12. The particular height of one or more ribs 20 is important only in that the height is sufficient to provide abutting contact with the outer surface of rear flange 103 of syringe barrel 100, but not so high as to interfere with the processing to which syringe nest 10 is subjected, such as filling and stoppering processes, sealing of a tub containing the nest, etc.

[0048] In the illustrated embodiment, the one or more ribs 20 comprise a pair of ribs, each of which extends around slightly less than halfway around the circumference of the top opening 15 of the receptacle 12, resulting in a small gap between the first and second ribs. In other (not shown) embodiments, the one or more ribs 20 may be a single rib that extends around the entire circumference of the top opening 15 of the receptacle 12. In still other (not shown) embodiments, the one or more ribs 20 may include any number of ribs, such as three ribs, four ribs, five ribs, six ribs, etc., spaced apart around the circumference of the top opening 15 of the receptacle 12.

[0049] The one or more ribs 20 are configured to limit radial movement of the syringe barrel 100 within the receptacle by providing abutting contact between the one or more ribs and the outer surface of the syringe barrel rear flange 103. By doing so, the one or more ribs 20 are configured to keep the syringe barrel 100 substantially centered within the receptacle 12.

[0050] Desirably, one or more ribs 20 may be positioned to provide an inner abutment contact surface having a diameter that is close to (but larger than) the diameter of the rear flange 103 of the particular type of syringe barrel 100 for which, for example, the syringe nest 10 is specifically designed.

[0051] In some embodiments, for example, one or more ribs 20 may be configured to be positioned 1.5 mm or less from the outer surface of rear flange 103 when the syringe barrel is centered within receptacle 12 (meaning that the diameter of one or more ribs, as measured from one side of receptacle top opening 15 to the other side of the receptacle top opening, can be within 3.0 mm of the diameter D3 of the rear flange); alternatively, one or more ribs may be configured to be positioned 1.5 mm or less from the outer surface of rear flange 103 when the syringe barrel is centered within receptacle 12. (meaning that the diameter of the one or more ribs can be within 2.5 mm of the diameter D3 of the rear flange when measured from the inner surface of the rib on one side of the top opening of the receptacle to the inner surface of the rib on the opposite side of the top opening of the receptacle), or alternatively, the one or more ribs can be configured to be positioned 1.0 mm or less from the outer surface of the rear flange 103 when the syringe barrel is centered within the receptacle 12. (meaning that the diameter of the one or more ribs may be within 2.0 mm of the diameter D3 of the rear flange when measured from one side of the top opening of the receptacle to the opposite side of the top opening of the receptacle), or alternatively, the one or more ribs may be configured to be positioned 0.75 mm or less from the outer surface of the rear flange 103 when the syringe barrel is centered within the receptacle 12 (meaning that the diameter of the one or more ribs may be within 2.0 mm of the diameter D3 of the rear flange when measured from one side of the top opening of the receptacle to the opposite side of the top opening of the receptacle). When the syringe barrel is centered within the receptacle 12, the one or more ribs may be configured to be positioned 0.5 mm or less from the outer surface of the rear flange 103 (meaning that the diameter of the one or more ribs may be within 1.0 mm of the diameter D3 of the rear flange when measured from one side of the top opening of the receptacle to the other side of the top opening of the receptacle).

[0052] Thus, in these embodiments, radial, i.e., lateral, movement of the syringe barrel may be limited to no more than 1.5 mm from the central position, alternatively no more than 1.25 mm from the central position, alternatively no more than 1.0 mm from the central position, alternatively no more than 0.75 mm from the central position, alternatively no more than 0.50 mm from the central position.

[0053] In some embodiments, depending on the surface area of ​​the top surface 16 of the cylindrical wall supporting the rear flange 103 of the syringe barrel 100, the one or more ribs 20 may be positioned such that the inner surface of the one or more ribs is about 0.50 mm to about 2.0 mm from the top opening 15 of the receptacle 12, alternatively about 0.75 mm to about 1.75 mm from the top opening of the receptacle, alternatively about 1.0 mm to about 1.5 mm from the top opening of the receptacle.

[0054] In some embodiments, the difference between D4 and D1 may be at least 4 mm, meaning that in the absence of one or more ribs 20 of the present disclosure, the syringe barrel 100 can move radially from the center position by 2 mm or more in any direction, i.e., the gap G is at least 2 mm. In some embodiments, the difference between D4 and D1 may be at least 5 mm, meaning that in the absence of one or more ribs 20 of the present disclosure, the syringe barrel 100 can move radially from the center position by 2.5 mm or more in any direction, i.e., the gap G is at least 2.5 mm. For example, in some embodiments, the difference between D4 and D1 may be about 4 mm to about 7 mm, meaning that in the absence of one or more ribs 20 of the present disclosure, the syringe barrel 100 can move radially from the center position by about 2 mm to about 3.5 mm in any direction, i.e., the gap G is about 2 mm to about 3.5 mm.

[0055] An example of syringe barrel movement that may occur without the ribs 20 of the present disclosure is shown in FIG. 8. As shown in FIG. 8, the body portion 101 of a syringe barrel held within the receptacle 12 of the syringe nest can move from any radially centered position (three examples of which are shown). Such radial movement of the syringe barrel 101 can cause a filling needle used during the filling process, which is preferably aligned with the center of the receptacle, to contact a portion of the syringe barrel (e.g., the top surface of the flange 103, the inner surface of the wall defining the lumen, etc.), resulting in improper filling and / or damage to the syringe barrel, the filling device, or both. Similarly, large radial movements of the syringe barrel 101 can cause the plunger during the stoppering process to contact a portion of the syringe barrel (e.g., the top surface of the flange 103), which can have similar undesirable effects, such as not stoppering the filled syringe barrel and / or causing damage to the syringe barrel, the stoppering device, or both. More abrupt radial movement of the syringe barrel 101 within the receptacle 12 can result in the plunger being inserted into the lumen of the syringe barrel, but in a manner that does not provide a proper seal and therefore receptacle closure integrity (CCI).

[0056] If one or more ribs 20 are positioned to provide an inner surface that is closer to the outer surface of the rear flange 103 of a syringe barrel 100 inserted into the receptacle 12, it may be desirable to provide one or more ribs 20 with a chamfered or sloped surface 21 configured to orient the syringe barrel flange toward the receptacle's top opening 15 during insertion of the syringe barrel into the receptacle. An example of such a chamfered surface 21 is shown in FIG. 2. By providing a sloped transition between the top surface and the inner surface of each of the one or more ribs 20, if the syringe barrel 100 is not perfectly aligned with the receptacle 12 when inserted, the syringe barrel's rear flange 103 will contact the chamfered surface 21 and orient the syringe barrel for better alignment with the receptacle.

[0057] Embodiments of the syringe nest 10 of the present disclosure can be used to hold multiple syringe barrels 100 during a method of preparing multiple pre-filled syringes, including, for example, during a filling step, a stoppering step, or both. By reducing radial movement of the syringe barrels 100 within the receptacle 12 of the syringe nest 10, i.e., by keeping each of the syringe barrels substantially centered within the receptacle, the ribs 20 help ensure the filling inserts (also called filling needles). More importantly, the plungers 130 are properly aligned with the multiple syringe barrels during the filling and / or stoppering process, given the close dimensional tolerances between the plungers and the interior walls of the syringe barrels 100 into which they are inserted.

[0058] Accordingly, embodiments of the present disclosure are directed to a method of preparing a plurality of pre-filled syringes. The method may include a filling step, a stoppering step, or both, in which a plurality of syringe barrels 100 are positioned within receptacles 12 of a syringe nest 10 according to embodiments of the present disclosure. Each of the syringe barrels 100 may include a removable tip cap 120 whose diameter is larger than the diameter of the syringe barrel's body portion 101. The syringe nest 10 may also include one or more ribs 20 around the top opening 15 of each receptacle 12 configured to hold each syringe barrel substantially stable, i.e., limited to radial movement and centered within the receptacle.

[0059] In some embodiments, the method may include a step of inserting multiple plungers into the lumens of multiple syringe barrels, i.e., a stoppering step. Examples of systems that may be used in the stoppering step are shown, for example, in FIGS. 4-5 . In such a step, multiple syringe barrels 100 are held in receptacles 12 of one embodiment of the syringe nest 10 disclosed herein, and multiple plungers 30 are held in a plunger nest 300. For example, as shown in FIG. 5 , the syringe nest 10 and plunger nest 300 are aligned so that each plunger 30 is positioned substantially directly above the rear opening 105 of the syringe barrel 100. One or more ribs 20 surrounding each receptacle 12 of the syringe nest 10 ensure that each of the multiple syringe barrels 100 is substantially centered within the receptacle 12 of the syringe nest and is therefore positioned to receive a plunger 30. Next, a fixture including multiple plunger insertion rods 400 is operated to push each plunger 30 out of the plunger nest 300 and into the lumen 104 of the syringe barrel 100 held within the syringe nest 10.

[0060] In some embodiments, the method may include filling the lumens of multiple syringe barrels with an injectable medical solution. In such a step, multiple syringe barrels 100 are held within a syringe nest 10 as disclosed herein. The syringe nest 10 is then aligned with a fixture containing multiple fill needles, with the fill needles positioned substantially directly above the rear opening 105 of each syringe barrel 100. One or more ribs 20 surrounding each receptacle 12 of the syringe nest 10 ensure that each of the multiple syringe barrels 100 is substantially centered within the receptacle of the syringe nest and therefore properly positioned to receive the fill needle. The multiple fill needles are then inserted into the lumens 104 of the syringe barrels 100 through the rear opening 105, and the injectable medical solution is injected through the fill needles into the lumens of the multiple syringe barrels until a desired amount of solution is present in the lumens. The filling needle is then removed from the lumen 104 of the syringe barrel 100, and the syringe nest 10 can be transported to a stoppering station where the syringe barrel can be stoppered, for example, as described herein.

[0061] Embodiments of the present disclosure are also directed to a package of pre-filled syringes, where the pre-filled syringes are positioned within the receptacle 12 of a syringe nest 10 according to embodiments of the present disclosure. An example of such a package is shown in FIG. 1. The package may include a syringe nest 10 as described herein, a plurality of pre-filled syringes, and a tub 200 in which the syringe nest is held. The tub 200 may include a shoulder on which the syringe nest 10 rests, such that the syringe nest 10 and the syringes contained therein are positioned within the interior of the tub as defined by the tub's sidewalls. Typically, the syringes may be suspended above the tub's bottom wall. The package may also include a removable cover, such as a flexible membrane sealed to the tub's top flange. The tub may be constructed in accordance with ISO 11040-7.

[0062] In some embodiments, the nest 10 may be made of plastic. For example, the nest 10 may be made of polypropylene. In some embodiments, the nest 10 may be a single, integral part. For example, in some embodiments, the nest 10 may be injection molded from a plastic material, such as polypropylene.

[0063] In some embodiments, nest 10 may include 100 receptacles, for example, 10 rows of 10 receptacles.

[0064] Illustrative Embodiments 1. a substantially planar base; a plurality of syringe receptacles, each of the receptacles including a cylindrical wall defining an upper opening; each of the receptacles is sized and configured to receive a syringe barrel having a body portion, a forward dispensing portion, and a rearward flange; a plurality of syringe receptacles, each having an inner surface of a cylindrical wall having a diameter greater than the diameter of the body portion of the syringe barrel but less than the diameter of the rear flange; one or more upwardly extending ribs positioned around the top opening of each receptacle; The syringe nest, wherein the one or more ribs are configured to limit radial movement of the syringe barrel within the receptacle through contact between the one or more ribs and an outer surface of the syringe flange. 2. a substantially planar base; a plurality of syringe receptacles, each of the receptacles including a cylindrical wall defining an upper opening; each of the receptacles is sized and configured to receive a syringe barrel having a body portion, a front dispensing portion, and a rear flange; a plurality of syringe receptacles, each having an inner surface of a cylindrical wall having a diameter greater than the diameter of the body portion of the syringe barrel but less than the diameter of the rear flange; one or more upwardly extending ribs positioned around the top opening of each receptacle; The syringe nest, wherein one or more ribs are configured to maintain each of the plurality of syringe barrels substantially centered within the receptacle. 3. 3. A syringe nest according to any one of embodiments 1 to 2, further comprising a syringe barrel having a body portion, a front dispensing portion, and a rear flange positioned within each receptacle. 4. a substantially planar base; a plurality of syringe receptacles, each of the receptacles including a cylindrical wall defining an upper opening; a plurality of syringe barrels, each syringe barrel removably positioned within one of the plurality of receptacles, each syringe barrel having a body portion, a front dispensing portion, and a rear flange; one or more upwardly extending ribs positioned around the top opening of each receptacle; the inner surface of the cylindrical wall has a diameter greater than the diameter of the body portion of the syringe barrel but less than the diameter of the rear flange; and A syringe nest, wherein one or more ribs limit radial movement of the syringe barrel within the receptacle through contact between the one or more ribs and an outer surface of the syringe flange. 5. a substantially planar base; a plurality of syringe receptacles, each of the receptacles including a cylindrical wall defining an upper opening; a plurality of syringe barrels, each syringe barrel removably positioned within one of the plurality of receptacles, each syringe barrel having a body portion, a front dispensing portion, and a rear flange; one or more upwardly extending ribs positioned around the top opening of each receptacle; the inner surface of the cylindrical wall has a diameter greater than the diameter of the body portion of the syringe barrel but less than the diameter of the rear flange; and A syringe nest, wherein one or more ribs maintain each of the plurality of syringe barrels substantially centered within the receptacle. 6. A syringe nest according to any one of embodiments 1 to 5, wherein the one or more ribs include a single rib extending around the periphery of the top opening of the receptacle. 7. A syringe nest according to any one of embodiments 1 to 6, wherein the one or more ribs include two or more ribs, each of which extends around a portion of the periphery of the top opening of the receptacle. 8. A syringe nest described in any of embodiments 1 to 7, wherein at least a portion of the cylindrical wall of the receptacle extends upward from the base and one or more ribs extend from the top surface of the cylindrical wall. 9. A syringe nest according to any one of embodiments 1 to 8, wherein the upper opening of the receptacle is substantially planar with the upper surface of the base, and one or more ribs extend upward from the upper surface of the base. 10. A syringe nest according to any one of embodiments 1 to 9, wherein the cylindrical wall of each receptacle also defines a lower opening. 11. 11. A syringe nest as described in any of embodiments 1 to 10, wherein the one or more ribs are configured to have an inner surface that is positioned no more than 1.5 mm, alternatively no more than 1.25 mm, alternatively no more than 1.0 mm, alternatively no more than 0.75 mm, alternatively no more than 0.50 mm from the outer surface of the flange when the syringe barrel is centered within the receptacle. 12. 12. A syringe nest according to any of embodiments 1-11, wherein the one or more ribs have an inner surface positioned no more than 1.5 mm, alternatively no more than 1.25 mm, alternatively no more than 1.0 mm, alternatively no more than 0.75 mm, alternatively no more than 0.50 mm from the flange when the syringe barrel is centered within the receptacle. 13. 13. A syringe nest according to any one of embodiments 1 to 12, wherein the one or more ribs provide an inner surface positioned about 0.50 mm to about 2.0 mm from the top opening of the receptacle, alternatively about 0.75 mm to about 1.75 mm from the top opening of the receptacle, alternatively about 1.0 mm to about 1.5 mm from the top opening of the receptacle. 14. A syringe nest described in any of embodiments 1 to 13, wherein the diameter of the inner surface of the cylindrical wall is at least 4 mm larger than the diameter of the main body portion of the syringe barrel, alternatively at least 5 mm larger than the diameter of the main body portion of the syringe barrel. 15. A syringe nest described in any of embodiments 1 to 14, wherein each of the one or more ribs includes a chamfered surface configured to orient a flange of the syringe barrel toward the top opening of the receptacle during insertion of the syringe barrel into the receptacle. 16. 16. A syringe nest according to any one of embodiments 1 to 15, wherein the syringe comprises a fixed needle and a removable needle shield. 17. 17. A syringe nest according to any one of embodiments 1 to 16, wherein the needle shield is tamper-evident. 18. 18. A syringe nest according to any one of embodiments 1 to 17, wherein the needle shield has a diameter larger than the diameter of the main part of the body of the syringe and smaller than the diameter of the rear flange. 19. 19. A syringe nest according to any one of embodiments 1 to 18, wherein the syringe comprises a luer tip and a removable tip cover. 20. 20. A syringe nest according to any one of embodiments 1 to 19, wherein the tip cover is tamper-proof. twenty one. 21. A syringe nest according to any one of embodiments 1 to 20, wherein the tip cover has a diameter larger than the diameter of the main part of the syringe body and smaller than the diameter of the rear flange. twenty two. 22. A syringe nest according to any of embodiments 1-21, wherein the nest is made of plastic, optionally the nest is made of polypropylene, and optionally the nest is injection molded. twenty three. 23. A syringe nest according to any one of embodiments 1 to 22, wherein the nest comprises 50 to 100 receptacles. twenty four. 24. A syringe nest according to any of embodiments 1-23, wherein the syringe barrel has a volume of 1 mL or less, optionally less than 1 mL, optionally 0.75 mL or less, optionally less than 0.75 mL, optionally 0.5 mL or less, optionally wherein the syringe barrel has a volume of 0.5 mL. twenty five. A set of nested syringe barrels, comprising: A syringe nest according to any one of embodiments 1 to 24; a plurality of syringe barrels, each of the plurality of syringe barrels being received within one of the plurality of receptacles; 26. A set of nested syringes, comprising: A syringe nest according to any one of embodiments 1 to 24; a plurality of syringes, each of the plurality of syringes having a syringe barrel received within one of the plurality of receptacles; Each of the plurality of syringes comprises: an injectable medical solution within the lumen of the syringe barrel; a removable needle shield or removable tip cap that seals the dispensing opening; a plunger sealing the rear opening of the lumen; and a set of nested syringes. 27. A syringe nest according to any one of embodiments 1 to 24; a plurality of syringes, each of the plurality of syringes having a syringe barrel received within one of the plurality of receptacles; a tub including a shoulder on which the syringe nest rests such that the syringe is positioned within an interior of the tub defined by tub sidewalls; a cover sealed to the tub to enclose the syringe therein; Each of the plurality of syringes comprises: an injectable medical solution within the lumen of the syringe barrel; a removable needle shield or removable tip cap that seals the dispensing opening; and a plunger that seals the rear opening of the lumen. 28. 28. A syringe package according to embodiment 27, wherein the cover is a flexible membrane. 29. 1. A method of preparing a plurality of pre-filled syringes, the method comprising: inserting a plurality of plungers into lumens of a plurality of syringe barrels; A plurality of syringe barrels are held in the syringe nest of any one of embodiments 1 to 24; A plurality of plungers are held within the plunger nest; The plunger nest aligns with the syringe nest, The method, wherein a fixture including a plurality of plunger insertion rods pushes a plurality of plungers from a plunger nest a desired distance into the lumen of the syringe barrel. 30. 1. A method of preparing a plurality of pre-filled syringes, the method comprising: filling lumens of a plurality of syringe barrels with an injectable medical solution; A plurality of syringe barrels are held in the syringe nest of any one of embodiments 1 to 24; A plurality of filling needles are inserted into the lumen of the syringe barrel; The method, wherein an injectable medical solution is injected from a fill needle into the lumen of a plurality of syringe barrels. 31. 31. The method of any of embodiments 29-30, wherein one or more ribs ensure that each of the plurality of syringe barrels is substantially centered within the receptacle of the syringe nest. 32. 1. A method of preparing a plurality of pre-filled syringes, comprising: (i) filling the lumens of a plurality of syringe barrels with an injectable medical solution; A plurality of syringe barrels are held in the syringe nest of any one of embodiments 1 to 24; A plurality of filling needles are inserted into the lumen of the syringe barrel; filling, in which an injectable medical solution is injected into the lumen of the plurality of syringe barrels through a fill needle; (ii) inserting a plurality of plungers into the lumens of a plurality of syringe barrels; A plurality of syringe barrels are held in a syringe nest; A plurality of plungers are held within the plunger nest; The plunger nest aligns with the nest, a fixture including a plurality of plunger insertion rods for pushing and inserting the plurality of plungers from the plunger nest into the lumen of the syringe barrel; The method, wherein the one or more ribs ensure that each of the plurality of syringe barrels is substantially centered within the receptacle of the nest during both the filling step and the plunger insertion step.

[0065] It will be seen that the described embodiments provide a unique and novel syringe nest having many advantages over those in the art. While certain specific structures embodying the invention have been shown and described herein, it will be apparent to those skilled in the art that various modifications and rearrangements of parts may be made without departing from the spirit and scope of the underlying inventive concept, and that these are not limited to the specific forms shown and described herein, except as indicated by the appended claims.

Claims

1. A syringe nest, comprising: a substantially planar base; a plurality of syringe receptacles, each of said receptacles including a cylindrical wall defining an upper opening; each of the receptacles is sized and configured to receive a syringe barrel having a body portion, a forward dispensing portion, and a rearward flange; a plurality of syringe receptacles, the inner surface of the cylindrical wall having a diameter greater than the diameter of the body portion of the syringe barrel but less than the diameter of the rear flange; one or more upwardly extending ribs positioned around the top opening of each receptacle; The syringe nest, wherein the one or more ribs are configured to limit radial movement of the syringe barrel within the receptacle through contact between the one or more ribs and an outer surface of the syringe flange.

2. A syringe nest, comprising: a substantially planar base; a plurality of syringe receptacles, each of the receptacles including a cylindrical wall defining an upper opening; a plurality of syringe barrels, each syringe barrel removably positioned within one of the plurality of receptacles, each syringe barrel having a body portion, a front dispensing portion, and a rear flange; one or more upwardly extending ribs positioned around the top opening of each receptacle; the inner surface of the cylindrical wall has a diameter greater than the diameter of the body portion of the syringe barrel but less than the diameter of the rear flange; and The syringe nest, wherein the one or more ribs limit radial movement of the syringe barrel within the receptacle through contact between the one or more ribs and an outer surface of the syringe flange.

3. The syringe nest of any one of claims 1 to 2, wherein the one or more ribs are configured to maintain each of the plurality of syringe barrels substantially centered within the receptacle.

4. The syringe nest of any one of claims 1 to 3, wherein the one or more ribs include a single rib extending around the periphery of the top opening of the receptacle.

5. The syringe nest of any one of claims 1 to 4, wherein the one or more ribs include two or more ribs, each of which extends around a portion of the periphery of the top opening of the receptacle.

6. A syringe nest according to any one of claims 1 to 5, wherein at least a portion of the cylindrical wall of the receptacle extends upward from the base, and the one or more ribs extend from a top surface of the cylindrical wall.

7. A syringe nest according to any one of claims 1 to 6, wherein the upper opening of the receptacle is substantially planar with the upper surface of the base, and the one or more ribs extend upward from the upper surface of the base.

8. 8. The syringe nest of any of claims 1-7, wherein the one or more ribs are configured to have an inner surface that is positioned no more than 1.5 mm, alternatively no more than 1.25 mm, alternatively no more than 1.0 mm, alternatively no more than 0.75 mm, alternatively no more than 0.50 mm from the outer surface of the flange when a syringe barrel is centered within the receptacle.

9. 9. The syringe nest of claim 1, wherein the one or more ribs provide an inner surface positioned about 0.50 mm to about 2.0 mm from the top opening of the receptacle, alternatively about 0.75 mm to about 1.75 mm from the top opening of the receptacle, alternatively about 1.0 mm to about 1.5 mm from the top opening of the receptacle.

10. 10. The syringe nest of claim 1, wherein the diameter of the inner surface of the cylindrical wall is at least 4 mm larger than the diameter of the main body portion of the syringe barrel, alternatively at least 5 mm larger than the diameter of the main body portion of the syringe barrel.

11. 11. A syringe nest according to any preceding claim, wherein each of the one or more ribs includes a chamfered surface configured to orient the flange of the syringe barrel toward the top opening of the receptacle during insertion of the syringe barrel into the receptacle.

12. 12. The syringe nest of claim 1, wherein each of the plurality of syringes includes a fixed needle and a removable needle shield, optionally a tamper-resistant removable needle shield, the needle shield having a diameter greater than the diameter of the body portion of the syringe and less than the diameter of the rear flange of the syringe.

13. 13. The syringe nest of any one of claims 1 to 12, wherein each of the plurality of syringes includes a luer tip and a removable tip cover, optionally a tamper-evident removable tip cover, the tip cover having a diameter greater than the diameter of the body portion of the syringe and less than the diameter of the rear flange of the syringe.

14. 14. The syringe nest of any of claims 1-13, wherein each of the plurality of syringe barrels has a volume of 1 mL or less, optionally less than 1 mL, optionally 0.75 mL or less, optionally less than 0.75 mL, optionally 0.5 mL or less, optionally wherein each of the plurality of syringe barrels has a volume of 0.5 mL.

15. A set of nested syringes, comprising: A syringe nest according to any one of claims 1 to 14, a plurality of syringes, each of the plurality of syringes having a syringe barrel received within one of the plurality of receptacles; Each of the plurality of syringes comprises: an injectable medical solution within the lumen of the syringe barrel; a removable needle shield or removable tip cap that seals the dispensing opening; a plunger sealing a rear opening of said lumen.

16. A syringe nest according to any one of claims 1 to 14, a plurality of syringes, each of the plurality of syringes having a syringe barrel received within one of the plurality of receptacles; a tub including a shoulder on which the syringe nest rests such that the syringe is positioned within an interior of the tub defined by tub sidewalls; a cover that is sealed to the tub to enclose the syringe therein; Each of the plurality of syringes comprises: an injectable medical solution within the lumen of the syringe barrel; a removable needle shield or removable tip cap that seals the dispensing opening; a plunger sealing a rear opening of the lumen.

17. 1. A method of preparing a plurality of pre-filled syringes, the method comprising inserting a plurality of plungers into lumens of a plurality of syringe barrels; A plurality of syringe barrels are held in the syringe nest according to any one of claims 1 to 14, A plurality of plungers are held within the plunger nest; the plunger nest is aligned with the syringe nest; A fixture including a plurality of plunger insertion rods pushes the plurality of plungers from the plunger nest a desired distance into the lumen of the syringe barrel.

18. 1. A method of preparing a plurality of pre-filled syringes, the method comprising filling lumens of a plurality of syringe barrels with an injectable medical solution; A plurality of syringe barrels are held in the syringe nest according to any one of claims 1 to 14, a plurality of filling needles inserted into the lumen of the syringe barrel; An injectable medical solution is injected through the fill needle into the lumen of the plurality of syringe barrels.

19. 1. A method of preparing a plurality of pre-filled syringes, comprising: (i) filling the lumens of a plurality of syringe barrels with an injectable medical solution; A plurality of syringe barrels are held in the syringe nest according to any one of claims 1 to 14, a plurality of filling needles inserted into the lumen of the syringe barrel; filling, in which an injectable medical solution is injected through the fill needles into the lumens of the plurality of syringe barrels; (ii) inserting a plurality of plungers into the lumens of a plurality of syringe barrels; the plurality of syringe barrels are held within the syringe nest; A plurality of plungers are held within the plunger nest; the plunger nest is aligned with the nest; and inserting a fixture including a plurality of plunger insertion rods to push the plurality of plungers from the plunger nest into the lumen of the syringe barrel; The method, wherein the one or more ribs ensure that each of the plurality of syringe barrels is substantially centered within the receptacle of the nest during both the filling step and the plunger insertion step.

20. The method of any of claims 17 to 19, wherein the one or more ribs ensure that each of the plurality of syringe barrels is substantially centered within a receptacle of the syringe nest.

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