Syringe Packaging System with Oxygen Absorber for Drug Stability
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Solution Overview
Problem
Pre-filled syringes face degradation due to atmospheric oxygen, which reduces their shelf life and potency, as existing packaging methods fail to effectively minimize oxygen levels within the syringe assembly.
Innovation Solution
A syringe packaging system that includes a syringe barrel, a plunger rod, and an oxygen absorber, where the packaging member encloses the syringe barrel and plunger rod, with the oxygen absorber drawing and absorbing oxygen from the syringe barrel and the packaging compartments, using materials like polyolefin or polyester to maintain low oxygen levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional packaging methods are used for pre-filled syringes, then the packaging is simple and cost-effective, but oxygen levels remain high causing drug degradation and reduced shelf life
Solution Approach 1:
The packaging member is divided into multiple compartments (first compartment for syringe barrel, second compartment for plunger rod, third compartment for oxygen absorber) that are in gaseous communication. This segmentation allows the oxygen absorber to be separately positioned while maintaining oxygen removal efficiency throughout the entire packaging space, resolving the contradiction between packaging complexity and drug stability protection.
Solution Approach 2:
An oxygen absorber is introduced as an intermediary substance within the packaging system. The oxygen absorber actively removes oxygen from the packaging environment and draws oxygen from the syringe barrel through permeable materials, serving as a mediator between the external atmosphere and the drug-containing syringe, thereby protecting drug stability without requiring complex vacuum or inert gas filling systems.
2Duration of action of stationary object
If oxygen absorber is added to the packaging system, then oxygen levels are reduced extending shelf life, but packaging complexity increases
Solution Approach 1:
The oxygen absorber is pre-positioned within the packaging member during the packaging process, and the compartments are designed to be in gaseous communication from the outset. This preliminary arrangement ensures that oxygen removal begins immediately upon packaging, extending shelf life without requiring additional activation steps or complex mechanisms, thus minimizing the increase in packaging complexity.
Solution Approach 2:
The packaging system creates an inert-like environment by using an oxygen absorber to remove oxygen from the packaging compartments. This approach achieves the benefits of an inert atmosphere (protecting oxygen-sensitive drugs) without requiring expensive inert gases like nitrogen or argon, and without the complexity of gas filling and sealing systems, thereby extending shelf life with minimal added complexity.
3Reliability
If multiple compartments are used in packaging, then oxygen absorption efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
Multiple compartments (first, second, and third compartments) are merged into a single packaging member structure with shared gaseous communication pathways. This merging approach allows each compartment to serve its specific function (syringe barrel storage, plunger rod storage, oxygen absorber containment) while collectively achieving superior oxygen removal efficiency through the unified oxygen-absorbing environment, without requiring separate packaging assemblies that would increase manufacturing complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system significantly reduces oxygen levels within the syringe assembly, thereby extending the shelf life and maintaining the potency of oxygen-sensitive drugs by preventing oxidative degradation.
Implementation Method 1
the oxygen absorber is adapted to draw oxygen from within the syringe barrel and to absorb oxygen contained within at least one of the first compartment, the second compartment, and the third compartment of the packaging member
Data Source
AI summary
A syringe packaging system that includes a packaging member defining a first compartment, a second compartment, and a third compartment that are in gaseous communication theretogether is disclosed. The first compartment is structured to receive a syringe barrel therein, the second compartment is structured to receive a plunger rod therein, and the third compartment is structured to receive an oxygen absorber therein. With the packaging member enclosing the syringe barrel, the plunger rod, and the oxygen absorber, the oxygen absorber is adapted to draw oxygen from within the syringe barrel and to absorb oxygen contained within at least one of the first compartment, the second compartment, and the third compartment of the packaging member. The syringe packaging system of the present disclosure also allows for reduced storage space of a syringe assembly.