Metal-free glass syringes for biotechnologically manufactured active ingredients

Gerresheimer's patented innovative production technology

Production of a metal-free syringe: The pin used to shape the cone with the new technology is no longer made from the tungsten usually used or an alternative metal, but instead of a special ceramic.

Biotechnologically manufactured active ingredients demonstrate a series of special features. Some are highly viscous, concentrated and in individual cases, tend to interact with silicone oil or, for example, tungsten residue from syringe production. Gerresheimer Biological Solutions offers a special metal-free manufactured syringe produced with a patented innovative production technology for these applications.

“Our metal-free syringes are especially suitable for our customers and partners who are involved in the development of biotechnologically manufactured active ingredients,” says Stefan Verheyden, global vice president Gx Biological Solutions & Sales Syringes Medical Systems. A production technology specially developed and patented by Gerresheimer ensures that the pin used for conical shaping is no longer made of the tungsten or an alternative metal usually used, but of a special ceramic.”

Metal-free technology for residue-free cone shaping

One problem associated with syringe use is that traces of tungsten or other metals occasionally leave residue behind the bore when the syringe cone is shaped. Especially for medications based on biotechnologically manufactured active ingredients, the customers require pre-fillable syringes that ideally exclude the possibility of contamination with metal.

With the development of innovative patented production technology, Gerresheimer has addressed this requirement and creates a metal-free 1 ml long Luer Lock Gx RTF syringe that is ready for series production. This process can also be transferred to other Luer Lock syringe sizes or Luer cone syringes of various sizes at any time. The pin used to shape the cone with the new technology isn’t made of conventional tungsten or alternative metal, but a special ceramic. External studies confirm that Gerresheimer can manufacture residue-free syringes for the packaging of especially sophisticated medications with this new technology. The Fresenius Institute conducted a study confirming that no ceramic residue can be detected in the syringe. A biocompatibility study also verifies the non-cytotoxicity of the ceramic material.

Gerresheimer is a leading global partner to the pharma and healthcare industry. With specialty glass and plastic products, the company contributes to health and well-being. Gerresheimer operates worldwide, and its approximately 10,000 employees manufacture products in local markets, close to its customers. With plants in Europe, the Americas, and Asia, Gerresheimer generates revenues of around EUR 1.4 billion. The comprehensive product portfolio includes pharmaceutical packaging and products for the safe, simple administration of medicines: Insulin pens, inhalers, micro pumps, prefillable syringes, injection vials, ampoules, bottles, and containers for liquid and solid medicines with closure and safety systems as well as packaging for the cosmetics industry.


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