Jun. 26, 2025
Prefilled syringes have revolutionized drug delivery in veterinary and human medicine, merging packaging and administration into one seamless system. Comprising a barrel, plunger rod, tip cap, and piston, these injectors ensure precision dosing while reducing contamination. Yet their manufacturing efficiency hinges on a critical choice: assembly method. Understanding the two dominant approaches—Cap-Separate (Front Filling) and Plunger-Separate (Back Filling)—empowers pharma companies to optimize production workflows and cut costs.
1. Cap-Separate Assembly: The Front-Filling Solution
Ideal for: Needle-side drug loading (e.g., vaccines, biologics)
Process Flow:
Barrel and plunger pre-assembled
Tip cap packaged separately
Drug filled through needle port
Cap applied post-fill
Key Advantages:
⚡ Faster Line Speeds: Eliminates cap interference during filling
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