Presented by
Management Forum

Pre-Filled Syringes: End-to-End Processing

Topics such as quality of syringe manufacture, quality of syringe components and why, quality of filling (volume check, reject reduction), quality of inspection and product release will be discussed in detail.

30-31 Mar 2022 + 1 more date

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  • Format: Live online
  • CPD: 12 hours for your records
  • Certificate of completion

Course overview

This intensive two-day course has been designed to offer a comprehensive, practical and usable review of the production of PFS and will provide the latest information on all aspects of the process from manufacture and packaging for fill/finish through to final (post-fill) inspection. Quality will be a key focus of the programme and there will be extensive coverage of improvements in the manufacturing process, including advances in cleanroom technology and sterilisation. Other sessions will address visual inspection and the latest regulatory requirements to ensure that you are fully up to date. The faculty of speakers will provide key guidance and advice from their practical experience in this field and there will be ample opportunity for discussion.

Who should attend?

This event is ideal for pharma start-ups, small and medium-sized pharma companies, CROs, CMOs, machine suppliers, hospital dispensaries, and anyone new to PFS or wanting to learn more in a relaxed and open environment. It will be of value to those working in the area of PFS with responsibility for device programmes, product development, product life cycle management, regulatory affairs, quality assurance and combination products. Drug delivery specialists, business development managers and product development managers will also find this course beneficial.

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The Pre-Filled Syringes: End-to-End Processing course will cover:

Syringe manufacture from components to the final product – an overview

  • The initial choice – bulk or pre-sterilised components?
  • Siliconisation – not beloved, but required
  • Handling and filling overview

PFS over time

  • Evolution of components
  • Evolution of processes and equipment
  • Evolution of application and application systems

PFS for biotech: improvement in the manufacturing processes

  • Controlled tungsten
  • Optimised silicone oil
  • Tighter controlled dimensions • Fit-for-device function

Trends with PFS

  • New PFS formats
  • Safety devices
  • Self-injection devices
  • Leachable and extractable considerations

Filling and closing: multi-format machine for nested syringes, vials and cartridges

  • Dosing and filling systems in comparison
  • Closing methods and their applications
  • Format parts – easy to change
  • Containment

Secondary packaging of PFS/vials/cartridges

  • Materials/dimensional requirements
  • Compatibility with existing filling lines
  • Handling of ready-to-fill vials and cartridges

Advances in cleanroom technology

  • Isolator
  • RABS
  • V-CRT®

Panel discussion

  • PFS component choice
  • PFS filling and closing
  • Cleanroom technology

Terminal sterilisation of pre-filled syringes – strange but feasible

  • Points to consider
  • Aseptic filling vs terminally sterilised

Visual inspection of pre-filled syringes

  • Why do we inspect? Regulatory requirements
  • Inspection basics
    • Defects – classification and defect evaluation lists
    • Pros and cons of different inspection methods
  • Automated visual inspection of syringes – scope and limitations
  • Current developments

Case study/workshop

Based on the key user requirements provided, participants will come up with outputs for:

  • Design features of the PFS
  • Test methods
  • Manufacturing processes and manufacturing environment

Open floor: all topics and related topics


  • Good distribution practice (GDP)
  • Drug delivery devices: auto-injectors, pen injectors, wearable devices

PFS state-of-the-union address and event summary

  • Review of market drivers and drug development
  • Future trends in PFS

Final discussion session and concluding remarks

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Dale Charlton

Dale Charlton is a Freelance Consultant for automation and fill / finish. Dale has spent a lifelong career in Life Sciences and Biotechnology encompassing both the academic and industrial sectors. Dale worked in a technical capacity in basic R&D at a major University and EMBL Heidelberg before embarking on a more formal academic career in biotechnology and studying for a PhD within the Drug Discovery Group of Pfizer into growth factor research (rGH, GHRF, IgF) . With industrial spells at Porton Down and Pittman-Moore (formerly Glaxo Animal Vaccines) in API and API scale-up, Dale settled back into biotech manufacture and moved more into the supply chain of finished drug products for small molecules & biologics, first as the MD of a life sciences distribution company and later as Director of Business Development, Optima pharma in sterile production automation. Having worked in the pharmaceutical industry from R&D to finished drug product, Dale has a unique understanding of the entire drug development life cycle and offers insight from both the pharma and a suppliers perspective.

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Andreas Rothmund

Dr. Andreas Rothmund is Qualified Person (retd) at Vetter Pharma-Fertigung in Ravensburg, Germany, an independent contract manufacturer specialised in the aseptic production of pre-filled application systems. He started his industrial career in 1985 as a lab manager. After two years he took over production responsibility for a German company specialised in eye drops and eye ointments, a position he held for nearly eight years.

He joined Vetter in 1994, where he has held several positions, including Head of Production for one of Vetter’s aseptic production units. He holds a degree in organic chemistry from the University of Constance, Germany.

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Patrik Thoma

Patrik Thoma,is Managing Director of Zellwag Pharmtech AG. Zellwag Pharmtech AG develops and builds filling and sealing systems for the pharmaceutical, health care and cosmetics industries in the medium-performance segment. Filling different types of containers on the same machine is their specialty. The machines and systems are modular and compact in design.

Patrik comes from the field of engineering and has 25 years of experience in the conception and production of customized systems in the areas of pharmaceuticals, cosmetics, health care, food and chemicals. He began his career as a project- and engineering director. Proximity to customers and products has shaped his development which has involved addressing customers, meeting product and market requirements in different areas and the development of new solutions.

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Book Pre-Filled Syringes: End-to-End Processing Live online training

30-31 Mar 2022

Live online

09:00-17:00 UK (London) (UTC+01)
10:00-18:00 Paris (UTC+02)
04:00-12:00 New York (UTC-04)
Course code 11587

  • GBP 1,099 1,299
  • EUR 1,579 1,859
  • USD 1,786 2,098

Until 23 Feb

View basket 

21-22 Sep 2022

Live online

09:00-17:00 UK (London) (UTC+01)
10:00-18:00 Paris (UTC+02)
04:00-12:00 New York (UTC-04)
Course code 11926

  • GBP 1,099 1,299
  • EUR 1,579 1,859
  • USD 1,786 2,098

Until 17 Aug

View basket 

Reviews of IPI's Pre-Filled Syringes: End-to-End Processing training course

Very knowledgeable and helped answer numerous questions. Very helpful and interested in individual challenges.

Mar 27 2019

Gabrielle Kelsey
Production Manager, Torbay Pharmaceuticals

Mar 20 2017

Very informative, good overview of PFS development. Speakers were knowledgeable.

William Turner
Associate Bioedical Engineer, Meridian Medical Technologies, a Pfizer Company

Mar 20 2017

Friendly, knowledgeable people. I would have liked to go a bit deeper into the technical parts (syringes, tubs, machines)

Marc van Nispen
Project Engineer, EMCM B.V.


  • 3P Innovation Ltd
  • 42 Technology Ltd
  • Archimedes Pharma Ltd
  • Astech Projects Limited
  • AstraZeneca
  • Becton Dickinson UK Ltd (Oxford)
  • Bespak Europe Ltd
  • Calea UK Ltd
  • Cambridge Design Partnership
  • Cardinal Health
  • Catalent Pharma Solutions
  • Ethypharm
  • Future Injection Technologies Limited
  • Glide Pharmaceutical Technologies Limited
  • Harro Hoefliger Packaging Systems Ltd
  • IT Pharma
  • Martindale Pharma
  • Medicines and Healthcare Products Regulatory Agency (MHRA)
  • OnDrugDelivery Ltd
  • Oval Medical Technologies Ltd
  • Owen Mumford Ltd
  • QRC Consultants Ltd
  • Salvus Technology Limited
  • Sanofi-Aventis
  • Team Consulting Ltd
  • Technology Partnership Plc
  • Terry Weston
  • Teva Pharmaceuticals Europe B.V.
  • Limited
  • Torbay Pharmaceuticals
  • UCB Celltech
  • ViiV Healthcare
  • West Pharmaceutical Services
  • West Pharmaceutical Services Cornwall Ltd
  • Wyeth Pharmaceuticals


  • Abbott Products GmbH
  • B Braun Melsungen AG
  • Bayer Pharma AG
  • Gerresheimer Bunde GmbH
  • Medac GmbH
  • Nipro Glass Germany AG
  • Optima Group pharma
  • Rexam Pharma GmbH
  • Robert Bosch GmbH
  • RPC Formatec GmbH
  • Sanofi-Aventis Deutschland GmbH
  • Schott AG
  • Schreiner Group GmbH & Co KG
  • Vetter Pharma International GmbH


  • Actelion Pharmaceutical Ltd
  • CSL Behring AG
  • F. Hoffmann-La Roche Ltd
  • Forteq Healthcare
  • Geistlich Pharma AG
  • Haselmeier GmbH
  • Komax Systems LCF SA
  • Merck
  • Mikron SA Boudry
  • Novartis Pharma AG
  • Schott Schweiz AG
  • Ypsomed AG

United States of America

  • Abbott Laboratories
  • Advanced Electron Beams
  • Alexion Pharmaceuticals Inc
  • BD
  • Eli Lilly and Company
  • Genetech Inc
  • IDEO
  • Meridian Medical Technologies Inc
  • Meridian Medical Technologies, a Pfizer Company
  • Portal Instruments
  • West Pharmaceutical Services Inc.


  • Aptar Pharma
  • BD Medical – Pharmaceutical Systems
  • Becton Dickinson
  • Cabinet Michel Richebourg
  • Guerbet
  • Linac Technologies
  • Stelmi SA


  • Amgen Europe BV
  • Bilthoven Biologicals BV
  • EMCM B.V.
  • Interdos Pharma B.V.
  • MSD B.V.
  • MSD/NV Organon
  • Synthon Biopharmaceuticals BV


  • Elcam Medical Ltd
  • Flextronics Design srl
  • Sindolor Medical Ltd
  • Teva Pharmaceutical Industry Limited
  • Teva Pharmaceuticals Industries Ltd
  • West-Medimop


  • Apotek Produktion & Laboratorier AB
  • Apoteket Produktion & Laboratorier AB
  • BD Medical - Pharmaceutical Systems
  • Q-Med AB


  • Baxter Innovations GmbH
  • BD Medical - Pharmaceutical Systems
  • EBEWE Pharma
  • Sandoz GmbH
  • Takeda Austria GmbH


  • ALK-Abello A/S
  • Bang & Olufsen Medicom AS
  • Ferring Pharmaceuticals A/S
  • LEO Pharma
  • Novo Nordisk A/S


  • Baxter R&D Europe
  • Datwyler Pharma Packaging Belgium NV
  • Glaxo Smithkline Biologicals
  • Toxikon Europe NV


  • Crospon Limited
  • Tech Group Europe


  • Alfa Wassermann S.p.A
  • Nuova Ompi srl
  • Sinclair Pharma SRL


  • DelSiTech Ltd
  • Phillips-Medisize


  • Agency for Medicinal Products and Medical Devices of Croatia (HALMED)


  • Gedeon Richter Plc.


  • Piramal Healthcare Limited


  • Daicel Corporation


  • Admiral S.A.

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Multiple colleagues?
Talk to one of our training experts to discuss how to:

Run this course conveniently and cost-effectively in-house for your staff and colleagues

Aleksandra BEER
Training expert

+44 (0)20 7749 4749