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Management Forum

Pre-Filled Syringes: End-to-End Processing Training Course

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.

★★★★★ "I enjoyed it. I came to the webinar knowing nothing about the process, and I got away with a lot of ... more"

6-7 November 2024
+ 20-21 March 2025, 21-22 July 2025, 5-6 November 2025 »

from £1099

Need help?  Enrol or reserve

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.

This course is of our range of Medical Devices training courses - now also including Medical Devices Cyber Security training to help improve your data security.

Benefits of attending

  • Explore recent improvements in the manufacturing process
  • Understand visual inspection
  • Know the latest regulatory requirements

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.

Enrol or reserve

This 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 process overview

PFS over time

  • Evolution of systems
  • Evolution of components
  • Evolution of application and application systems

Overview: trends in PFS Drug Delivery

  • New PFS formats
  • Safety devices
  • Self-injection devices

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

  • PFS Dosing Systems
  • PFS Closing Methods
  • Containment

Terminal sterilisation of pre-filled syringes – strange but feasible

  • Points to consider
  • Aseptic filling vs terminally sterilised

Trends in PFS: Machine Technology

  • Pumps ‘fit for purpose’
  • In Process Control (IPC), filling & stoppering
  • Use of Robotics

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
  • How to set up a manual VI

Secondary packaging machines for PFS: hero or villain of the PFS world?

  • Walk through a typical facility 2° packaging line
  • Trends in secondary packaging
  • PFS handling: reduction of glass-to-glass contact


  • Target Product Process
  • Impact Primary packaging material
  • Assembling steps
  • Inline Controls
  • Function / Release Tests
  • Final Packaging

Regulatory requirements for pre-filled syringes

  • ISO design compliance
  • New MDR – what about it?
  • US requirements for combination products

Moving from vial to pre-filled syringe

  • Points to consider
  • Available options

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

Shipping PFSs all over the world

  • Points to consider
  • Shipping validation
  • GDP - Good Distribution Practices

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

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

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Dale Charlton
DCBio Automation SIA

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.

More details

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.

More details

Susanne Hall
Vetter Pharma

Susanne Hall began her career in 1990 at Dr. Karl Thomae in Biberach as Head of Packaging
Technology. In 1993, she joined Vetters Research and Development department as Head of
Packaging Material Incoming Control and in 2008 was named Team Leader of Secondary
Packaging. Since 2019, she has been the Director of Secondary Packaging and AVI Projects. In
this position, Susanne leads three teams that ensure the implementation of customer products
from development to commercial into production. For secondary packaging this includes device
assembly, labeling and final packaging as well as implementing tests for a controlled safe
process and the meeting of customer expectations. She is also responsible for the transfer of
products from manual visual inspection to fully automated inspection lines. Susanne has a
diploma in engineering from the College of Engineering where she focused on specialized
precision engineering.

More details

Susanne Hall
Vetter Pharma

More details

NEW higher discounts for multiple bookings - bring your colleagues to make your training budget go further:

  • 30% off the 2nd delegate*
  • 40% off the 3rd delegate*
  • 50% off the 4th delegate*

Please contact us for pricing if you are interested in booking 5 or more delegates

6-7 November 2024

Live online

09:30-17:00 UK (London) (UTC+00)
10:30-18:00 Paris (UTC+01)
04:30-12:00 New York (UTC-05)
Course code 14035

  • GBP 1,099 1,299
  • EUR 1,589 1,869
  • USD 1,817 2,129

Until 02 Oct

View basket 

Not ready to book yet?

for 7 days, no obligation

20-21 March 2025

Live online

09:30-17:00 UK (London) (UTC+00)
10:30-18:00 Paris (UTC+01)
05:30-13:00 New York (UTC-04)
Course code 14610

  • GBP 1,099 1,299
  • EUR 1,589 1,869
  • USD 1,817 2,129

Until 13 Feb

View basket 

Not ready to book yet?

for 7 days, no obligation

21-22 July 2025

Live online

09:30-17:00 UK (London) (UTC+01)
10:30-18:00 Paris (UTC+02)
04:30-12:00 New York (UTC-04)
Course code 14876

  • GBP 1,099 1,299
  • EUR 1,589 1,869
  • USD 1,817 2,129

Until 16 Jun

View basket 

Not ready to book yet?

for 7 days, no obligation

5-6 November 2025

Live online

09:30-17:00 UK (London) (UTC+00)
10:30-18:00 Paris (UTC+01)
04:30-12:00 New York (UTC-05)
Course code 15045

  • GBP 1,099 1,299
  • EUR 1,589 1,869
  • USD 1,817 2,129

Until 01 Oct

View basket 

Not ready to book yet?

for 7 days, no obligation

* Early booking discounts may not be combined with other discounts or offers. As such, the discounts for 2nd/3rd/4th delegates are based on the full price; and apply only when booking multiple delegates on the same date.

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

I enjoyed it. I came to the webinar knowing nothing about the process, and I got away with a lot of knowledge. I enjoyed the chat between Andreas and Dale during the presentation, sharing their experience and complementing each other, that was knowledge beyond videos and presentations.

Mar 30 2023

Serge Batubenge
Mgr. Engineering , Regeneron Pharmaceuticals, Inc.

Mar 30 2022

It was very good, I was impressed, I would have loved to do this course in person but this was a good alternative. The speakers were very good, very knowledgeable but also good at teaching/ relating information. The presentations were easy to follow, it was useful to have the documents there to follow along as the speakers talked. All the content was relevant to the topic and occasional humus. I enjoyed the course and would recommend Management Forum to my colleagues.

Zhané Healey
Senior Laboratory Technician, Medical Engineering Technologies

Mar 27 2019

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

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.

United Kingdom

  • 3P Innovation Ltd
  • 42 Technology Ltd
  • Almac Group
  • 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
  • Fuji Film
  • Future Injection Technologies Limited
  • GlaxoSmithKline
  • Glide Pharmaceutical Technologies Limited
  • Harro Hoefliger Packaging Systems Ltd
  • IT Pharma
  • Martindale Pharma
  • Medical Engineering Technologies
  • 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
  • Torbay Pharmaceuticals Ltd
  • 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

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
  • NA
  • Portal Instruments
  • Regeneron Pharmaceuticals, Inc.
  • West Pharmaceutical Services Inc.


  • Actelion Pharmaceutical Ltd
  • Bioeq AG
  • 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


  • 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
  • Sever Pharma Solutions
  • 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


  • Alfa Wassermann S.p.A
  • Chiesi Farmceutici S.p.A.
  • Nuova Ompi srl
  • Sinclair Pharma SRL
  • TÜV Rheinland Italia S.r.l.


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


  • Crospon Limited
  • Tech Group Europe


  • DelSiTech Ltd
  • Phillips-Medisize


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




  • Gedeon Richter Plc.


  • Piramal Healthcare Limited


  • Daicel Corporation


  • DCBio Automation SIA


  • Admiral S.A.

Enrol or reserve

Run Pre-Filled Syringes: End-to-End Processing Live online for your team

2 days

Typical duration

Pricing from:

  • GBP 800
  • Per attendee, based on 10 attendees
  • Course tailored to your requirements
  • At your choice of location, or online


We can customise this course to your requirements and deliver it on an in-house basis for any number of your staff or colleagues.

Contact our in-house training experts Aleksandra Beer and Yesim Nurko to discuss your requirements:

Multiple colleagues? See above for details of our discounts for 2, 3, or 4 delegates. For more, 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

Aleksandra BEER
Training expert

Yesim Nurko

Training expert

+44 (0)20 7749 4749