Package: Duoject's Inter-Vial is a packaging system that contains, mixes, and injects medicine in a single unit. This medical device-drug package hybrid allows a health professional to reconstitute a lyophilized (freeze-dried) drug by mixing it with a liquid diluent. The drug is then injected, using the same device. The Inter-Vial consists of several intricately molded plastic pieces that have to be snapped or screwed together.
Challenges: Coupling the different pieces made resin selection critical, according to Daniel McDonald, director of engineering services at Toronto-based Duoject. High melt flow, clarity, and gloss were all important. The material also had to permit injection molding with close tolerances for secure fits between parts. Polycarbonate was the initial choice, but it "couldn't provide the flexibility needed to adequately mold specific undercuts, snap-fits, latches, and grooves, whereas the K-Resin did," he says. The K-Resin SBC is from Chevron Phillips.
Benefits: The two parts of the Inter-Vial made from K-Resin BK15 SBC are the syringe socket, which houses a glass cartridge, and the vial socket, into which the lyophilized drug vial is snapped. These two sockets have to be screwed together during the drug reconstitution process. Extremely fine threads and fittings are critical, and the BK15 SBC grade of K-Resin provides just that. McDonald adds that the package also stands up well under gamma sterilization.
Greater convenience, controlled and accurate dosing, and improved drug freshness are among the key benefits of the Inter-Vial compared to other delivery systems.
