Optimising medical injection moulding for syringe components and beyond

The growth of the global syringe market has been notably robust and innovations in this area have created an impact on the medical sector as well. Husky Technologies^TM has released the guidebook “Optimizing Medical Injection Molding for Syringe Components and Beyond”, which explores the growth of the syringe and medical components market, including growth trends, key components, technical aspects, and how Husky’s cutting-edge hot runner technology and medical tooling expertise can enable customers to optimise injection moulding processes for these exciting market opportunities.

Growth trends in the syringe market

The guidebook noted that the global syringe market¹ is forecasted to grow from 14.8 billion to 18.5 billion between 2020 and 2026, at a CAGR of 7.7%. Asia is driving much of this growth, with over 50% of the market share, followed by Europe and North America, at 25% and 18% respectively. It is also estimated that an additional 7 billion units of global syringe production capacity will be required to meet demand over the next five years.

The syringe market operates within the broader context of the medical applications and devices sector, which is also experiencing significant growth. Medical components experiencing surging demand include pipettes, blood collection tubes, and reagent sampling, among others. Some of the factors driving this growth include have been identified: growing global population; ageing population; increased urbanisation; and prevalence of chronic diseases

The guidebook also mentioned several additional forces are contributing to the growth and transformation of the medical applications market. These include: re-shoring and localisation where the growing trend is towards localised manufacturing and supply chain management; glass to plastic conversion; demand for scalable and precise medical components; rise in self-medication/home medication; digitalisation; shift towards environmentally friendly and circular value chain models; focus on cost-effectiveness and efficiency; and the need to comply with stringent regulatory standards in the healthcare industry.

Materials for syringe and its components

The choice between plastic and glass syringes is critical for manufacturers, impacting material cost, production efficiency, safety, and compliance. Each material offers distinct advantages. For instance, plastic syringes are commonly used due to their lightweight, durable, and disposable nature. They offer cost advantages in manufacturing and transportation and are well-suited for a wide range of medical applications. Glass syringes on the other hand, are valued for their inert properties, making them suitable for handling sensitive medications and chemicals. They provide high transparency for precise volume measurements, and are repeatable in their precision.  

The demand for syringe is growing with Asia driving much of this growth with over 50% of the market share.

The syringe market is further segmented into staked needle syringes and needle-free syringes, including Luer slip and Luer lock syringes. While staked needle syringes are primarily used for biological and pharmaceutical drugs, needle-free syringes are mainly used for vaccinations.  There are also various types of syringes based on the requirements. Safety syringes are designed to reduce the risk of needlestick injuries and the transmission of bloodborne pathogens. Many nations have now introduced legislation requiring the use of safety syringes, which include: retractable needle syringes in which the needle retracts into the syringe barrel after use; shielded needle syringes with a shield that covers the needle after use, offering additional protection; and auto-disable syringes, also referred to as AD syringes, which are a type of safety syringe recommended for immunization programs as they prevent re-use by locking after a single use and come in various types, including syringes with clips or flanges, which minimise the risk of a second injury. However, not all auto-disable syringes have this feature.

Pre-filled syringes may look the same but they are usually made of different materials like glass or with injected materials, such as Cyclic Olefin Copolymer (COC) or Cyclic Olefin Polymer (COP). Pre-filled syringes also require a capping and tamper-evident function to ensure the integrity and safety of the medication. These features are not typically found in regular syringes. Syringe components have also been more diverse owing to the fast-changing requirements of the medical industry.

Enhancing efficiency in syringes production  

Quality is a top priority in the medical applications industry. Thriving manufacturers are leveraging cutting-edge technologies to optimize the injection moulding process, enabling consistent quality, operational efficiency, and cost-effectiveness.

Many are opting for an integrated injection moulding system, and Husky stands as a global leader in this field. Its innovative, integrated injection moulding systems systems rely on Schöttli™ moulds powered by Husky, which have set the global standard for high-precision medical moulding. This collaboration has empowered us to produce more than 50,000 cavities for syringe components over the years.

The quick change system provides swift access to the sensitive Luer lock feature, and enables operators to efficiently and rapidly swap threaded cores in unscrewing systems. The system offers higher part quality, mould availability, increased reliability, and reduced maintenance time. Thread unwinding tooling uses movement and rotation to produce parts quickly and efficiently. Internal or external threading is meticulously designed to meet rigorous safety and effectiveness standards for a multitude of medical applications. The synchronized slide actuation tooling ensures reliability and predictability in part production, from injection to ejection; while the high precision actuation enables consistently superior part quality and ensures producers achieve maximised cycle times. Synchronized slide actuation allows for more compact tool concepts and therefore a higher number of cavities per mould. 

Industry-leading cluster system moulds offer enhanced precision, speed, mould longevity, predictability, and consistency. Like synchronized slide actuation, the cluster system facilitates a higher cavitation rate per cluster unit, increasing efficiency.

Husky’s hot runner technology for medical applications

Husky’s hot runner systems are ideal for medical applications, enabling total design freedom and the capability to produce the superior quality parts needed to meet exacting medical standards. Performance benefits include: speed and consistency, flexibility, energy efficiency, fast cycle times, high production volumes, and customizability. The company’s hot runner technology seamlessly integrates with Schöttli’s proprietary gating technologies to produce high-quality medical plastic parts, ensuring precision and reliability while allowing for customisation. These technologies include: Schöttli’s side-gating is designed for optimal part filling, compact mould dimensions, and reliable scalability. With the ability to accommodate up to 384 cavities per mould, it provides unmatched productivity and cost-efficiency per square meter. Mould cooling is crucial for maintaining part quality and cycle times. Husky prioritises engineering studies to optimize cooling solutions and ensure the longevity and performance of moulds that exceed industry expectations.

Husky provides tools for detailed investment modeling, offering key metrics like Net Present Value (NPV) and Internal Rate of Return (IRR). This facilitates sophisticated analyses, including Total Cost of Ownership (TCO) and sensitivity studies of influential variables. Comparing part costs and annual profits between Husky moulds based on full hot runner technology and local competitors using semi-hot runner technology reveals significant advantages. For one, full hot runner technology eliminates runner wastage and associated labour costs. Fastest cycle times for medical components, especially syringes is achieved. Modular mould design and ease of maintenance keep costs in check; while minimal manpower requirements and high uptime (95% and above) lead to increased part production, reduced overheads, and higher profits from the same facility.

Husky maintains transparency and prioritises customer satisfaction, delivering exceptional medical moulds, integrated moulding machines (IMM), and real-time monitoring solutions like Advantage+Elite™. This ensures efficiency, cost savings, and quality in production. For more information,visit: https://www.husky.co/en/industries/medical/.

Download the guidebook at: https://campaigns.husky.co/syringe-components-guide

Notes:

¹https://www.fnfresearch.com/syringe-market

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