Reducing Risk in Injectable Drug Development Starts with Primary Packaging

Primary packaging is often treated as a late-stage procurement decision, in reality, it can influence formulation stability, manufacturing, regulatory strategy, device performance, and ultimately how quickly a therapy reaches patients.

In this episode of Life Science Solutions, host Chris Adkins sits down with Katie Falcone, Director of Technical Services for Integrated Systems at West Pharmaceutical Services. Katie draws on her decade of primary packaging experience to explain why drug developers (especially lean, emerging biotechs) need to integrate primary packaging decisions into early pre-formulation work rather than treating it as a late-stage commodity purchase.

Together, they dive into the technical nuances of parenteral packaging and explore how integrated platforms - like the West Synchrony™ system - are replacing the traditional, fragmented supplier model to significantly de-risk and speed up time-to-clinic.

Topics Include:

• Vials vs. Dynamic Systems: How transitioning from static vials to pre-filled syringes introduces dynamic functional forces (break loose/glide force), ISO device standards, and combination product complexities.
• The "Three-Headed Monster": The headaches drug sponsors face when attempting to stitch together specifications, extractables/leachables data, and Drug Master Files (DMFs) from three separate component suppliers.
• Integrated Platforms: How pre-tested, single-source platforms offer two years of aged drug-independent data, complete DMF files, and copy-and-paste regulatory packages for EU Notified Bodies.
• Early Technical Nuances: Why critical decisions around gas ingress, silicone oil specs, container closure integrity (CCI), and needle gauge vs. viscosity directly dictate patient comfort and auto-injector performance.
• Fill/Finish & CDMO Alignment: Ensuring that packaging selections align with commercial fill/finish line mechanics, coefficients of friction, and CDMO capabilities early to prevent costly launch delays.
• The Shift to At-Home Care: Supporting the growing industry push toward high-volume, high-viscosity subcutaneous injections that empower patients to manage complex therapies at home.

Whether you are formulating a sensitive biologic or preparing your first combination product submission, this conversation provides a clear blueprint for selecting the right primary packaging from day one.

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