The new nest design allows pharma companies to increase their efficiency by up to 67%, significantly reduce their manufacturing costs and reduce the product carbon footprint by 17% while maintaining high quality and sterility.
By collaborating with Bausch + Ströbel, the new nest is compatible with high-tech machines leading to efficient and reliable fill-and-finish operations for pharma companies.
SCHOTT Pharma developed a new nest design for prefillable polymer syringes, which holds a total of 160 syringes without changing the size of the nest. This marks an increase of 60% compared to the standard nest that fits 100 syringes. This means that drug manufacturers benefit from an increased output compared to the standard setup: In the same cycle time, the new nest from SCHOTT Pharma enables pharma companies to fill significantly more syringes per hour than the nest with 100 syringes. As a result, pharma companies are able to increase their efficiency by up to 67% while significantly reducing their manufacturing costs and reducing the product carbon footprint (PCF) by 17%. “Through this step, we are actively addressing one of the main levers to improve the costs of pharma companies and reorganizing their value chain,” says Andreas Reisse, CEO of SCHOTT Pharma. “This innovation is a testament to our engineering expertise and with it, we’re enabling pharma manufacturers to meet their needs for efficiency, sustainability, and compliance, while assuring uncompromised quality. We have received positive feedback from the market so far and first customers are already planning to implement the new product.” Besides direct cost reduction, additional savings come from minimizing transportation needs, storage space and ready-to-use waste.
As drug manufacturers strive to meet the increasing demand for high-speed, large-scale production, they require drug containment solutions and delivery systems that can be filled quickly and efficiently. At the same time, they are looking to reduce costs without compromising on quality or regulatory compliance. Additionally, with growing regulatory pressure, companies are looking for ways to reduce CO2 emissions and minimise waste management costs. SCHOTT Pharma’s new enhanced SCHOTT TOPPAC® Nest 160 is specifically designed to meet these diverse demands in one comprehensive solution, enabling more efficient production of high-quality drugs, including vaccines, derma fillers, or diluents. Thanks to economy of scale effects, the total fix cost is greatly reduced due to the higher output.
Collaborating with industry leaders
The nest builds on the strong collaboration between SCHOTT Pharma and Bausch + Ströbel, a leading machine manufacturer. “By working closely together with SCHOTT Pharma, we have achieved seamless integration of the new SCHOTT TOPPAC® Nest 160 with our high-speed filling lines. We’re able to ensure an easy implementation, which only requires minor retrofit changes, thereby increasing efficiency and ensuring reliable operations for pharma companies," adds Marco Eller, Product Manager at Bausch + Ströbel.
Extensive portfolio of high-value solutions
SCHOTT Pharma has a proven track record of manufacturing prefillable polymer syringes from cyclic olefin copolymer (COC) for over 20 years. The industry’s trust in the company is underlined by the broad customer base for these solutions, including over 100 commercial customers, as well as leading mRNA drug manufacturers. Already today, four blockbuster drugs, which are drugs that generate a turnover of more than USD 1 billion per year, are stored in the company's COC syringes.
Image: SCHOTT Pharma’s new nest design holds 160 prefillable polymer syringes to enhance the operational excellence and sustainability measures of pharma manufacturers. Source: SCHOTT Pharma/Oana Szekely
