Pharmaceutical packaging is crucial in ensuring medicine safety, stability, and ease of use. The prefilled syringe and vial are two common packaging and delivery methods, widely used for the storage and administration of biologics, vaccines, and other medicines.
As an increasing number of biotech therapies and drug candidates can only be administered via injection, the easy-to-use medicine packaging market is gradually shifting from vials to prefilled syringes. So, what are the differences between these two? And which applications are they suitable for? Read on for more information.
What is a Prefilled Syringe and Vial?
Both the syringe and vial are used to deliver injectable medicines, but they work in very different ways:
1. What’s a Vial?
A vial is a small and sealed container, usually made of glass or plastic, that holds liquid or lyophilized medicine, such as vaccines, biologics, antibiotics, etc.
It is commonly used in hospitals and clinics, allowing for storing multiple doses in one container. To use a vial of medicine, a healthcare worker inserts a sterile needle through the rubber top and draws the liquid into a syringe.
The vial and syringe method allows for flexible dosing, which is especially useful when the drug is needed in different amounts for different patients. However, each use requires careful handling to avoid contamination.
2. What’s a Prefilled Syringe?
A prefilled syringe (PFS) is a ready-to-inject device that already contains a single, measured dose of medicine. It generally includes a needle, a barrel, a plunger, and a protective cap, and some products come with a safety device.
Unlike a syringe vial, to use it, simply open the packaging, expel air, and inject. No additional drug-drawing steps are required.
This prefilled design reduces operational steps, minimizes the risk of contamination and dosing errors, which is particularly suitable for high-value drugs.
Prefilled Syringe Vs. Vial
The debate between the syringe and vial use in pharma is becoming more relevant as drug delivery needs evolve. Both options have benefits, but the right choice depends on several factors:
1. Convenience
Prefilled syringes are quick to use because they come with the exact dose already inside, ready for injection. PFS injection meaning saves time, especially in emergencies or busy clinics. Moreover, it supports convenient self-injection, such as insulin and anticoagulant drugs, making it suitable for patients with chronic conditions.
In comparison, a syringe and vial setup allows for multiple uses (such as anesthetics, multi-dose vaccines), making it suitable for situations requiring dose adjustments. However, it takes extra steps: drawing the drug, checking the dose, and then making sure everything stays clean. All this can slow down the process and would need trained handling.
2. Safety
Prefillable syringes offer better safety for both patients and healthcare workers. Since the medicine is sealed and ready to use, it lowers the chances of accidental needle injuries or contact with harmful drugs, risks that happen when drawing from vials. The fixed dose in a prefilled syringe also helps prevent measurement errors, which improves treatment accuracy.
As for vials, in addition to the risks of contamination and dosage measurement errors, they also rely more heavily on standardized operation by medical staff, potentially resulting in higher error rates.
3. Cost
Vials are generally cheaper to produce and can store multiple doses, making them cost-effective for hospitals. However, this also leads to higher chances of leftover drugs being wasted. Another important waste is overfill. Manufacturers have to add 20-30% more medicine to vials to make up for waste during preparation. [1] Prefilled syringes almost eliminate this need. A syringe and vial system may save on packaging, but not necessarily on overall waste.
Prefilled syringes are more expensive per unit, but they reduce waste and simplify logistics. Another advantage is that the medicine inside a prefilled syringe can stay sterile and safe to use for up to two or three years, depending on the drug. [2] All these make it the optimal solution for high-value medicines.
4. Drug Compatibility
Some sensitive biological drugs are more stable in prefilled syringes due to reduced air exposure. The drug quality in the vial might be affected if opened repeatedly, especially with delicate formulas that degrade quickly.
5. Environmental Friendliness
Prefilled syringes offer certain environmental advantages due to their integrated syringe design, which reduces packaging material usage. Additionally, prefilled syringes often use recyclable glass, further minimizing environmental impact.
In contrast, vials require additional syringes for use. Multi-dose vials may also lead to drug wastage due to residue or short shelf life after opening, increasing resource consumption.
Applications of Prefilled Syringes and Vials
Given the respective characteristics of the prefilled syringe and the vial, they are suitable for different applications:
1. Vial
Vials are widely used due to their flexibility and cost advantages, particularly in:
- Multi-dose drugs:Such as vaccines and antibiotics, are suitable for mass immunization or repeated dosing needs.
- Lyophilized biologics:Including monoclonal antibodies and lyophilized powders, which can be stored stably for long periods.
- Intravenous (IV) drugs:Such as anesthetics and nutrient solutions, especially when large doses or continuous infusion are required.
- Chemotherapy agents:Healthcare professionals adjust dosages based on the patient’s specific condition.
2. Prefilled Syringe
Prefillable syringes offer convenience and safety, making them suitable for:
- Self-administration:For example, insulin allows patients to inject at home, reducing reliance on medical professionals.
- High-value biologics:Single-dose design prevents waste and ensures precise dosing.
- Large-scale vaccination:Such as flu vaccines and HPV vaccines. The ready-to-use features improve efficiency and reduce operational errors.
- Emergency medications:Enable rapid response to save lives.
WEGO Medical – Professional Prefilled Syringe Manufacturer
With the global pharmaceutical industry’s increasing demand for safety, convenience, and precise drug delivery, prefilled syringes have become the preferred packaging solution for biologics, vaccines, and high-end therapeutic drugs. In this field, WEGO Medical is a key global supplier in the prefilled syringe market. We offer:
- Prefillable syringes are available in materials ranging from glass to COP/COC, certified with FDA 510K, CE, ISO9001, and ISO13485 approvals.
- Multiple capacity specifications, supporting designs such as Luer lock, needle-attached, and more.
- Eco-friendly materials, free from chlorine and other halogens, ensure no environmental pollution.
- High transparency with 98% light transmittance.
- Excellent low protein adsorption properties.
- Smooth needle surfaces and burr-free tips to ensure optimal performance.
- Our products are designed to meet the highest industry standards while prioritizing safety, precision, and sustainability.
Conclusion
Both prefilled syringe and vial have their respective advantages and applicable scenarios. As a significant innovation in pharmaceutical packaging, prefilled syringes are becoming the preferred solution in the easy-to-use medicine market due to their safety, convenience, and precise dosing advantages.
At WEGO Medical, we provide trusted, high-quality options that meet the immensely growing needs of modern healthcare. If you’re looking for trustworthy and ready-to-use packaging, now’s the time to check out our full range and find your perfect fit.
References
[1] Prefilled syringes: An innovation in parenteral packaging. Available at: https://pmc.ncbi.nlm.nih.gov/articles/PMC3465144/#sec1-12 (Accessed: 11 July 2025)
