Delivering the most viscous drug ever put in an autoinjector

Sanner helped a client solve a problem that enabled the device to go to market.

Project Description

Sanner partnered with a leading pharmaceutical company to optimize the performance of an autoinjector designed to deliver one of the highest viscosity biologic drugs ever administered using a self-injection device. Through advanced modelling, statistical analysis and engineering expertise, we identified the root causes of performance issues and developed practical solutions that enabled the product to be successfully commercialized. 

The Challenge

The increased use of highly concentrated biologic therapies presents significant challenges for drug delivery devices. In this project, the exceptionally high viscosity of the drug required unprecedented injection forces, placing considerable mechanical stress on the autoinjector and creating a number of low-frequency but unacceptable reliability issues. 

With the client’s drug patents approaching expiry, development timelines were critical. The challenge was to determine whether the existing device platform remained commercially viable while rapidly identifying the underlying causes of the observed failures without delaying product launch.

Our Approach

Sanner worked closely with the client to assess both the technical and commercial viability of the existing autoinjector platform. Our engineers developed detailed mathematical models and Monte Carlo simulations to predict the expected behavior of the device under demanding operating conditions.  

Working with limited numbers of expensive drug-filled devices, Sanner designed innovative test methods capable of characterizing low-frequency failures with statistically meaningful results. Combining practical engineering, experimental physics and advanced statistical analysis, we rapidly identified the root causes affecting device performance. 

Results

Sanner enabled the client to successfully launch their autoinjector in multiple international markets by resolving critical performance issues associated with delivering an exceptionally high-viscosity biologic drug. The optimized design maintained compatibility with existing manufacturing processes while significantly improving reliability and reducing development risk. 

By combining advanced engineering analysis with practical product development expertise, Sanner accelerated problem resolution, protected the client’s development timeline and supported the successful commercialization of a complex drug delivery platform that has gone on to generate significant commercial value. 

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