Dual Chamber Syringe (DCS) Filling Machine Market

[113 Pages Report] The installed base global dual chamber syringe (DCS) filling machine market size is projected to grow from USD 258 million in 2020 to USD 381 million by 2025, at a CAGR of 8.2% between 2020 and 2025. The factors promoting the growth of the market are technological advancements in filling machines, growth in lyophilized drugs, and the growing biopharmaceutical industry.

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COVD-19 Impact on the pharmaceutical industry supply chain

Dual chamber syringe (DCS) filling machine market is not directly impacted by the COVID 19, but disruption in supply is expected to have implications in the near future:

• COVID-19 pandemic has caused global havoc in the first half of the year, and the economic and social situation does not seem to recover till next year, at least. It has put millions of people around the world under lockdown and has killed more than 660,000 people so far. However, the pharmaceutical industry is gearing up to fight COVID-19, with rapid development for new drugs and vaccines. At the same time, the industry has suffered immense damage due to the pandemic, mainly through the disruption in the supply chain. In order to prevent the spread of the virus, various countries have gone under lockdown, which has disrupted the supply chain of the industry.
• China is one of the sources of Active Pharmaceutical Ingredients (APIs) and was also the epicenter of the COVID-19 outbreak initially. The country was put under lockdown quite early, which led to the stoppage of manufacturing and hence a decline in the export. Although China has now relaxed its restriction, there are many other countries that have implemented export control measure that has impacted the pharmaceutical supply chain
• The only positive impact of COVID-19 could be that companies will look to spread their production to different markets in order to prevent any future disruptions. According to Chemical & Engineering News, in April 2020, Senator Tom Cotton (R-AR) and Representative Mike Gallagher introduced the Protecting Our Pharmaceutical Supply Chain from China Act that calls for terminating purchases of active pharmaceutical ingredients from China by 2022. A similar trend was observed in Europe.
• As per Chemical & Engineering News, in May 2020, Evonik announced that it would invest USD 27 million to increase its active pharmaceutical ingredients production capacity at its Rosenheim and Hanau sites in Germany. The expansion has to be completed by 2021, with further expansion planned in 2024. Steps have been taken to increase the domestic supply of drug chemicals and also to reduce sourcing insecurities and overdependence on China for supply

Dual chamber syringe (DCS) filling machine  Market Dynamics

Driver: Technological advancements in filling machine manufacturing

Technological advancements in double chamber syringe filling machine involve the usage of isolators and Restricted Access Barrier Systems (RABS). The introduction of these technologies creates robust sterile manufacturing environments that effectively separate human operators from the fill-finish process. A large number of equipment manufacturers in the fill-finish manufacturing market are focusing on the development of barrier isolation systems, which are integrated fill-finish machines capable of carrying out all stages of fill-finish processes.

In contrast to barrier isolation systems, standalone equipment used in fill-finish operations is both time-consuming and expensive, thus making the entire process complex and prone to contamination. Additionally, in traditional filling machines, the conventional stainless steel systems require additional cleaning and sterilization (CIP/SIP), whereas a single-use system eliminates the critical steps of sterilization and further reduces the change-over-time by simplifying end-of-batch breakdown and decontamination operations. For instance, DARA Pharmaceutical Packaging has introduced such a filling machine for dual-chamber syringes. Due to these factors, many biopharmaceutical companies are adopting these machines in drug production facilities.

Restraint: The high cost of isolators and RABS

Isolators and Restricted Access Barrier System (RABS) are equipped with advanced features and functionalities and are therefore priced at premium rates, as compared to standalone systems. The average cost of isolators and RABS is around USD 4.0 million to USD 8.0 million, which is five times that of standalone systems. This severely restricts their accessibility, especially for small companies. Therefore, the adoption of isolators and RABS is very low as compared to standalone systems in underdeveloped or developing countries, including China and India. Furthermore, research institutes find it difficult to afford such instruments, as they have restricted budgets for the purchase of such instruments. Standalone systems are, however, still used in small pharma and biopharma companies, R&D laboratories, and academic institutes.

Opportunities: Investments made by prefilled syringe manufacturers.

In 2018, Nipro Corporation invested USD 14 million in its Japan and Germany plant to increase the production capacity of prefilled syringes. The company is also focusing on the development of dual chamber prefilled syringes for treating patients with prostate cancer and breast cancer. This type of development will create opportunities for DCS filling machine manufacturers to capture the market

Challenges: Maintaining sterility during the filling operations

Aseptic filling operations, which are used in filling syringes, carry more risk than non-sterile processes. It requires careful planning, trained personnel, and specialized facilities & machines to properly execute the process. Ensuring sterility is of utmost importance as any failure can lead to massive financial losses and can also have life-threatening effects on patients.

All the components used in the filling processes must be sterilized before use. Sterilization with pressurized steam, irradiation, or hydrogen peroxide must be performed in a manner that does not affect the stability of the drug. This indicates the need for careful designing of cleanroom facilities to ensure sterility, thereby incurring high costs. Sterile lyophilizing requires investments for specialized equipment and facilities. For those products that require lyophilizing, strict steps must be taken to ensure that the risk of contamination is minimized during the loading and unloading processes.

ECOSYSTEM DIAGRAM

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Source: MarketsandMarkets Analysis

Automatic type segment projected to lead dual chamber syringe (DCS) filling machine  market from 2020 to 2025

The automatic segment accounted for the largest share in the overall dual chamber syringe (DCS) filling machine  market. Automatic filling machines are used by companies with large-scale operations and high-production requirements. These types of machines are the Food and Drug Association (FDA) approved because most of the operations in automatic machines do not have human involvement, which decreases the chances of drug contamination 

The industrial pharmacy is estimated to be the largest application of a dual chamber syringe (DCS) filling machine .

The industrial pharmacy led the overall dual chamber syringe (DCS) filling machine  market in 2019, both in terms of value and volume. The reason for the industrial segment leading the market is it involves research, production, packaging, quality control, marketing, and sales of pharmaceutical goods. A dual chamber syringe is used for the delivery of two drugs or for the ease of use it provides with lyophilized injectable drug products. The pharmaceutical industry is looking to offer convenient products to patients for self-administration. 

APAC estimated to account for the highest share of the global dual chamber syringe (DCS) filling machine  market in terms of volume.

APAC is projected to have the largest share in the global dual chamber syringe (DCS) filling machine  market, in terms of volume, from 2020 to 2025. The growing aging population, significant medical device manufacturing capacity, growing per capita healthcare spending, and increased health awareness in the country are driving the market in the region.

Key Market Players

Key players in the market are  Syntegon Technology (Germany), Prosys Servo Filling Systems (US), DARA Pharmaceutical (Spain), TurboFil Packaging Machines (US),. Very few companies have adopted strategies to enhance their growth in the market. 

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Scope of the Report

This research report categorizes the dual chamber syringe (DCS) filling machine market based on type, application, and region.

By Type

• Automatic
• Semi-automatic
• Manual

By Application

• Industrial Pharmacy
• Hospital Pharmacy

By Region

• North America
• Europe
• APAC
• Rest of World (RoW)

Recent Developments

• In February 2019, DARA Pharmaceutical launched new equipment for the processing of dual chamber syringes.
• In January 2019, DARA Pharmaceutical launched model NFL / 2 DC, a new machine for the filling and closing of vials, cartridges, and double chamber syringes. 

Frequently Asked Questions (FAQ):

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