Method and Apparatus for Manufacturing, Filling and Packaging Medical Devices and Medical Containers

A filled syringe made in accordance with a method comprising the steps of:

• forming a plastic syringe barrel in an injection molding machine, said syringe barrel having a cylindrical side wall, an open proximal receiving end and a frustoconically shaped outlet nozzle at its distal end;
• transferring said syringe barrel into an environmentally controlled area without exposing said syringe barrel to unfiltered air;
• directing a stream of filtered are toward said syringe barrel in said environmentally controlled area to remove particles from surfaces thereof to clean said syringe barrel;
• delivering a stopper in said environmentally controlled area;
• inserting said stopper into said open proximal end of said syringe barrel to close said proximal end;
• filling said syringe barrel with a substance through its outlet nozzle;
• delivering a tip cap to said environmentally controlled area;
• air washing said tip cap in said environmentally controlled area;
• assembling said tip cap to said outlet nozzle of said syringe barrel to form a prefilled syringe;
• and
• removing said prefilled syringe from said environmentally controlled area.

A plastic drug or medical container made in accordance with a method comprising the steps of:

• forming said medical or drug container;
• transferring said drug or medical container to an environmentally controlled area without exposing said drug or medical container to unfiltered air;
• directing a filtered air stream towards at least one surface of said drug or medical container in said environmentally controlled area;
• and
• applying a vacuum to remove particulates loosened from said drug or medical container within said environmentally controlled area.

A plastic vial made in accordance with a method comprising the steps of:

• forming said vial;
• transferring said vial to an environmentally controlled area without exposing said vial to unfiltered air;
• directing a filtered air stream towards at least one surface of said vial in said environmentally controlled area;
• and
• applying a vacuum to remove loosened particulates from said vial within said environmentally controlled area.

A plastic ampoule made in accordance with a method comprising the steps of:

• forming said ampoule;
• transferring said ampoule to an environmentally controlled area without exposing said ampoule to unfiltered air;
• directing a filtered air stream towards at least one surface of said ampoule in said environmentally controlled area;
• and
• applying a vacuum to remove particulates loosened from said ampoule within said environmentally controlled area.