System and method of limiting subvisible particles in a syringe

A method of limiting subvisible particles in a syringe partially filled with a drug product, the method comprising:

• applying a quantity of silicon oil to a syringe barrel of a syringe, the syringe barrel including a proximal end, a distal end, and a reservoir, wherein a drug product is disposed in a distal end of the reservoir at the distal end of the syringe barrel, and the quantity of silicon oil is in a range of approximately 0.4 mg to approximately 0.6 mg;
• disposing the syringe into a carton;
• and
• disposing the carton into a suspension packout system configured to reduce generation of subvisible particles in the syringe during transport, the suspension packout system including packing material surrounding the carton including the syringe, limiting contact of the carton to the packing material.

A syringe partially filled with a drug product, the syringe comprising:

• a syringe barrel including a proximal end, a distal end, and a reservoir, wherein a drug product is disposed in a distal end of the reservoir at the distal end of the syringe barrel, the syringe barrel having a quantity of silicon oil in a range of approximately 0.4 mg to approximately 0.6 mg, the quantity of silicon oil configured to limit an amount of subvisible particles generated in the syringe barrel;
• a plunger portion disposed at a depth within the syringe barrel, the plunger portion spaced from the drug product;
• and
• an air gap disposed between the plunger portion and the drug product, the air gap having an air gap length in a range of approximately 1.2 mm to approximately 3.5 mm.