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Mechanical Disturbances and Sterility Integrity in Pre-Filled Syringe Assembly: Evaluating Risks of Stopper Displacement and Rotation During Plunger Rod Installation
Xin Zhou, Yajing Xu, Wei Chen, Shuying Ji*, Jeremy Guo*

The increasing use of pre-filled syringes (PFS) for macromolecule delivery makes plunger rod installation a critical step, with risks of stopper rotation and axial displacement. In this study, simulated rod-installation tests showed that axial displacement depended on insertion speed, while torque requirements varied by stopper–rod combination. Stopper rotation could alter break-loose force and affect functionality. However, sterility tests under stringent conditions confirmed no breach of aseptic integrity. Overall, minor stopper movements during assembly pose low sterility risk but highlight the need for optimized process controls.

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