Ugo Gay- President of the Drug Containment Solutions Business Unit and Shared Services, Stevanato Group
The healthcare sector is undergoing a profound transformation as at-home injectable treatments become increasingly prevalent. An estimated 129 million people in the U.S. have at least one major chronic disease (e.g., heart disease, cancer, diabetes, obesity, autoimmune disorders) as defined by the U.S. Department of Health and Human Services. This remarkable growth is underpinned by the convergence of rising incidence of these diseases, rapid advancements in drug delivery technologies, and the expanding use of biologics and biopharmaceuticals. More patients are taking an active role in their care and creating demand for self-administered therapies that are safe, reliable, and also elevate patient experience standards. As a result, needle-free systems and intuitive autoinjectors have emerged as a cornerstone of chronic condition management.
Among the most significant innovations in these types of patient-centric drug delivery systems are microvials, a primary packaging container that features enhanced security and precision and addresses many of the common barriers to injection and self-injection. By overcoming challenges such as complex handling and dosing inaccuracies, micro vials are empowering individuals to manage their treatments confidently at home or in emergencies, ultimately supporting better adherence and improved health outcomes.
Core Principles of Patient-Centric Packaging
Patient-centric packaging is fundamentally designed to put the needs, abilities, and experiences of the consumer at the forefront, promoting both safety and autonomy throughout the treatment journey. With the World Health Organization reporting that 50% of patients with chronic conditions don’t take their medications as prescribed, the importance of packaging that supports adherence can’t be overstated.
True patient-centric packaging is built around features that make medication easier to access, such as easy-open mechanisms, single-handed operation, and portability. Simplicity and safety are prioritized through innovations like pre-filled syringes and autoinjectors, which eliminate the need for dose measurement and reduce the risk of errors. Intuitive design elements, such as ergonomic shapes, tactile feedback, and one-button operation, ensure that even those with dexterity challenges or limited vision can use the product correctly. Clear instructions, visual aids, and color coding further reduce anxiety and confusion, while step-by-step guides, sometimes enhanced with QR codes linking to video demonstrations, make the process accessible for all users. Accessibility is also addressed with lighter, easy-grip packaging and instructions available in multiple languages or icon-based formats, accommodating seniors, people with disabilities, and diverse populations. Advanced features like smart packaging with digital reminders and dose counters help users stay on track, allowing them to manage their treatment effectively.
An example of innovation in drug delivery is the Aidaptus® auto injector, developed by Owen Mumford with engineering and manufacturing support from Stevanato Group. This two-step, single-use device is designed to accommodate both 1 mL and 2.25 mL prefilled glass syringes within a single platform - eliminating the need for changing parts. Its self-adjusting plunger rod automatically adapts to varying plunger positions and fill volumes, while supporting a broad range of drug viscosities. Aidaptus® also enhances patient safety and ease of use with intuitive operation and automatic needle shielding, keeping the needle concealed before, during, and after injection.
Another example of smart drug delivery designed to improve patient experience is the Vertiva® on-body delivery system. This platform features a unique design with a single-use pod paired with a reusable, smart controller. The pod contains a pre-filled, pre-loaded cartridge -available in 3 mL to 10 mL formats - assembled at the factory and ready for immediate and intuitive use by patients.
A recent wearability study confirmed that the 10 mL version of Vertiva® is generally well-accepted by users. Patients found it comfortable to wear, with secure adhesion that didn’t restrict movement, allowing them to continue daily activities with ease.
The Vertiva® platform can be pre-programmed to accommodate different motor-driven dosing profiles, from micro-precision basal delivery to full-content bolus injections. This makes it even more flexible from both the patient’s and the medical care provider’s point of view.
Ultimately, when packaging is intuitive, it simplifies self-injection and builds the confidence essential for long-term treatment success outside the clinical setting.
Micro Vials: A Game-Changer in Packaging Design
Micro vials represent a significant advancement in pharmaceutical packaging, particularly for at-home and alternative-route drug delivery. Their compact size - typically ranging from 0.3 mL to 1.7 mL - makes them ideal for low-volume applications such as nasal or sublingual administration, where precise dosing and ease of use are essential.
Designed to integrate seamlessly with nasal spray devices, micro vials ensure accurate dosing and consistent spray performance. Their compatibility with a wide range of drug viscosities and delivery systems also makes them well-suited for emergency treatments, where reliability and speed are critical. A notable example is Neffy®, the needle-free epinephrine nasal spray developed by ARS Pharmaceuticals, which utilizes microvials supplied by Stevanato Group.
Nasal delivery is particularly valuable for parents caring for young children, whether managing chronic conditions or responding to urgent situations like severe allergic reactions. The needle-free format reduces fear and discomfort, while the simple, intuitive administration allows caregivers to act quickly and confidently when every second counts.
As at-home treatments continue to evolve, micro vials have emerged as a key enabler - offering enhanced safety, dosing accuracy, and user friendliness. By simplifying the delivery process and supporting better adherence, they empower patients and caregivers alike to take greater control of health from the comfort of home.
Ultimately, packaging is more than just a container - it’s a vital part of the therapeutic experience. As healthcare increasingly embraces self-administered care, innovations like micro vials will play a central role in ensuring treatments are not only effective but also accessible, intuitive, and patient-centered.
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