Testing of Autoinjectors to DIN EN ISO 11608-5 

ZwickRoell offers testing systems for automated testing of autoinjectors. 

Objective of the Autoinjector Test DIN EN ISO 11608-5

An autoinjector is a medical instrument (medical device) with which liquid medication can be administered, and is therefore subject to strict quality controls. In the past, autoinjectors were mainly used when a drug needed to be administered as quickly as possible by medically untrained persons. Examples of this are adrenalin injectors used in cases of anaphylactic shock and morphine or atropine injectors used by soldiers in combat missions. Today there are two other factors that contribute to the increased use of autoinjectors.

One is injection vs. ingestion, meaning certain substances (for example, biopharmaceuticals) cannot be administered in tablet form, because they would be digested in the patient's gastrointestinal tract and would not enter the bloodstream. The other is that the autoinjector functions as the an extension to the doctor's arm. Injectors guarantee a high level of application safety.

The correct injection and proper dose of medicine are vital to achieve the best therapeutic success. Therefore, pharmaceutical manufacturers strive to achieve a high level of automation in autoinjector technology. The patient simply removes the safety cap, positions the injector, and injects the drug by pressing a button. The process that follows is completely automated. However, this also means that all of the injector's relevant functions must be checked before the production batch is released on the market. This test is performed to DIN EN ISO 11608-5.

Autoinjector Testing to DIN EN ISO 11608-5 with ZwickRoell

ZwickRoell offers testing systems that can perform the following automated tests:

  • Removal force of the safety cap
  • Autoinjector activation force and travel
  • Injection time measurement
  • Determination of the administered drug volume, including the last drops with an integrated high-resolution scale
  • Effective needle length for injection
  • Safety function of the needle shield
  • Testing of injectors with/without actuating button
  • Color recognition on autoinjector/actuating button
  • Acoustic recognition of start/end of injection
  • Mistake-proofing through design (Poka-Yoke)
  • Daily checks on load cell, scale, microphone, needle-length and fluid-presence sensors, as well as color recognition
  • Measurement of ambient humidity and temperature

The integrated test offers the benefit that all tests can be performed on a single specimen without changing test tools. The testing system can be expanded to accommodate additional tests, satisfying a variety of market requirements and product developments. With an optional microphone to provide audible feedback, the system can detect autoinjector clicks, which indicate the start and end of the injection. In addition, an HD camera can be integrated to document liquid emission. You can save these images with the test results to support traceability. The machine can be equipped with a monitoring mechanism that complies with the requirements of DIN EN ISO 13849. testXpert III testing software manages the control and evaluation of these additional functions, as well as the entire test control sequence.

Summary of advantages:

  • Multifunctional testing machine for all test sequences on one sample
  • Elimination of operator influences through sequential tests on one injector
  • Five different Daily Checks guarantee reliable test results
  • Testing machine for autoinjectors with and without actuating button
  • Modular, flexible robotic system for fully automated specimen feeding
  • Fast cycle times
  • Validation support through expanded ZwickRoell qualification documentation (DQ/IQ/OQ)

DIN EN ISO 11608-5 – Automation Options

It is particularly important that the testing process save time and resources when dealing with large production batches. The testing system offers different levels of automation— from a manual solution to a fully automated robotic testing solution that places the injectors in the testing machine. A typical market solution is a semi-automated testing machine where the operator inserts the autoinjector into the machine, closes the safety door, and starts the test. All test steps are then carried out automatically by the machine. 
Smart lightweight robot roboTest N for automated function tests on autoinjectors