From vial to prefilled delivery devices in autoimmune diseases: Exploring the formulation and technological pharmaceutical challenges

• Pre-filled delivery devices are used for the management of autoimmune diseases. • Repurposing from vial to prefilled devices implies reformulation development. • Marketed prefilled devices have a lower shelf life than the respective vial. • Pre-filled delivery devices allow for improved patient safety and convenience. The use of medicines in the daily clinical practice and meeting the desired effectiveness is many times dependent upon patient experience and compliance with the therapy. This is particularly relevant in chronic diseases, such as the case of autoimmune diseases. The management of autoimmune diseases often involves the regular administration of biologic therapies, which require precise dosing and consistent adherence to treatment regimens. Prefilled syringes, prefilled pens, and auto-injectors have emerged as pivotal tools in this therapeutic landscape, offering significant benefits in terms of convenience, safety, and accuracy. Despite the R&D efforts involved in the repurposing of the pharmaceutical form from a vial to a ready-to-use prefilled syringe, the time saved for both doctor and patient, and the convenience to the patient are intangible values. This review provides a comprehensive overview of the use of drug prefilled delivery devices in the treatment of autoimmune diseases. A special focus is given to the formulation differences when comparing vials with prefilled delivery devices, addressing the modifications in terms of strength, primary packaging, shelf life, and excipients. It delves into the technological advancements that have led to the development of these devices, describing the composition and function of each component on the currently marketed injectable drug delivery devices for autoimmune diseases. Through a review of current research and clinical practices, this study highlights the critical role these devices play in enhancing the effectiveness of autoimmune disease management, ultimately leading to better patient outcomes.