HealthStar, Inc. Unveils Patented Autoinjector with Blow-Fill-Seal (BFS) Carpule Technology

[Braintree, MA], September 8, 2025 — HealthStar, Inc., a leader in innovative Pharmaceutical packaging and processing solutions, is thrilled to announce the development of our patented autoinjector syringe featuring a blow-fill-seal (BFS) produced polyethylene carpule. This cutting-edge device is designed to deliver precise doses ranging from 1ml to 10ml, offering a cost-effective, safe, and user-friendly solution for patients and healthcare professionals.

The autoinjector incorporates a sterile polyethylene carpule manufactured using the BFS process, ensuring exceptional sterility and reliability, minimizing contamination risks and enhancing patient safety. Unlike traditional glass carpules, which are costly and time-consuming to produce, the BFS carpules are lightweight, durable, and significantly more economical, with a mid-range BFS machine capable of producing up to 45 million carpules annually in a compact footprint. The BFS production process is fully compliant with Annex 1 standards for aseptic production.

Key advantages of HealthStar’s autoinjector include:

• Ease of Use: A simple twist of a knob activates the syringe, deploying the needle for injection by patients or healthcare professionals. Post-injection, the needle is safely retracted and sealed, allowing for standard sharps disposal.
• Cost Efficiency: The use of BFS-produced polyethylene carpules drastically reduces production costs compared to glass-based autoinjectors, enabling broader access to life-saving medications.
• Versatility: The device supports a wide range of injectable therapies, accommodating doses from 1ml to 10ml, making it suitable for various medical applications.
• Sustainability: Polyethylene carpules are more environmentally friendly than glass, offering a lighter and more recyclable alternative.

The BFS process itself provides significant advantages, including:

• Enhanced Sterility: The fully automated, single-step BFS process minimizes human intervention, ensuring a sterile product with reduced risk of contamination.
• High Throughput: BFS technology enables rapid production rates, supporting scalability for high-demand medications.
• Stability and Compatibility: HealthStar offers comprehensive BFS prototyping services to assess drug stability and compatibility, ensuring optimal performance for a variety of pharmaceutical formulations.

“This innovation represents a significant leap forward in autoinjector technology,” said William Grabowski, CEO of HealthStar, Inc. “By combining our patented design with BFS technology, we’re delivering a solution that is not only cost-effective but also enhances patient safety and accessibility to critical treatments.”

HealthStar invites pharmaceutical companies, healthcare providers, and investors to explore our autoinjector design. Full BFS prototyping services are available through HealthStar to evaluate drug compatibility and stability, paving the way for customized solutions tailored to specific therapeutic needs.

For more information or to discuss this development, please contact Info@healthstaronline.com for more information

About HealthStar, Inc.

Since 1983, HealthStar has been a trusted leader in packaging and processing solutions for the Pharmaceutical and Healthcare product industries. Our expertise is sterile automation utilizing blow-fill-seal technology. With a global focus on advanced manufacturing technologies, HealthStar is dedicated to developing innovative, cost-effective, and patient-centric solutions for drug delivery worldwide.

Media Contact:

HealthStar, Inc.

Email: Info@healthstaronline.com

Phone: 1-781-961-5456