A TOTAL COST OF OWNERSHIP MODEL TO QUANTIFY THE VALUE OF RFID INTEGRATION IN PRE-FILLED SYRINGES
Author(s)
Matthias Borms, PharmD1, Julia D. Lucaci, PharmD, MS2, Yacine Haddadi, PharmD3.
1Becton Dickinson, Le Pont de Claix, France, 2Becton Dickinson, Chicago, IL, USA, 3Becton Dickinson, Pont-de-Claix, France.
1Becton Dickinson, Le Pont de Claix, France, 2Becton Dickinson, Chicago, IL, USA, 3Becton Dickinson, Pont-de-Claix, France.
OBJECTIVES: The integration of radio-frequency identification (RFID) technology at the unit level in pre-filled syringes (PFS) has the potential to enhance manufacturing efficiency and process robustness across pharmaceutical fill-finish operations. This study presents a total cost of ownership model developed to quantify the economic value of RFID-enabled PFS by capturing operational gains across multiple use cases within a typical large-scale production environment.
METHODS: The model incorporates five key value drivers: automated reconciliation, mix-up prevention, precise batch segregation, process improvement, and false reject reduction. Each use case was parameterized using a combination of literature data, industry studies, and expert input from pharmaceutical manufacturers. The baseline scenario assumes an annual production capacity of 12 million units, with improvements in overall equipment effectiveness, cost of goods, and scrap reduction translated into monetary value.
RESULTS: RFID integration was estimated to generate total annual savings of approximately $9.8 million. The primary value drivers were precise segregation at $3.0 million, process improvement at $2.7 million, and false reject reduction at $2.0 million, followed by reconciliation at $1.3 million and mix-up prevention at $0.8 million. These savings reflect improvements in line efficiency, reduced downtime, avoidance of batch losses, and enhanced process visibility. After accounting for an estimated $3.2 million investment in RFID chips, system implementation and regulatory compliance, the model yielded a net annual benefit of approximately $6.6 million for a production volume of 12 million units.
CONCLUSIONS: Overall, RFID-enabled traceability at the primary packaging level can deliver substantial economic benefits. Additional use cases were not quantified, such as incoming inspection, process development and simulations via digital twins, clinical trial traceability, anti-counterfeiting, and real-time release testing which may further enhance value. Beyond quantifiable gains, RFID can support regulatory compliance with existing regulations, reduce mix-up and recall risks, and may strengthen regulatory confidence, enabling more efficient inspections and lifecycle management.
METHODS: The model incorporates five key value drivers: automated reconciliation, mix-up prevention, precise batch segregation, process improvement, and false reject reduction. Each use case was parameterized using a combination of literature data, industry studies, and expert input from pharmaceutical manufacturers. The baseline scenario assumes an annual production capacity of 12 million units, with improvements in overall equipment effectiveness, cost of goods, and scrap reduction translated into monetary value.
RESULTS: RFID integration was estimated to generate total annual savings of approximately $9.8 million. The primary value drivers were precise segregation at $3.0 million, process improvement at $2.7 million, and false reject reduction at $2.0 million, followed by reconciliation at $1.3 million and mix-up prevention at $0.8 million. These savings reflect improvements in line efficiency, reduced downtime, avoidance of batch losses, and enhanced process visibility. After accounting for an estimated $3.2 million investment in RFID chips, system implementation and regulatory compliance, the model yielded a net annual benefit of approximately $6.6 million for a production volume of 12 million units.
CONCLUSIONS: Overall, RFID-enabled traceability at the primary packaging level can deliver substantial economic benefits. Additional use cases were not quantified, such as incoming inspection, process development and simulations via digital twins, clinical trial traceability, anti-counterfeiting, and real-time release testing which may further enhance value. Beyond quantifiable gains, RFID can support regulatory compliance with existing regulations, reduce mix-up and recall risks, and may strengthen regulatory confidence, enabling more efficient inspections and lifecycle management.
Conference/Value in Health Info
2026-11, ISPOR Europe 2026, Vienna, Austria
Value in Health, Volume 29, Issue 12S
Code
MT21
Topic
Economic Evaluation, Medical Technologies, Methodological & Statistical Research
Disease
No Additional Disease & Conditions/Specialized Treatment Areas