The Luer syringe delivers the overwhelming majority of the estimated 16 billion injections dispensed annually. Luer syringes retain up to 30% of a 0.5mL dose in the interior cavity of the syringe nozzle and female hub (deadspace) after the dose is dispensed, meaning billions of potential doses are being discarded. Vials and prefilled Luer syringes are routinely overfilled to ensure the prescribed dose is dispensed.

The injectable drug-delivery market was valued at $756.22 billion in 2025, growing at an estimated CAGR of 9.56% thru 2034, valuing the market at $1.720 trillion. The worldwide needle/syringe market was valued at $26.8 billion in 2025, with an estimated CAGR of 9.0% through 2035, valuing the market at $64.3 billion. (References available upon request)

This entry focuses on the monetary gain a meaningful reduction of Luer deadspace will create for the global injectables market by converting the reduced wastage into additional doses, billable revenue and net profit.

The solution must be simple and low cost: reduce the undispensed overfill to create billions more doses and billions of dollars in revenue without modifying the existing tooling now producing billions of Luer syringe components annually.

The multi-patented PRO-FLO™ Low-Deadspace Syringe utilizes a small, add-on insert that displaces the majority of the volume in the deadspace, converting the reduced overfill into additional injections (AI) and billable doses from existing production-lot volumes. The PRO-FLO syringe produces 9 full 0.5mL doses from 5mL of volume, where the elongated-piston, low-deadspace Luer syringe produces 8 full 0.5mL doses. This 11% increase in dose-yield is a generational leap, translating to billions of dollars of billable doses, reducing the GOGS per dose by simply reducing, dispensing and monetizing the now-undispensed overfill. 

The PRO-FLO insert can be assembled into the distal end of any size Luer syringe nozzle via a continuous, in-line workstation without changing the existing tooling, packaging or sterilization, so production can be scaled quickly at a reasonable cost in a shortened amount of time.

The insert can be molded with a medical-grade polymer or butyl-based elastomer, and may include a fluoropolymer spray coating or film to eliminate any extractable and leachable materials in the insert from interacting with the injectables in the syringe. The insert may also be formed via a progressive die and coated if necessary.

This financial model demonstrates the intrinsic value proposition (totaling $253,119,960 of the injectables now discarded in Luer syringes) an 11% increase in dose-yield creates from the production-lot volume now producing 10 million single-dose vials. The pharmaceutical supplier, syringe supplier, distributor and the Centers for Medicare and Medicaid Services (CMS) all benefit from the additional doses when the PRO-FLO Low-Deadspace Syringe System is bundled with reduced-overfill single-dose vials.

PRO-FLO Syringe = 1.1mm Extra Vials from Existing 10mm Vial Volume

RSV Abrysvo CMS 2025-2026 CMS 2025-2026 CMS New Supplier
Price Undiscounted Price 4% Discount CMS Savings New Revenue
Dec. 2025 Price $230.89 /Vial $230.89 /Vial $220.89 /Vial $9.20 /Vial $13.60 /Vial
Vials 10,000,000 11,100,000 11,100,000 11,100,000 11,100,000
Vaccine Value $2,300,900,000 $2,553,999,000 $2,451,839,040 $102,159,960 $150,960,000