Health

Glass vials and drug packaging

Borosilicate vials, prefilled syringes, and stoppers for injectable drugs and vaccines.

Why it matters · Injectable drug and vaccine bottlenecks when packaging supply is constrained — medicine is available but cannot be delivered.

5

Inputs

5

Companies

4

Facilities

6

Source countries

How it's made

The process

  1. 01

    Raw Material Batching

    High-purity silica sand (SiO₂, ~80%), boron trioxide (B₂O₃, ~10%), aluminum oxide (Al₂O₃), and sodium oxide (Na₂O) weighed and mixed into a homogeneous batch. Impurity control is critical — trace metals cause delamination downstream.

  2. 02

    Glass Melting & Refining

    Batch melted in continuous furnaces at 1,600–1,700°C. Borosilicate melt refined to remove bubbles and inclusions. Furnaces run 24/7 and require major capital (a new furnace takes 18–24 months and $200M+ to build), creating structural capacity constraints.

  3. 03

    Glass Tube Drawing (Danner or Vello Process)

    Molten glass drawn over a rotating mandrel into continuous borosilicate glass tubing at precise outer diameter and wall thickness. Tubing coiled and shipped from upstream producers (Schott, Gerresheimer, Nipro, NEG) to downstream vial conversion plants.

  4. 04

    Vial Hot-Forming (Tube-to-Vial Conversion)

    Glass tubes heated and formed into vials using tungsten mandrels on rotary forming machines. Bottom sealed, neck and opening shaped in a single high-temperature operation. Dimensional precision is critical for stopper-vial sealing in fill-finish.

  5. 05

    Annealing

    Formed vials pass through a lehr (annealing oven) at controlled temperature gradients. Relieves thermal stresses induced during hot-forming — prevents cracking, warping, and surface micro-fractures that cause later delamination.

  6. 06

    Inspection & Surface Treatment

    Automated optical inspection for dimensional defects, inclusions, and cracks. Surface treatments applied where needed (e.g., ion-exchange for Corning Valor Glass, silicone coating for siliconized vials). Delamination-susceptible batches tested per USP <1660> protocol.

  7. 07

    Depyrogenation, Sterilization & Packaging

    Vials washed, depyrogenated (bacterial endotoxin removal by dry heat >250°C or RABS/isolator wash-fill), and packaged in tubs or bulk. Ready-to-use (RTU) format includes pre-sterilized vials in nest-and-tub to eliminate drug manufacturer's washing/sterilization step.

Where it comes from

Country dependencies

Weighted share of upstream inputs sourced from each country.

CountryWeighted shareInputs supplied to glass vials and drug packaging
TRTurkey73%Boron Trioxide (B₂O₃)
DEGermany45%Borosilicate Glass Tubing (Type I)
USUnited States17%Boron Trioxide (B₂O₃) · Borosilicate Glass Tubing (Type I)
CNChina15%Borosilicate Glass Tubing (Type I)
INIndia8%Borosilicate Glass Tubing (Type I)
RURussia5%Boron Trioxide (B₂O₃)

Who makes it

Supplier companies

5 companies in this supply chain, sorted by market share.

Eti Maden
HQ TR38% share

Turkish state-owned enterprise (est. 1935) — the world's largest boron producer and exporter. Controls approximately 70% of global boron mineral reserves. Supplies boron compounds (including B₂O₃ feedstock) to pharmaceutical glass manufacturers globally. EU quality standards certified.

Supplies these inputs

Boron Trioxide (B₂O₃)

Replaceability

Substitutability 10% · 36 mo to replace

Business segments

  • Boron Minerals (World #1 — 70% of Global Reserves)60% rev
  • Borate Chemicals (B2O3, Borax, Boric Acid)35% rev
  • Export Policy5% rev

German pharmaceutical glass specialist (FRA: 1SXP; IPO September 2023 at ~€3.6B market cap); subsidiary of SCHOTT AG, which is wholly owned by the Carl Zeiss Foundation — a non-profit foundation structure that has owned SCHOTT since 1884. SCHOTT Pharma is the world's largest manufacturer of pharmaceutical primary packaging glass, holding an estimated 35-45% of the global pharmaceutical borosilicate glass tubing market from which vials, ampoules, and syringes are drawn. Type I borosilicate glass has been SCHOTT's core product since founder Otto Schott invented borosilicate glass composition in 1884, and SCHOTT has the longest continuous manufacturing history of any pharmaceutical glass maker. Key pharmaceutical glass vial production plants in Müllheim (Germany), Jena (Germany), Schweinfurt (Germany), and multiple international sites. Supplied hundreds of millions of vials for COVID-19 vaccine programs including BioNTech/Pfizer mRNA vaccines.

Supplies these inputs

Borosilicate Glass Tubing (Type I)

Replaceability

Substitutability 25% · 24 mo to replace

Business segments

  • Pharmaceutical Glass Tubing (Type I Borosilicate)40% rev
  • Formed Packaging (Vials + Syringes + Cartridges)55% rev
  • Specialty Containers5% rev

American borate mining operation (Boron, Kern County, California; Rio Tinto subsidiary since 1968 acquisition of US Borax, itself founded 1872); the world's largest open-pit borax mine, located in the Mojave Desert of California. The Boron mine — locally known as the '20 Mule Team Borax' mine after the historical method of transporting borax from the Mojave — has been continuously operating since 1872, making it one of the oldest mining operations in California. Rio Tinto Boron is the second-largest global boron producer after Turkey's Eti Maden, producing refined boric acid, anhydrous borax, and B2O3 from deposits that underlie the California desert. The town of Boron, California (population ~2,500) exists primarily as the community built to house the mine's workforce. US Borax was the company behind the Borax household cleaning brand ('20 Mule Team Borax' cleaner) — the same California desert mining company whose product whitened Victorian-era laundry also supplies the boron that makes pharmaceutical vials thermally stable.

Supplies these inputs

Boron Trioxide (B₂O₃)

Replaceability

Substitutability 50% · 6 mo to replace

Business segments

  • Boron Mining & Primary Processing60% rev
  • Industrial Boron Products30% rev
  • Consumer & Brand Products10% rev

German pharmaceutical packaging company (XETRA: GXI; MDAX; ~€1.8B revenue 2023); headquartered in Düsseldorf. Gerresheimer is a major pharmaceutical glass and plastic primary packaging manufacturer serving both Type I glass vials (for injectables) and plastic pharmaceutical containers. Glass manufacturing plants include Wackersdorf (Bavaria) and Tettau (Thuringia) in Germany, plus international plants in US (Vineland NJ), India, Mexico, Czech Republic. Gerresheimer is vertically integrated — operates both primary glass tubing drawing capacity and downstream vial conversion at some sites. Listed company focused primarily on high-value pharmaceutical packaging; roughly 17-20% global pharmaceutical glass vial market share.

Supplies these inputs

Borosilicate Glass Tubing (Type I)

Replaceability

Substitutability 25% · 24 mo to replace

Business segments

Specialty glass and ceramics manufacturer; pharmaceutical glass via Life Sciences segment. Acquired Gerresheimer glass tubing business (2015). Developed Valor Glass — premium ion-exchange-strengthened borosilicate alternative approved by FDA (2025). Received $261M in US government funding (Operation Warp Speed) to expand vial production capacity.

Supplies these inputs

Borosilicate Glass Tubing (Type I)

Replaceability

Substitutability 25% · 24 mo to replace

Business segments

  • Optical Communications (Fiber + Cable)30% rev
  • Display Technologies (LCD Glass)25% rev
  • Gorilla Glass + Specialty Cover Glass15% rev
  • Environmental Technologies (Automotive + Diesel Substrates)15% rev

Where it's made

Facilities

4 facilities producing inputs that feed glass vials and drug packaging.

Corning Harrodsburg Glass Fab (Kentucky)

US

Corning · Kentucky · fab

Corning Incorporated's primary display glass substrate manufacturing plant in Harrodsburg, Mercer County, Kentucky. Produces Corning Lotus NXT and Eagle XG glass substrates used as the base for virtually all LCD and OLED display panels. Corning holds approximately 60% of global display glass substrate supply; the Harrodsburg plant is Corning's largest U.S. display glass facility. Display glass must be made near-zero impurities (5 parts per billion iron), thermally stable, and ultra-flat — Corning's fusion draw process is the only method capable of meeting these specifications at scale. Without Corning's glass substrates, all major display panel fabs (BOE, AUO, Innolux, LG Display) would halt production within weeks. Source: https://www.corning.com/worldwide/en/innovation/corning-emerging-innovations/corning-lotus-nxt-glass.html

Eti Maden Kırka Borax Mine

TR

Eti Maden · Kırka, Eskişehir · mining_and_processing

One of the world's largest known borate deposits. Mines tincal (borax ore) and processes to refined boron compounds. Critical supplier to global glass and pharmaceutical industries.

Gerresheimer Wackersdorf Glass Plant

DE

Gerresheimer AG · Wackersdorf, Bavaria · glass_vials

Key German vial and ampoule production facility. Part of Gerresheimer's 15+ global manufacturing sites for pharmaceutical glass.

Schott Pharma Mainz Headquarters & Production

DE

SCHOTT Pharma AG & Co. KGaA · Mainz, Rhineland-Palatinate · glass_tubing_and_vials

Primary R&D and production facility. Produces borosilicate glass tubing (Fiolax) and finished primary packaging.