Accepted answer
At 6.67 mg/mL every microlitre left behind is 6.67 µg, so a 50 µL hub costs 0.334 mg per draw and a 5 µL fixed-needle barrel costs 0.0333 mg. Multiply by the draws, not by the doses: ten draws through a 50 µL dead space is 3.33 mg gone, which at 6.67 mg/mL is 0.5 mL of solution you paid for and never administered. Against a 2 mg dose that 50 µL is 16.7 per cent; against a 0.25 mg dose it is 133.4 per cent, which is why the loss matters most at exactly the doses where you can least afford it. an 18G drawing needle has a bore, a hub and a length, and the hub dominates: a fixed-needle insulin barrel has almost none, a luer connection has a measurable one before the needle even starts.
The underlying point is that dead space is irreducible with a high-dead-space syringe, which is why the hardware matters more than any technique.
Dead space quantified: a fixed-needle insulin syringe holds roughly 3 to 5 µL in the hub and needle after the plunger bottoms out. A luer-lock syringe with a detachable needle holds 35 to 100 µL depending on the hub design.
The complete rule: fix the syringe architecture first, and then the reconstitution volume becomes a free choice you can make on stability grounds rather than on economics.
Published inter-laboratory comparisons of dead-space measurements on identical syringes show good agreement, suggesting the numbers are reliable.
The caveat is that dead space is a yield loss and not a dose-accuracy loss, so the person feeling this loss most is the person with the most total draws.
Buy the right syringe — a fixed-needle insulin syringe is cheap and solves the problem.