Recent Packaging Technologies

Blow-fill-seal technology

Aseptic blow-fill-seal (BFS) technology is the process by which plastic containers are formed, filled with sterile filtered product and sealed in an uninterrupted sequence of operations within the controlled sterile environment of a single machine.

The blow-fill-seal process is a robust, advanced aseptic processing technology, recognized by worldwide regulatory authorities for its inherent operational advantages over conventional aseptic production. Blow-fill-seal systems offer a unique combination of flexibility in innovative packaging design, low operating cost and a high degree of sterility assurance. The machines require a minimum number of operating personnel and have a relatively small space requirement.

A variety of polymers may be used in the process, low and high-density polyethylene and polypropylene being the most popular. The innate ability to form the container/closure during the actual aseptic packaging process allows for custom design of the container to meet the specific needs of the application. This flexibility not only improves container ease of use, but provides a means of interfacing with many of today's emerging drug delivery technologies, most notably in the field of respiratory therapy.

Blow-fill-seal process

Container moulding

Thermoplastic is continuously extruded in a tubular shape. When the tube reaches the correct length, the mold closes and the parison is cut. The bottom of the parison is pinched closed and the top is held in place with a set of holding jaws. The mold is then transferred to a position under the filling station.

Container filling

The nozzle assembly lowers into the parison until the nozzles form a seal with the neck of the mold. Container formation is completed by applying a vacuum on the mold-side of the container and blowing sterile filtered air into the interior of the container. The patented electronic fill system delivers a precise dosage of product into the container. The nozzles then retract into their original position.

Container sealing

Following completion of the filling process, the top of the container remains semi-molten. Separate seal molds close to form the top and hermetically seal the container. The mold opens and the container is then conveyed out of the machine.

The cycle is then repeated to produce another filled container. The filled containers are tested and checked to ensure that they meet the very strict specifications laid down for such products.

The duration of the complete cycle is between 10-18 seconds, depending on the container design and the amount of liquid to be filled.