Blowing-Filling-Sealing(BFS) System

Blowing-Filling-Sealing (BFS) System is an advanced packaging technology used for the aseptic filling of pharmaceuticals, food, and cosmetic products. It is a fully automated system that integrates the processes of container forming, filling, and sealing into a single continuous operation. This technology ensures the sterility and integrity of the product by forming containers from a sterile plastic granulate, filling them with the product under aseptic conditions, and then sealing them with a pre-sterilized plastic closure.

BFS aseptic packaging blow fill seal system

The BFS blow-fill-seal all-in-one machine uses a special packaging-free technology and operates continuously to make polyethylene (PE) or polypropylene (PP) particles into containers, fully automatically complete the filling and sealing process, and produce rapid and continuous cycles. It integrates several pharmaceutical production processes into the same equipment and completes the blow molding, filling and sealing of plastic containers in a single process under aseptic conditions, which can effectively ensure the safety of pharmaceutical use. This equipment has the advantages of low production cost and management cost, good sterility stability, high intrinsic quality of finished products, and low product cross-contamination rate. It is widely used in eye drops, aerosols, inhalants, injections, disinfectants, and large infusions. Sterile packaging of plastic containers such as pharmaceutical industry and disposable cosmetics.

Introduction to continuous blow-fill-seal (BFS) production line

The main purpose:

• The continuous BFS equipment plasticizes and sterilizes plastic particles under high temperature and high pressure, and extrudes them into a single oval parison. Sterile gas provides positive pressure protection to the oval parison, the filling needle is inside the parison, and filling is completed in a sterile closed space. The filled container belt is conveyed to the punching equipment, where product and waste are separated. According to different structures, continuous BFS is divided into two types: multi-mode continuous type and single-mode continuous type:
• Multi-mode continuous mode: The parison is continuously extruded and transported to a continuously circulating mold chain. Multiple sets of molds are installed on the mold chain. After the rotating mold completes the molding of the container, the liquid is filled through the filling needle, and then The next set of molds on the rotating mold chain seals the container and simultaneously completes the container molding of the next set of products in a continuous cycle. The cycle steps of forming, filling and sealing product containers are completed within 3 to 4 seconds.
• Single-mode continuous mode: The parison is continuously extruded and transported to a set of vertically running molds. The molds are divided into bottle body molds and bottle head molds. The left and right centers open and close the molds. The parison extrusion speed is in line with the vertical running mechanism of the mold. The speed is synchronized to continuously form a BFS cycle of container-filling-sealing, and the cycle steps are completed within 7 to 10 seconds.

Process flow:

• The parison (oblate tube blank) is made by heating and extruding plastic particles;
• Suction in the mold to make a bottle;
• After the bottle is formed, the liquid is filled;
• Bottle sealing;
• Output the continuous pattern to the punching station for punching;

The difference between traditional packaging and blow-fill-seal packaging

Glass packaging

• It requires higher material transportation costs and needs to be equipped with a complete glass bottle production line, which greatly increases manufacturing costs and warehouse area.
• A complete transportation system and at least two layers of packaging are required to prevent the glass from breaking, which increases transportation and personnel costs.
• When the flame is generated, a negative pressure will be generated in the ampoule. When it is opened, surrounding contaminants will be pushed into the bottle, contaminating the liquid.

Blow pot seal

• BFS machines produce packaging containers under sterile conditions, reducing human interference
• Low production costs, no need for excessive packaging in shatterproof plastic containers
• The BFS machine is sealed and flame-free, and has an opening that can be easily twisted off for easy injection.

Wash potting

• Heavy equipment and long-line equipment used in production require higher production bases and large-area purification workshops.
• Multiple machines are required from bottle input to final product, and the production line requires more operators to operate and maintain.
• During the high-temperature sterilization process, it is easy to cause variations in the medicinal solution, such as changing the pH value and effectiveness of the medicinal solution, causing quality risks.

Blow pot seal

• Since the BFS equipment occupies a small area, it saves a lot of infrastructure investment
• Integrate all processes into a fully automated system like the BFS machine, which requires only 2 operators
• BFS equipment provides an efficient sterile production environment, eliminating unnecessary sterilization needs

Freeze drying process

• Crystals must be added to the product for crystallization, and the product cannot be tested for insoluble particles
• Before use, a large amount of process pure water and energy are needed for cleaning to ensure sterility.
• The freeze-drying process requires long working hours, low output, and high energy consumption, resulting in very high operating costs.

Blow pot seal

• BFS creates a sterile filling environment with no additives necessary
• There is no need for special cleaning starting from raw materials
• Complete all processes on one BFS machine, reducing time and capital investment