Blow-fill-seal (BFS)
Continuous, automated forming, filling, and sealing of sterile plastic containers, eliminating human contact risks.
Technology Overview
Blow-Fill-Seal (BFS) technology is widely recognized as an advanced aseptic process by regulatory agencies. Thermoplastic resin is extruded into a parison, blown into a container mold, sterile-filled, and hermetically sealed in a single continuous automated machine run.
This integrated operation removes manual handling steps, making it ideal for preservative-free ophthalmic drops and respiratory inhalation solutions.
Technical Capabilities & Parameters
| Parameter | Nichepharm Specifications |
|---|---|
| Fill Volume Range | 0.2 mL to 20 mL (with ±1% dosing accuracy) |
| Resin Materials | Medical Grade Low-Density Polyethylene (LDPE) or Polypropylene (PP) |
| Forming Temperatures | 170°C to 200°C (ensuring absolute container sterility during extrusion) |
| Container Layouts | Single unit doses, cards of 5 or 10 droppers, multi-dose squeeze bottles |
| Formulation Scope | Aqueous solutions, ophthalmic drops, inhalation fluids, ear drops |
| Inspection Standards | 100% online vacuum leak testing, high-voltage spark testing |
Aseptic Processing Advantage
Because the plastic container is extruded, filled, and sealed within a localized clean air shower in seconds, the bioburden exposure risk is minimized. BFS formulations can be manufactured without chemical preservatives, improving ocular compatibility and safety.
Start a BFS Packaging Consultation
Submit your ophthalmic or inhalation formulation requirements to our technical transfer team for compatibility review.
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