Functionality of BFS

How Blow-Fill-Seal Technology Works

At its core, Blow-Fill-Seal (BFS) technology streamlines the complex processes of traditional aseptic filling methods into three fully automated, seamless steps, ensuring precision, sterility, and efficiency in every container produced.
B Blow

Pure polymer granules are extruded to form a tube, which is then formed into a sterile container using vacuum and sterile air.

F Fill

The container is instantly filled with the liquid or semi-solid substance in precisely the right quantity.

S Seal

Finally, the container is hermetically sealed.

B

Blow

Pure polymer granules are extruded to form a tube, which is then formed into a sterile container using vacuum and sterile air.

F

Fill

The container is instantly filled with the liquid or semi-solid substance in precisely the right quantity.

S

Seal

Finally, the container is hermetically sealed.

100 %

aseptic

0,1 - 2000 ml

filling volume

up to 33 k

units per hour

Benefits

Benefits of Blow-Fill-Seal

Advanced Aseptic Filling Technology
Advanced Aseptic Filling Technology

The industry recognizes BFS technology as one of the most advanced aseptic filling technologies, as it eliminates contamination risks. 

User Convenience
User Convenience

Designed for easy opening and precise dispensing, BFS containers enable safe and reliable applications.

Flexibility in Container Design and Function
Flexibility in Container Design and Function

From ampoules to bottles, with features like hangers, recessed grips, droppers, embossed or labeled, vented or non-vented withdrawal - BFS adapts to your individual requirements.

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Compliant by Design

BFS is engineered to meet the strict regulatory standards of global health authorities such as the FDA, EMA, and ANVISA, ensuring compliance across various product categories and international markets. By using high-purity, additive-free polymers like LDPE, BFS containers meet the rigorous requirements of the European Pharmacopoeia.

Minimal Logistics, No Cleaning, or Sterilization Processes
Streamlined Logistics

Since there are no prefabricated containers to store, transport, clean, or sterilize, Blow-Fill-Seal technology simplifies your logistics and significantly cuts costs.

Break-Proof Containers
Break-Proof Containers

BFS containers don't break or shatter like glass, reducing injury risks and contamination from shards. Their impact resistance also lowers the risk of damage during transport.

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Sustainability

Sustainability Benefits of Blow-FIll-Seal

BFS technology uses polymer granulate, eliminating the need for energy-intensive glass production and significantly reducing resource consumption.
Unlike other aseptic filling methods that require costly cleaning and sterilization of prefabricated containers, BFS technology produces and fills containers in a sterile environment within a single seamless process.
BFS technology utilizes high-quality, recyclable pharma-grade monomaterial (polymer granulate). Production waste can be efficiently re-granulated and reused within the BFS process or reintroduced into the recycling cycle.

BFS containers are lightweight, saving transportation weight and eliminating the need to transport empty containers prior to filling, significantly reducing CO2 emissions.
Landschaftsbild mit Agrarwiesen, Baumbestand und Wolkenhorizont um den Nachhaltigkeits-Gedanken zu untermalen.

PRIMARY PACKAGING

Perfect BFS Primary Packaging for Every Application

Our ampoules and bottles are as individual as the products inside.

Available in volumes from 0.1 to 50 ml, these ampoules are designed to deliver the exact amount needed for each application. They can be produced in functional packaging units, with up to 33,000 ampoules manufactured per hour.

Key Benefits:

  • Precise dosing while maintaining sterility, even without preservatives
  • High production rates: up to 33,300 ampoules per hour in various block sizes
  • Versatile packaging options, including foldable ampoule blocks and functional connectors
Rendering of different Blow-Fill-Seal ampoules

Our Blow-Fill-Seal technology enables the creation of diverse bottles ranging from 50 milliliters to 2 liter, perfect for various liquid products. Suitable for upright and suspended applications, these bottles provide limitless shape, function, and usability possibilities.  Each bottle is precisely engineered to suit its specific requirements.

Key Features:

  • Versatile Volume Options: Produce bottles ranging from 50 ml to 1 liter using the same mold, enhancing flexibility and efficiency in your production process.
  • High Production Capacity: Achieve a manufacturing rate of up to 9,200 bottles per hour.
  • Customizable Design Elements: Choose from various closures and tabs with vented or unvented withdrawal options, including piercing or pouring openings.
Rendering of different Blow-Fill-Seal bottles

Bellows containers provide a simple, safe, and highly convenient solution for specialized pharmaceutical applications. Their ease of compression makes them ideal for dispensing gels or ointments. With BFS technology, the primary packaging container can also function directly as an applicator, e.g., for vaginal and rectal applications, and is produced in a single operation.

Key Benefits:

  • User-Friendly Design: Functional shape offers greater convenience than classic tube packaging
  • Integrated Applicators: Applicators are formed directly during the Blow-Fill-Seal process
  • Ideal for Sensitive Applications: Perfect for dispensing gels and other substances in sensitive areas, providing both hygiene and convenience
Rendering of a blow-fill-seal bellow container and applicator
Rendering of different Blow-Fill-Seal ampoules
Rendering of different Blow-Fill-Seal bottles
Rendering of a blow-fill-seal bellow container and applicator

Connectors and Closures

Functional Connectors and Closures

Illustration of Luer-Fit and Luer-Lock Closure
Luer-Fit and Luer-Lock Compatible

Enables easy withdrawal of liquids using syringes without needing an additional needle. Ampoules with a vented Luer connection offer automatic pressure compensation, ensuring a smooth and consistent flow.

Illustration of Twist-off Cap
Twist-off Cap

Formed directly during the sealing process, the twist-off cap is firmly attached to the container. Simply twist it to open. This method has been proven billions of times and offers highly flexible design options to meet diverse packaging needs.

Illustration of KME Closure
KME Closure

The KME closure system features a screw cap with an integrated puncture pin. By twisting the cap into the bottle top, it creates an opening suitable for dripping or spraying, making it ideal for multi-use applications.

Illustration of a Eurocap Closure
Eurocap

This closure system combines a sealed container with a Eurocap and is specifically designed to meet the stringent requirements of infusion bottles.

Illustration of a Nipplehead Closure
Nipplehead

An alternative to Eurocaps, the nipplehead closure is formed during the sealing process, offering a different closure option to suit specific needs.

Multi-layered BFS

Excellent Barrier Properties with Multilayered BFS

If specific barrier properties are needed, BFS offers the option of a Coextrusion process. Our multilayer BFS containers achieve excellent barrier properties against water vapor and gas, protecting sensitive liquids from environmental factors.

Perspective illustration to visualize the advantages of the BFS coextrusion process.
Mood image of a BFS container with ice cubes to visualize the filling of temperature-sensitive liquids.

coolBFS

coolBFS for the Filling of Temperature-Sensitive Liquids

Temperature control is essential in handling temperature-sensitive products. Rommelag's coolBFS technology protects products like vaccines from the elevated heat levels of conventional BFS processes by cooling freshly formed containers before and after filling.
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One-Stop-Partner

More Than a Machine Supplier—Your BFS One-Stop-Partner

We provide various options for integrating our Blow-Fill-Seal technology into your operations. Whether you're seeking to outsource production through our contract filling services or establishing your own in-house facilities with our bottelpack filling machines, we have a solution to meet your needs.
Furthermore, our experienced team is available to offer comprehensive support in developing and optimizing your product for BFS, ensuring a seamless transition from concept to market.

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Schedule Your Free BFS Consultation

As the inventor and global leader in Blow-Fill-Seal technology, Rommelag offers unmatched expertise. Let us demonstrate the tangible benefits for your operation. In a complimentary consultation, our experts will guide you step by step to:

  • Find the optimal BFS Solution for your product
  • Customize container design and features to match your product and application needs
  • Make sure that your filling process complies with all regulatory requirements
  • Map the right integration path for you, from machine ownership to our CDMO services