Aseptic Filling with Blow Fill Seal Technology

Aseptic Filling with Blow Fill Seal Technology

Rommelag’s bottelpack machines are capable of manufacturing up to 34,000 containers an hour in a wide variety of forms and plastic blends, with filling volumes ranging from 0.04 to 10,000 ml, aseptically, and taking all the applicable pharmaceutical regulations into account. Sounds good, you say? That’s what our customers say, too, and they enjoy the flexibility, precision, reliability, and virtually unlimited scope of BFS technology.

BFS: Aseptic Processing from Fill to Finish

Every BFS process begins with the extrusion of a sterile polymer tube within the machine. The container is then instantly molded, filled, sealed, and demolded – all in a single process, in an enclosed system, and without any external intervention. This eliminates expensive logistics for and the time-consuming cleaning and sterilization of prefabricated containers. 

All the filling processes including the dosing system are designed with CIP/SIP in mind. As such, all the product-handling lines are cleaned, sterilized with pressurized steam, and dried with sterile-filtered air by automatic programs. This makes bottelpack technology the most reliable aseptic filling method.

THE BLOW-FILL-SEAL PROCESS

The container is blown, filled with the product, and securely sealed – all in a single process. Watch the video to learn about all the advantages.

Extrusion

Extrusion

The plastic tube extruded from the granules is fed into the opened blow mold.

Molding

Molding

The main mold closes, sealing the base in the process. The mandrel is lowered onto the neck of the mold and uses compressed air to blow the tube section into the container shape. Small containers are molded with a vacuum.

Filling

Filling

The container is filled with the precise product amount as measured by the dosing system, again via the mandrel.

Sealing

Sealing

The mandrel is removed, the head mold closes, and the required closure is formed by a vacuum.

Demolding

Demolding

The blow mold opens, the container leaves the machine, and the next cycle begins. A conveyor system takes the container to the next processing stage.

THE ADVANTAGES OF BFS TECHNOLOGY

  • Shatterproof plastic containers
  • Ideal for the aseptic filling of liquids and gels
  • Maximum safety due to ISO Class 5 conditions at the filling point
  • From the inventor of and global market leader in BFS technology
  • Officially recognized as an advanced aseptic system
  • Fully automatic manufacture, filling, and sealing in a single process
  • Maximum process and product reliability
  • Maximum filling precision
  • Virtually unlimited scope in terms of container design
  • Customizable to different uses and dosage forms
  • Modular design for easy separation of gray and white system zones
  • Considerably smaller footprint than with conventional filling systems
  • Automatic execution of the necessary cleaning and sterilization processes
  • And much more besides

FROM THE INVENTOR OR FROM ELSEWHERE

If it says “bottelpack” on it, you can rely on the uncompromisingly good quality offered by the inventor of blow-fill-seal technology. With a combination of German engineering expertise and Swiss precision, we make sure that your machine only ever produces precisely what you defined – from the smallest ampoule to the largest container. And that’s a promise!