Blowing-Filling-Sealing (BFS) System

BFS technology is ideal for packaging sterile liquid products that do not require preservatives or terminal sterilization. Based on our equipment parameters:
JW-BFS-C series (2ml – 10ml containers)
Typical products: Eye drops, nasal sprays, inhalation solutions, small volume parenterals (SVP), wound care liquids, veterinary vaccines.
Real case: A leading ophthalmic manufacturer uses the JW-BFS-C25S-VII (25 cavities, 10ml) to produce preservative-free artificial tears. Single-mold output: 10,000 units/hour (9-second cycle); dual-mold output: 20,000 units/hour. Daily output increased by 40%, with zero microbiological contamination maintained over 12 months.
JW-BFS-R series (100ml – 1000ml containers)
Typical products: Large volume parenterals (LVP) such as IV infusion bags, irrigation solutions, dialysis fluids, oral liquid preparations.
Real case: A European hospital pharmacy adopted the JW-BFS-R08-D (dual-mold, 8+8 cavities) to produce 500ml saline for irrigation. Operating at 2,700 units/hour, it replaced traditional glass bottles, reducing breakage rate by 90% and warehouse space by 60%.

A. High Productivity & Flexibility
C series: Up to 48,000 units/hour (2ml, dual-mold, 9-second cycle) – ideal for high-volume production of small-dose pharmaceuticals.
R series: Up to 3,100 units/hour (100ml, dual-mold) for medium batch sizes, with rapid mold changeover within 30 minutes to accommodate 250ml, 500ml, and 1000ml sizes.

B. Superior Sterility Assurance
Integrated process: Blowing, filling, and sealing are continuously performed within an aseptic environment (Grade A, ISO 5). No human intervention reduces particle and endotoxin risks.
Real result: A Chinese vaccine manufacturer using the JW-BFS-C40S-VII reported sterility test failure rate <0.1% across 3 million units.

C. Material & Cost Savings
Container weight reduced by 30-50% compared to glass or traditional blow-molded containers. For 10ml bottles, wall thickness can be optimized to 0.4–0.6mm without compromising integrity.

D. Compact Footprint
C series integrates single-mold/dual-mold options into the same frame, saving up to 40% floor space compared to traditional rotary BFS machines.

We follow a strict QC protocol based on ISO 13485 and cGMP guidelines. Key tests performed on JW-BFS equipment:

3.1 In-Process Controls
Leak test (vacuum decay method): Inspect every container from each cavity every 5 minutes. Acceptance criterion: pressure drop <0.2 psi over 30 seconds.
Wall thickness measurement: Using laser micrometer, take 5 samples per cavity per hour. Deviation ≤±0.05mm.
Fill volume check: Randomly sample 10 containers every 15 minutes. Tolerance: ±1% for 2ml; ±0.5% for 500ml.

3.2 Environmental Monitoring
Non-viable particles: Continuous monitoring in Grade A zone – particle count ≤3,520 per m³ for ≥0.5µm.
Viable particles: Settle plates and active air sampling every 4 hours – require zero CFU.

3.3 Final Product Testing
Container Closure Integrity Test (CCIT): Using dye ingress method (USP <1207>) or high-voltage leak detection.
Endotoxin test (LAL): <0.5 EU/ml for irrigation fluids.
Material compatibility: Testing for plastic containers per USP <661> and <381>.

Real QC case:
A Korean cosmetic filler manufacturer using the JW-BFS-R06-S (6 cavities, 250ml) operating at 1,300 units/hour implemented automated visual inspection. The rejection rate for appearance defects (flash, bubbles) dropped from 2.1% to 0.3% within the first quarter.

Product Parameters：

Q1:How long does it take to switch between single-mold and dual-mold modes on the C series?
A: Approximately 45 minutes – including changing mold carriers, adjusting parison programming, and performing a short validation run. The system can store recipe parameters for over 20 products.

Q2: Which materials are compatible with JW-BFS equipment?
A: LDPE, LLDPE, and PP. We also support custom multi-layer structures (e.g., EVOH barrier layer) for oxygen-sensitive drugs.

Q3: What is the minimum order quantity (MOQ) for molds?
A: No MOQ – we can manufacture single-cavity molds for clinical trial batches (e.g., 500 units) as well as up to 60-cavity molds for commercial production.

Q4: How is aseptic process validation performed?
A: Using media fill tests (TSB) under worst-case conditions (longest interruption time, longest holding time). Acceptance criterion: contamination rate ≤0.1% with 95% confidence. Our record shows that the JW-BFS-C25S-VII achieved 27 consecutive media fills with zero positives.

Q5: What is the typical energy consumption?
A: For JW-BFS-C40S-VII producing 10ml containers at 14,400 units/hour (dual-mold, 10-second cycle): 18 kW (extruder + hydraulics + air compressor). That is 25% lower than previous-generation BFS machines.

Q6: Can the equipment handle hot-fill (≥85°C) or cold-fill (2-8°C)?
A: Standard configuration supports 20–60°C. For hot-fill (up to 95°C), we offer upgraded seals and a cooling zone. For cold-fill (down to 2°C), we provide insulated hoppers and jacketed filling lines.

Q7: What after-sales services are provided?
A: 7x24 remote diagnostics (via VPN), spare parts delivered globally within 48 hours, on-site training (2 weeks) included. We also offer annual performance qualification services.