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Custom Blow/Fill/Seal (BFS) Aseptic Liquid Filling Services


At Plastikon Healthcare we provide custom blow molding and aseptic liquid fill contract manufacturing in a one-step process using BFS technology for a range of customers, in a variety of industries. Manufacturing is completed in our FDA registered, Class 10K or 100K cleanrooms. Plastikon operates in compliance with ISO 13485:2003, and ISO 9001:2008, and strictly follow the FDA’s Current Good Manufacturing Practices (cGMP) per 21CFR 210-211 and Quality Management System per 21CFR-820. In addition, we are environmentally sensitive with ISO 14001:2004 certification.

Our BFS system utilizes LDPE or pharmaceutical grade resin to produce custom bottles filled with sterile liquid, emulsions, or creams in volumes from 0.2-mL to 1000-mL We operate three filling suites that are capable of producing up to 10,000 units per hour. Our formulation capabilities include bottom to bottom transfer and recirculation with filtering and homogenization options. We use validated methods for formulation development and our engineering staff and PMP certified project managers can work with our customers from concept to final product. Our on-site Laboratory Services ensures quality standards are met throughout your product lifecycle with raw material, in-process, finished product, and stability testing.

For more information about our custom BFS capability, see the table below, or contact us directly.







Custom Blow Molding BFS Aseptic Liquid Filling Capabilities  · Additional Information

Custom Blow Molding BFS Aseptic Liquid Filling Capabilities

Industry Focus

Diagnostics
Medical Device

Nutraceutical

Pharmaceutical

Clean Rooms Designed and Validated to FDA Standards

Class 10,000 Clean Rooms with Gowning Room Access
Environmental monitoring program for particulate and microbial

Optical Clean Room Packaging Suites

Pressure Cascades to minimize microbial and particulate egress

Temperature controlled environment

Equipment and Processes Validated to FDA Standards

Audited by Quality and ISO certified Auditors
FAT and SAT of BFS Equipment at Start-Up

Performance Qualification of Sterile Line, Including Media Simulation Activities

Performed under an approved Validation Master Plan

Qualification/Validation of BFS Equipment and Components

Equipment

Calibrated Load Cells and Display
Clean in Place and Steam in Place Systems

Clean Steam Generator

Clinical Development Production Tools

Inline Filtration System

USP Purified Water System

Vacuum Charging System

Weiler BFS Machines

Material

LDPE
Pharmaceutical Grade Resin

Fill Volume Range

0.2 to 1000 mL

Formulation Development

Generic Drug Applications
HPLC Analysis

Microbial Attributes and Preservative Effectiveness

Physical Characterization

Product Transfers

Formulation Capacity

11 Stainless Steel Tanks range from 1,000 to 12,000 L
Bottom to Bottom Transfer Capabilities

Calibrated load Cells and Display

Clean in place and Steam in Place Systems

Recirculation Capabilities with Filtration and Homogenizer Options

Small Scale Vessels from 1 to 50 L

Wide Range of Bulk Liquid, Emulsions, and Creams

cGMP Microbiology Laboratory

Environmental Monitoring
Media Suitability

Microbial Count and Bioburden

Microbial Toxicity Testing

Sterility Testing

cGMP Analytical Chemistry Laboratory

Atomic Adsorption
Conductivity & pH

Dimensional Physical Attributes

HPLC & Spectroscopy

Titrations

Total Organic Carbon

Testing

Finished Product Release
In-process Inspection

Raw Material Compendia

Stability

Environment

Class 100K Formulation Area
Class 10K and 100K Cleanrooms

Reports

FMEAs
Internal & Supplier Corrective Action

Lot Code Traceability & Product Retains

Repeatability

Statistical Process

Additional Services

Bar Coding
Distribution

Engineering Services

Labeling

Logistics

Packaging

Part Design

Program Management

Project Management

Research & Development

Sales & Marketing

Sub-Assemblies

Warehousing

Production Volume

Large Production Runs
Low Volume Runs

Rapid Prototype


Additional Information

Project Management

PMP Accredited Specialist

Industry Standards

Drug Products (CDER)
Environmental Management Systems (EMS)

FDA Registered

International Society for Pharmaceutical Engineering (ISPE)

ISO 13485:2003 Certified

ISO 14001:2004 Certified

ISO 9001:2008 Certified

Medical Device (CDRH)

Minority Business Enterprise (MBE) Certified Company

Society for Process Engineers (SPE)

Efficiency

Kaizen
Lean Manufacturing

Six Sigma Certification



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