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T
he demand for blow-fill-seal (BFS) technol-
ogy has significantly increased in recent
years because of the rising demand for bi-
ologic-based drug products and vaccines.
Valued at $2.8 billion in 2022, the BFS technology
market is predicted to grow at a compound annual
growth rate of 9% until 2031, to reach $6.2 billion (1).
Created through automated manufacture, BFS is
being explored for unit dose containers for vaccines
and other biologic products. This BFS process can
positively impact the overall supply chain, lowering
manufacturing costs and enabling treatment for pop-
ulations in lower-income regions.
Understanding the benefits of BFS
BFS technology is a form of advanced aseptic manufac-
turing in which a container for a drug formulation is
formed, filled, and sealed in a continuous, automated
system. To create the aseptic container, manufactur-
ers continuously melt polymer granules to extrude a
sterile, formable polymer parison into a mold. Sterile
air is used to blow-mold the material into a container,
forcing the polymer to take the shape of the mold and
create a hollow space within. This container is filled
with a drug formulation before being sealed tightly,
traditionally through the application of both heat and
pressure to the open end of the vessel.
All containers have features that can make them
more or less suitable for a particular project. BFS is no
different, offering features that make it an increas-
ingly attractive option for pharmaceutical companies
developing or manufacturing sterile liquids, includ-
ing injectables. For example, BFS containers:
• Maintain high sterility and particulate contam-
ination integrity while optimizing production
line efficiency. BFS formation, filling, and seal-
ing can be easily incorporated into a sterile man-
ufacturing process, similar to those required for
Leveraging Blow-Fill-Seal
Technology for
Biologic Delivery
Vincenza Pironti, PhD,
is strategic marketing
director at Recipharm.
The rising demand for biologics and technological
innovations are driving blow-fill-seal capacity, harnessing
manufacturing efficiency, and benefitting patients.
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