Equipment to aseptically package liquids in hollow plastic containers with one integrated cycle hermetically sealing the product.

Blow Fill Seal Packaging for Sterile PharmaceuticalsBlow Fill Seal (BFS) by Rao Design Intenational

Rao Design Intl. has been producing Blow Fill Seal (BFS) machines for over 30 years in Chicago, IL, USA.

These machines are built with meet your demands and have quality standards as recommended by cGMP.

Whether for pharmaceutical, intravenous, beverage, chemical, cosmetics, or laboratory liquids our systems will deliver your product and in very favorable as containers.

Numerous plastic resins can be used in creating Blow-Fill-Seal containers.

BlowRespiruals, Vials from RAO Design's BFS Machinery.-Fill-Seal Machines, also widely known as Form Fill Seal, combine the proprietary APT technologies of aseptically blow molding hollow containers with a process to fill and seal the package, all in one machine cycle. By eliminating individual machines for creating the container, filling the container, and scaling the package great savings in space and efficiency can be realized while maintaining a medically sterile environment. One compact machine takes the place of an entire assembly line operation!
 Medical Manufacturing
BFS Molds and Tooling

In addition to building Blow Fill Seal machines, we also build tooling. We make and repair Blow Fill Seal molds for any type of BFS or FFS machinery. Have the people who know the BFS process be your molding supplier. You will receive our expertise in complete your molding project with good delivery/turnaround time. Aseptically blow mold or form your desired containers with this equipment.



BFS Trials

For early stage Blow Fill Seal projects we are able to produce molds and sample the design and produce prototypes. These prototypes can lead to a full-scale production system. Production runs of clean and nonsterile could be provided within a short period of time. Test your concept of single unit dosing with special tops for tear away, etc.

pic of BFS Vials


1. Blow Molding

In-house blow molding allows control over package design, stock levels and medical sterility that is not possible through outside procurement. The process involves the extrusion of material (plastic) clamping the two halves of a mold around the extrusion, and blowing air into the mold forming the container.

2. Filling

Once the container is formed, the valves controlling the air close, and valves controlling the liquid or viscous material open allowing a measured dose to flow into the container. The machine can be adjusted to use a variety of different fill products (from sterile water, infusion fluids and the like, to injectable medicines and vaccines). This process is completely sterile making it ideal for pharmaceuticals.

3. Sealing

The mold can be designed to hermetically seal blocks of containers (ideal for ampules) or individual units. A variety of closures can be utilized that are part of the molded container, completely eliminating the need for a separate capping process. Closure designs include twist-off, break-off, or cut-off.


Blow Fill Seal (BFS) Machines

Rao Design produces APT Blow Fill Seal Machines

” American Plastic Technologies, Inc. is America’s innovative producer of high-quality Blow Fill Seal for custom applications. We combine the APT technologies of blow molding hollow containers with a process to fill and seal the package, all in one machine cycle, in a fully sterile environment.”
picture bfs parts

How Blow Fill Seal is suitable for your application:

  • •  Customizable to many shapes,  including flat bag-shaped containers.
  • •  Will prevent contamination and the entry of foreign particles, more than other types of filling lines and      the traditional IV Bags.
  • •  Reduce contamination to reduce chances of causing dangerous infections.
  • •  Numerous advanced features exist, including septums, stoppers, and other special unique closures.
Aseptic Packaging

The process of cleaning and sterilizing containers delivered from the outside is completely eliminated. The container material is automatically sterilized in the heated extrusion process and in the pressurized parison head. There is no danger of contamination while transporting the container to a filling or capping station as this all occurs within the mold.

Application Oriented Medical Packaging. The benefit of using blow molded plastics is that the container can be manufactured in many different shapes and sizes. Collapsible packing is widely used for medical infusion solutions. The soft plastic material allows for the administration of intravenous solutions without the need for air compensation (filters or venting).

The complete Blow-Fill-Seal Machine allows for considerable savings in space, increased efficiency, and complete sterility. Complete control of the delivery, quality, and cleanliness of containers is held in-house.

Containers can be customized to the individual company, giving a unique package associated with your medical products. Flexibility in design allows for application oriented packaging (squeeze applicators, I.V. sets, pre-measured dosing). Molded closures eliminate the need for a separate capping machine/procedure. Complete safety from contaminants by completing the entire process in one machine, within a fully sterile environment.

Common Blow Fill Seal Applications:

Pharmaceutical, Injectable, Cosmetic, Chemical, Laboratory, Diagnostic, Food, Beverage, Ophthalmic, Respiratory, Parenteral, Intravenous Fluids, Irrigation, Antibiotic, Chemotherapy, Biologic, and many others.


American Plastic Technologies (APT) is America’s innovative producer of high quality
Blow Fill Seal for Custom Applications. APT is the design and engineering company to help you with numerous projects on any and every step of your project.

Engineering • Equipment • Installation • Commissioning