Blow / Fill / Seal

Customized aseptic processing that is cost effective and reliably supplied


With over 25 years of experience in providing scientific and manufacturing expertise in complex fill-finish treatments, we offer the highest-quality support systems to meet all your aseptic manufacturing needs. To better improve your product’s performance, we offer an extensive range of containers that can be customized to meet your unique needs, and our fully compliant network of manufacturing sites can be relied on to follow the highest-quality standards.

  • Capacity and flexibility
    • We offer the largest scale and widest breadth of B/F/S contract manufacturing services available:
      • Batch sizes up to 2000L scale
      • Solutions for products that are temperature-, light-, or oxygen-sensitive
      • Capability for complete customization for unit or multi-dose containers without reliance on stock containers
  • Accurate dosing
    • Customization for unit or multi-dose containers without reliance on stock containers
    • Proprietary insertion technology
  • Quality/Sterility assurance
    • Catalent’s network of manufacturing sites, following the highest industry standards, provides scalable capacity to meet customers’ unique demand requirements
    • Minimal operator interface and limited product exposure time
  • Processing efficiencies
    • Highly automated
    • Minimal component handling/pre-sterilization
    • High per-run output
Therapeutic Areas

Today we successfully use B/F/S in a wide variety of sterile and non-sterile liquid pharmaceuticals, including:

  • Respiratory
  • Ophthalmic
  • Biologics 
  • Oral liquids
  • Topicals
How It Works

An advanced aseptic process, B/F/S is a highly automated system with minimal operator interface. The basic concept is the combination of 3 major processing steps in a single contained process:

  • Container molding
  • Container filling
  • Container sealing

We can mold the container to fit almost any shape.

The plastic extrusion area and critical fill zone (ISO.5) are designed as partially isolated areas with localized protection, where exposure of the product and container to the environment is minimized. As a result, the sterile boundary is sterilized in place, eliminating aseptic connections.


All of our sites are subject to annual review so we can remain in compliance with:

  • FDA/cGMP
  • Canadian HPB
  • British MHRA
  • European community
  • Brazilian authorities
  • Woodstock, IL, U.S.A.
    • Global scope
      • Leading provider of aseptic packaging using B/F/S technology
      • Produce pharmaceutical products for distribution in U.S., Canada, EU, Japan, and Australia
    • Long history serving the pharmaceutical industry
      • 1968 Automatic Liquid Packaging (ALP) founded in 1968 in Elk Grove Village, IL
      • 1980 Woodstock facility built with 4 B/F/S lines
      • 1982 First production started with approximately 60 employees working 24/5
      • 1999 Cardinal Health purchased ALP
      • 2007 Cardinal Health PTS becomes Catalent Pharma Solutions, an independent company
    • Extensive capabilities
      • Filling of solutions, suspensions, or emulsions
      • Fill volumes range from .3 mL to 1 L
      • World-class critical utility systems including water for injection
      • Cold-storage capabilities
      • Solutions for products that are temperature, light-, oxygen-, or delivery-sensitive
      • Analytical and microbiology laboratories
      • 38 B/F/S lines working 24/7
    • Facility stats
      • 5,000 sq ft. micro and chemistry lab space
      • 190,000 sq. ft. warehouse space with controlled room temperature and cold storage
      • 5,000 sq. ft. central stock room
      • 20,000 sq. ft. production support areas
      • 30,000 sq. ft. R&D area
      • 45,000 sq. ft. administrative areas
      • 85,000 sq. ft. packaging service area