Blow Fill Seal (BFS) Technology Market

How Historical and Future Outlook of BFS Technology Market Match Up?

The blow fill seal technology originated in 1930 in Europe with the concept of manufacturing plastic containers from the nano-particles of polymer resins inside a machine equipped with blow fill seal technology. However the technology came into light for the first time in USA in 1960.

In the traditional approach, manufacturers had to follow three step process for packaging, manufacturing, and filling & sealing. Packaging formats are molded first and then transferred to the filling line where the packaging formats are filled and sealed. This might include chances of contamination during transit of production line.

In the BFS technology, the processes of blowing, filling, and sealing of the plastic containers is done in a single operation within the system under aseptic conditions. This ensures maximum protection for filling without need of human intervention. With the increasing demand for contamination free filling and packaging techniques, many of the end use industries such as food, beverage, pharmaceutical, cosmetics and others are gradually shifting to installation of BFS technology for plastic packaging solutions from the traditional approach.

Recently, the technology has been adopted rapidly in the pharmaceutical packaging industry due to the built-in effectiveness and aseptic advantages with different rules and regulations implemented by the USA Food & Drug Administration that has characterized the blow fill seal technology as an advanced aseptic process. The hiking usage of the blow fill seal technology in pharmaceutical sector is expected to continue as favorable business across the globe.

According To FMI’s Analysis, Sales of Blow Fill Seal Technology Associated products Increased 2.5 Times of Current Value, by 2031

Blow fill seal technology is primarily used for the producing containers in pharmaceutical industry. This technology is widely being used for fast and precise packaging solution. Apart from the pharmaceutical industry, this technology is now being rapidly used in cosmetics and personal industry.

Pharmaceutical packaging industry is shifting from conventional packaging types to more advanced pharmaceutical packaging forms. Innovation in packaging that can improve how patients manage their healthcare is also spurring the need for new packaging equipment

Moreover, global forces are changing the old paradigm, all new automated blow fill seal machines lead to low energy consumption, reduced waste generation and lower carbon footprint

Besides, with most exceptional B/F/S frameworks, various diverse container shapes can be delivered and today pre-formed, pre-disinfected inserts can be included once the container is filled, taking into account more conveyance alternatives

However, due to the COVID-19 outbreak, gains in market associated with global BFS technology has shrunk significantly. Therefore, the y-o-y growth in 2020 has been reduced by nearly 4.5% in comparison with 2019. Declined sales in food and beverage industry also was an outcome of disruption in the supply chain process.

On the contrary, increase in trade of pharmaceutical products and chemicals among various countries has been witnessed in the last quarter of 2020. Manufacturers are emphasizing on the sterile products packed using the blow fill seal technology for ensuring product safety of medicines and drugs during transit which boost the sales of packaging products associated with blow fill seal technology at the global level.

Why is Blow Fill Seal Technology Gaining Traction?

There has been a rising demand for tailor-made and automated solutions, particularly from the developed countries. North America and Western Europe pharmaceutical industries are highly advanced and have been exhibiting a rising demand for biotechnology-derived drugs as well as new bio manufacturing formats

These niche drugs require small scale yet more diverse production types. Moreover, many of the new biologics need special manufacturing techniques. Blow fill seal technology thus provides manufacturers with flexible filling solutions for the accommodation of different batch sizes. This is a major change in traditional contract facilities, which traditionally would focus on a single or only a few products

Consolidation of personalized approach to medicine has led to a transition in pharmaceutical manufacturing practices and has created demand for alternative methods of drug delivery.  The personalized medicine approach encourages customization in packaging as these machines are specially designed to target specific individuals and groups. As per FMI analysis, higher profitability margin is expected with the expanded use of large sized, higher value and efficient products manufactured with blow fill seal technology. Driven by these factors, the global blow fill seal technology market is estimated to expand at a growth rate of 9% over the coming decade.

How is Demand for Unit Dose Packaging Affecting Blow Fill Seal Technology Market Growth?

Pharmaceutical packaging industry is witnessing a shift from conventional packaging types to more advanced pharmaceutical packaging forms. Innovation in packaging that can improve how patients manage their healthcare is also spurring the need for new packaging equipment

Blow fill seal technology is being adopted across the globe and it has been witnessing increasing demand from pharma sector in developing countries of Latin America and Asia Pacific for improvised medication. Unit-dose packaging, like syringes which are prefilled, are generating demand, which in turn is creating opportunities for blow fill seal technology in these regions.

Moreover, global forces are changing the old paradigm, all new automated blow fill seal machines lead to low energy consumption, reduced waste generation and lower carbon footprint. Besides this, with most exceptional B/F/S frameworks, various container shapes can be delivered and pre-formed, pre-disinfected inserts can be included once the container is filled, taking into account more conveyance alternatives.

What is the Impact of Research and Development on BFS Technology Market?

The increasing application of blow fill seal technology results into a lesser requirement of labor. Additionally, the technology can help manufacturing companies to reduce a range of facility-related costs. This is made possible because the technology requires a smaller warehouse for storing materials and reduced utility consumption, which involves zero water for injection or washing requirement. The technology is capable of producing a very high equipment-effectiveness that results in a higher output for investment.

It has been recognized by regulatory agencies that key reason behind sterility-failure is human involvement. It is one of the key advantages of BFS technology provides to the world is the elimination of the human-effort from the process. Moreover, BFS technology helps in producing a complete accurate product only in a single machine-frame which ultimately diminishes the costly processes. The requirement of a better and faster process is pushing the world to research and make development in the existing process.

Country-wise Insights

How Big Is the Opportunity in the U.S.?

According to the report, the U.S. market is expected to outpace other countries during the forecast period. It is expected to create incremental revenue opportunity of nearly US$ 1.4 Bn, by the end of 2031. In North America, pharma & healthcare companies are using blow fill seal (BFS) technology extensively in order to fulfil the need for single-dose packaging.

As per Rommelag Engineering, the U.S. is adopting the blow fill seal technology with an increasing speed to produce efficient, aseptic and advanced pharmaceutical products. This technology is widely being used for packaging liquid and semi-solid drugs in U.S. Through the forecast period, the U.S. is expected to remain one of key markets.

Why Key Players are Investing in China Market?

North America and Europe are mature market, compelling key players to look for opportunities elsewhere. According to the report, China offers attractive scope for the expansion of the market.

As per the U.S. Food & Drug Administration, for all regulated drugs, China maintains 230 (13% of the total facilities) active pharmaceutical ingredients (API) facilities while U.S. maintains only 28% facilities. The rapid adoption of blow fill technology is expected to create more opportunities for China market. Therefore, key players of BFS technology are eying on exponential growth opportunities in China BFS technology market, on the backdrop of increasing pharmaceutical production and trade activities.

Why Has Blow-Fill-Seal Technology Been More Widely Adopted in Germany?

At the time of clinical trials-phase 3, a decision of placing the desired product into the final packaging solution is made and in most of the cases, containers made with blow fill seal technology don’t get the consideration. The numerous reasons for the exclusion include the presence of an existing equipment for packaging, choosing picking packaging solutions those are similar to other products present in the market, less knowledge about blow fil seal technology, and others.

Advanced aseptic isolator or filler technology is considered to be an underutilized technology in the U.S. which is getting accepted more in Europe as the FDA and United States Pharmacopeia only accept blow fill seal and other filler systems as an improved and advanced aseptic technology. In Germany as well the use of the technology is increasing in the production of injectable products.

What Drives BFS Technology Market in the U.K.?

The U.K. remains one of the key markets for blow fill seal technology. With the pharmaceutical spending in the country rising, the demand for advanced technologies for manufacturing is set to increase. According to the Organization for Economic Cooperation and Development, the U.K., the pharmaceutical spending in the U.K. accounted for 12.3% of the overall health spending in 2018.

With the number forecast to rise further on accounting of the rising incidence of various chronic ailments, the U.K. will present attractive prospects for pharmaceutical manufacturing. This will subsequently aid the overall expansion of the market.

Category-wise Insights

What’s the Market Share of Prefilled Syringes & Injectables?

The prefilled syringes & injectables are estimated to hold more than 65% of market share in the global market and expected to increase further by 400bps of 2021’s market share during the forecast period. As per FMI, this growth is anticipated due to the demand for completely aseptic and efficient product. Prefilled syringes are improves maintaining aseptic condition for treatment and drug intake.

This growth is attributable to the increasing demand for aseptic drug delivery to reduce impact of chronic diseases. However, consumption of vials is anticipated to increase in near future due to vaccine packaging in the COVID-19 pandemic situation.

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Why is Polyethylene More Sought-after?

PE is the most commonly used materials in blow fill seal manufacturing. Off late, several compatibility issues of the product with the material have been reported.

For instance, certain bio-based drugs are not compatible with PE, especially LDPE. The need for new product compatible materials is anticipated to create an opportunity in the blow fill seal technology market. PET, which has good barrier properties, has been studied by BFS manufacturers.

 However, it is posing problems in terminal sterilization. Also, PET fractures when the container is opened.

Materials which are compatible with the BFS technology makers testing procedures are still untapped and is anticipated to create an opportunity for the BFS Technology market.

Opportunities Abound In Tackling Pharmaceutical Counterfeits

A high ratio of illicit trafficking of counterfeit drugs has been observed globally, use of these drugs poses a global public health risk. According to the statistics, of the total identified cases of counterfeited drugs, around 27% are found to be originating from China.

China and India specifically are regarded as the major hubs for counterfeit drugs. Thus, proper measures must be taken by the pharmaceutical industry to curb the issue.

BFS Technology ensures that the product is used only once and is discarded thereafter. Moreover, once the product’s seal is broken, it cannot be resealed.

Blow fill seal technology effectively tackles the counterfeit drug menace and is particularly advantageous for expensive drugs.

Competitive Landscape

Companies operating in the market are consistently focusing on strategic collaborations and merger & acquisition to gain competitive strength. For instance, Juniper pharmaceutical Inc. was acquired by Catalent Inc. in 2018. Also in the same year, Curida AS completed the acquisition of As produksjonslab, a renowned Norwegian pharmaceutical manufacturer.

Some of the leading companies operating in the market are:

• Unither Pharmaceuticals SAS
• Rommelag Kunststoff-Maschinen Vertriebsgesellschaft mbH
• Catalent, Inc.
• Curida AS
• Unipharma LLC
• Weiler Engineering Inc
• GlaxoSmithKline plc
• Takeda Pharmaceuticals International AG
• Nephron Pharmaceuticals Corporation
• Horizon Pharmaceutical Inc
• Brevetti Angela S.R.L
• Recipharm AB
• Laboratorios SALVAT, S.A
• The Ritedose Corporation
• Unicep Packaging, LLC
• Pharmapack Co. Ltd
• Amanta Healthcare Ltd.
• Automatic Liquid Packaging Solutions LLC
• Asept Pak, Inc
• SIFI Spa

*The list is not exhaustive, and only for representational purposes. Full competitive intelligence with SWOT analysis available in the report.

Scope of the Report

Key Questions Answered in the Report

• Which is the most lucrative market for blow fill seal technology?

  The U.S. currently leads the global market for blow fill seal technology. Sales in the U.S. will be account for a considerable share of the global market over the coming decade.

• Which is the top-selling product associated with blow fill seal technology?

  Prefilled syringes and injectable are highly sought-after in the blow full seal technology market. The demand for ampules is expected to grow at an impressive rate in the near future.

• Which sector is accountable for driving sales of blow fill seal technology?

  Blow fill seal technology is increasingly used by the pharmaceutical sector. It will continue accounting for majority sales in the market between 2021 and 2031.

• Which are some of the leading companies offering blow fill seal technology oriented packaging?

  Some of the leading companies offering, Unither Pharmaceuticals SAS, RommelagKunststoff-Maschinen Vertriebsgesellschaft mbH, Catalent, Inc., Curida AS,  Unipharma LLC, Weiler Engineering Inc, GlaxoSmithKline plc among others.

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Is this research conducted by Future Market Insights?

Yes, the research has been conducted by expert analysts of Future Market Insights through a combination of primary research and secondary research. To know more about how the research was conducted, you can speak to research analyst

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FMI follows a methodology that encompasses demand side assessment of the market, and triangulates the same through supply side analysis. This methodology is based on use of standard market structure, methods and definitions. Request detailed methodology

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What are the sources of secondary research?

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Blow Fill Seal Technology Market by Category

Product Type

• Bottles
  • 0.2-100 ml
  • 100-500 ml
  • Above 500 ml
• Ampules
  • 0.1-10 ml
  • 10-100 ml
• Vials
  • 0.1-10 ml
  • 10-50 ml
• Others(prefilled syringes & Injectables)

Material Type

• PE
  • LDPE
  • HDPE
• PP
• Others

End Use

• Pharmaceuticals
  • Ophthalmic
  • Injectables
  • Biologics
  • Wound Care
  • Respiratory
• Food & Beverage
• Cosmetics & Personal Care
• Others

Region

• North America
• Latin America
• Asia Pacific Excluding Japan
• Eastern Europe
• Western Europe
• Japan
• Middle East and Africa (MEA)