Aseptic Blow Molding

The major disadvantage of in-mold labeling is the increased process complexity, and the required investment in capital equipment. It is not well suited to small production runs or where label copy changes frequently, even if bottles do not. Some experts claim in-mold labeling increases overall cycle time by 1.5 to 3.3 s, but others claim cycle time is not increased. 

In-mold labeling is used most often with extrusion blow molded HDPE bottles. It has also been used on PET and PP stretch blow molded bottles, as well as on injection molded tubs. The technique also finds applications outside packaging, such as in labels that are applied directly to electronics and other consumer goods. 

Two process variants exist. In both, the first step is to provide sterility for the blowing operation, including the air used in forming the container. In the blow and hold process, the bottle is sealed in the mold to preserve its sterility, and can then be released into a non-sterile environment. In a subsequent filling operation, it is cut open under sterile conditions, filled, and sealed again. In the blow-fill-seal process, the bottle is blown, filled with product (often while still in the mold), and sealed, all within the sterile environment of the blow molding machine, either at a single station or at multiple stations. 

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At the heart of the process is the blow-molding machine. This technology is not unique to aseptic (Mocessing. In the machine, molten plastic is extruded under high temperatures (around 200 C) and pressures (350 bar) as a hollow... 

The blow/fill/seal process is a complete packaging technique that integrates the extrusion or IBM and container filling steps. This can provide for aseptic filling of the hot as-blown container and is used for pharmaceutical, food, and cosmetic products. The process employs a two-part mold in which the container body mold cavity blocks are separate from the neck-forming members. 

The pharmaceutical BFS process combines the formation of plastic containers by blow/vacuum molding extruded pharmaceutical grade polymers, with an aseptic solution filling system. 

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