Brevetti Angela introduces the next generation of Blow Fill Seal technology for superior aseptic packaging
Brevetti Angela’s new SYFPAC®DUO™ represents the major advance in Blow Fill Seal (BFS) technology, specifically designed to meet the evolving demands of the pharmaceutical industry. This revolutionary BFS platform combines container formation, aseptic filling and sealing into one continuous operation that can be carried out from a tiny footprint.
The new SYFPAC®DUO™ incorporates leading-edge technologies to make it the fastest, smallest, safest, and most efficient Blow Fill Seal machine on the market and one that is also suited for cool production of vaccines and biologic products.
DUO™ technologies for aseptic filling and packaging
The DUO™ takes SYFPAC® BFS aseptic filling and packaging a major step further with its Closed Parison Technology in which containers are formed, filled, and sealed in the same position and under Grade A aseptic conditions in an isolated system, ensuring maximum safety and protection from the external environment. This advanced aseptic technology meets and exceeds the EU GMP Annex 1 requirements.
SYFPAC® DUO™ Blow Fill Seal machine also breaks new ground: insertion technology in a Closed Parison machine to support sterile production of prefilled syringes, multi-dose eye droppers and other innovative and cost-effective drug delivery devices within the closed parison.
This is a ‘best of both worlds’ advance that for the first time combines the versatility and operational advantages of the previous SYFPAC® shuttle system with the aseptic advantages of closed parison, now allowing insertions as well. Sterile production is taken a step further with the groundbreaking DUO™ Process Monitoring System that ensures that DUO™ can comfortably exceed EU GMP Annex 1 standards.
A Blow Fill Seal machine engineered for flexibility and cost-effectiveness
SYFPAC® DUO™ by Brevetti Angela offers a range of significant advantages, making it an outstanding solution for pharmaceutical manufacturers. One of its standout features is its modular design, which allows for scalable production with minimal modifications. The DUO™ can effortlessly scale up from micro-scale at 4,000 units per hour, through mini-scale at 10,000 units/h, max-scale (20,000 units/h) up to hyper-scale at 40,000 units/h, or 264 million doses per year, without adding bulky modules or increasing its compact footprint.
While total width/depth dimensions for DUO™ are 1.5 m x 4.5 m with an overall height of 2.6 m, only the front part (1.5m x 4m x 2.6m) needs to meet Class C standards, taking up only 6m² of cleanroom floor space. This gives DUO™ the highest productivity-to-size ratio of any Blow Fill Seal machine on the market. Furthermore, the modular design allows high layout flexibility including single-room, on-board, or a ‘black-and-white’ configuration.
DUO™ is also designed for flexibility in operation with fill volumes ranging from 0.2 ml up to 50ml, the ability to process different types of plastic like polyethylene (PE), polypropylene (PP) or High-density polyethylene (HDPE), without any hardware changes, only requiring recipe changes in the HMI operating interface. Mould changeovers can be accomplished in under ten minutes in a simple operation that does not require any special tools nor a technical intervention. This operational flexibility allows manufacturers to switch between different products and production requirements with minimal downtime.
What sets DUO™ further apart is its capability to support cold production processes, ideal for temperature-sensitive vaccines and biologicals, by operating under 25°C – an unprecedented feature for BFS closed parison machines. It is also containment-ready for potent or toxic products, complying with BSL level 4 isolation standards. The machine’s fully electric, servo-driven design eliminates the need for hydraulic oils, making it easier to clean and maintain. In summary, the DUO™ offers an unparalleled combination of scalability, flexibility, and hygiene, making it a perfect fit for modern pharmaceutical production environments that require efficiency, adaptability and cleanliness.
Sustainability and cost savings: a dual advantage of BFS SYFPAC® DUO™
BFS SYFPAC® DUO™ by Brevetti Angela stands out for its impressive sustainability features, making it an environmentally responsible and cost-effective solution for pharmaceutical production. Brevetti Angela’s proven Extrusion Technology, together with the innovative design and technology, allows DUO™ to be exceptionally resource-efficient, offering the industry’s lowest plastic granule consumption, with scrap reduced below 6%.
For high-volume manufacturers, this efficiency translates into substantial cost savings – up to € 900,000 per year in raw material expenses alone. The DUO™’s commitment to sustainability is further enhanced by its small cleanroom footprint. The machine can achieve up to 2.5 times greater production while occupying just one-third of the floor space compared to traditional aseptic packaging machines, significantly reducing operational overhead.
In addition to sustainability, the DUO™ is a versatile platform capable of replacing both Brevetti Angela’s SYFPAC® SVP and SECUREJECT™ machines. This adaptability allows for aseptic filling of small volume parenterals and prefilled syringes within a single machine, eliminating the need for multiple systems and further driving efficiency. Overall, the new DUO™ offers a compelling combination of reduced environmental impact and cost savings, making it a top choice for pharmaceutical manufacturers looking to balance sustainability with profitability.
For more information about the new SYFPAC® DUO™ Blow Fill Seal machine or other products proposed by Brevetti Angela, you can refer to www.syfpac-duo.com or you can contact us.
