Woodstock Sterile Solutions, a blow-fill-seal (BFS) contract development and manufacturing organization (CDMO), is expanding its BFS capabilities with an $8 million investment in a new automated, high-speed bottle packaging line at its facility in Woodstock, Illinois.

The new, high-speed bottle packaging line will enhance production efficiency, introducing new capabilities that will allow Woodstock Sterile Solutions to package bottles with inline serialization at a rate of 250-300 ppm. The new Serpa line can run 5 mL and 10 mL oval and round multidose bottles. 

Woodstock Sterile Solutions expects the new bottle packaging line to be installed in 2025 and can begin packaging in the first quarter of 2026. Once completed, this investment will add an incremental packaging capacity of approximately 85 million units, supported by 24/7 operations.

Woodstock’s system provides a high level of sterility and reduces contamination. In addition, Woodstock’s BFS technology allows for customized container design, accommodating a broad range of finished product types. 

“There is currently a lack of CDMO capacity for BFS manufacturing in the United States,” says Nick Buschur, CEO of Woodstock Sterile Solutions. “This limited access is creating challenges for drug manufacturers, as rising production costs and supply chain inefficiencies hinder their ability to obtain domestically supplied, yet affordable BFS manufacturing services. Our investment will help to address this gap as we offer more cost-effective manufacturing and packaging solutions to current and future customers.”

Woodstock Sterile Solutions has delivered BFS solutions covering a wide range of applications, including respiratory, ophthalmic, topicals, biologics, oral liquids, pediatrics, diagnostics, and others.