Woodstock Sterile Solutions Invests $8M in High-Speed BFS Packaging Expansion

• Woodstock Sterile Solutions is investing $8 million in a new automated, high-speed bottle packaging line at its Illinois facility, increasing its BFS packaging capacity.

• The company expects the packaging line to be operational in early 2026, adding approximately 85 million units of incremental packaging capacity.

Woodstock Sterile Solutions has announced an $8 million investment in a high-speed, automated bottle packaging line at its facility in Woodstock, Illinois. This expansion aims to enhance the company’s blow-fill-seal (BFS) capabilities, addressing the growing demand for BFS manufacturing in the United States.

The market for BFS technology is expected to expand significantly over the next decade. According to Future Market Insights, the global BFS market was valued at $3.1 billion in 2024 and is projected to reach $5.26 billion by 2034, with a 5.1% compound annual growth rate (CAGR).

“There is currently a lack of CDMO capacity for BFS manufacturing in the United States,” said 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.”

The new high-speed packaging line will introduce inline serialization and operate at a rate of 250-300 bottles per minute. It will handle 5 mL and 10 mL oval and round multidose bottles, adding approximately 85 million units of packaging capacity. The investment is part of the company’s broader strategy to provide cost-effective and flexible BFS solutions.

Installation of the new packaging line is expected in 2025, with production set to begin in the first quarter of 2026. Woodstock Sterile Solutions has been delivering BFS solutions for over 55 years, supporting applications in respiratory, ophthalmic, biologics, oral liquids, and more.