MOULD TOOLING
Our precision mould tooling solutions cover the complete lifecycle—from design and manufacturing to installation and optimization.
We supply BFS main moulds, head moulds, mould inserts, tooling spares, filling heads, and other critical components for demanding production environments.
Friscohn combines advanced engineering expertise with precision manufacturing to deliver reliable performance, consistent quality, and long-lasting tooling solutions.
BFS Moulds & Tooling
Friscohn provides BFS mould design and manufacturing for pharmaceutical Blow-Fill-Seal production.
Moulds & Tooling for all Rommelag make machine models
Moulds & Tooling for all Weiler make machine models
Moulds & Tooling for all Brevetti Angela make machine models
Our tooling capabilities are developed around specific machine platforms, container formats, production requirements and customer applications.
Our BFS Tooling Capabilities
Main Moulds
Precision moulds engineered for BFS production requirements.
Head Moulds
Application-specific tooling for BFS systems.
Mould Inserts
Precision inserts for required container configurations.
Filling Heads
Critical tooling components for BFS filling applications.
Custom Tooling
Engineering and manufacturing based on specific machine and product requirements.
From Design to Production
Our tooling process can include:
Design → Engineering → Manufacturing → Inspection → Installation → Optimization
We work with established BFS platforms including Rommelag, Weiler and Brevetti Angela.
Precision Matters.
When mould performance affects production, tooling is not simply a component. It is a critical part of the BFS system.
Discuss Your BFS Tooling Requirement →
MOULD APPLICATIONS
MOULD DESIGNS
The moulds are designed and manufactured to meet stringent pharmaceutical packaging requirements with emphasis on:
• Container dimensional consistency
• Uniform wall thickness distribution
• Process stability
• Long-term mould reliability
• GMP-compliant manufacturing standards
• Optimized cycle efficiency
TECHNICAL RESPONSE
1. MOULD DESIGN PHILOSOPHY AND ENGINEERING APPROACH
Our mould design philosophy is based on:
• Container geometry optimization
• Uniform material distribution
• Controlled vacuum-assisted formation
• Efficient thermal management
• Long operational life
• Ease of maintenance
The design process includes:
a) Product Design Review
· Evaluation of bottle geometry
· Fill volume verification
· Neck finish analysis
· Labeling area assessment
· Process feasibility review
b) Mould Flow & Process Evaluation
· Parison behaviour assessment
· Material shrinkage evaluation
· Air and vacuum distribution study
· Cooling performance optimization
c) Manufacturing Design
· Modular cavity construction
· Precision alignment systems
· Replaceable wear components
· Maintenance-friendly architecture
2. EXCLUSIVE EXPERTISE FOR BFS MOULDS
Years of extensive experience delivering themoulds for Rommelag BFS machines including:
• Rommelag 302, 3012, 3025, 305, 321, 360, 364, 460/4010
. All Weiler and Brevetti BFS Machines
Services performed include:
• New mould DESIGN & manufacturing
• Reverse engineering
• Cavity refurbishment
• Vacuum system upgrades
• Cooling system optimization
• Process troubleshooting
3. COMPATIBILITY WITH PURELL 3020D PHARMACEUTICAL LDPE
The proposed mould design is fully compatible with Purell 3020D pharmaceutical-grade LDPE.
4. MOULD MATERIALS AND SERVICE LIFE
Mould Material:
· AB2 (Aluminium Bronze) / STAVAC . Sourced directly from European OEM.
Expected Service Life -
Under normal pharmaceutical production conditions:
• 5–10 million cycles before major refurbishment
• Routine maintenance intervals as recommended
Actual life depends on operating conditions, maintenance practices, resin quality, and production volume.
5. CONTAINER DIMENSIONAL TOLERANCES AND QUALITY CONTROL
Typical Manufacturing Capability
Critical Dimensions:
±0.05 mm to ±0.10 mm
Neck Finish:
±0.03 mm to ±0.05 mm
Bottle Height:
±0.10 mm
Bottle Diameter:
±0.10 mm
Quality Control Measures
• Surface finish verification
• Vacuum channel inspection
• Cooling channel flow verification
• Material certification review
• Assembly verification
6. VACUUM SYSTEM INTEGRATION AND CONTAINER FORMATION CONTROL
Vacuum-assisted formation is a critical element of BFS technology.
Our mould design incorporates:
Vacuum Channel Configuration
• Dedicated vacuum distribution network
• Multi-point vacuum extraction
• Balanced cavity evacuation
• Optimized channel diameters
Vacuum Distribution Methodology
• Equalized vacuum paths
• Controlled vacuum pressure drop
• Uniform vacuum delivery to all 8 cavities
Venting Design
• Precision vent locations
• Controlled air evacuation
• Prevention of trapped air pockets
• Stable container replication
Process Control Considerations
The mould design supports:
• Consistent parison capture
• Uniform bottle formation
• Stable wall thickness development
• Reduced process variability
Benefits
• Improved dimensional accuracy
• Better surface quality
• Consistent bottle geometry
• Reduced reject rates
7. VACUUM EFFICIENCY AND DEFECT PREVENTION
The design minimizes:
• Incomplete bottle formation
• Thin wall sections
• Thick wall accumulation
• Surface blemishes
• Vacuum marks
• Distortion
• Panel collapse
• Stability issues
Optimization Methods
• Balanced vacuum channel layout
• Uniform cavity venting
• Controlled vacuum timing
• Material flow optimization
• Thermal balance management
These measures ensure reliable bottle formation throughout the production cycle.
8. COOLING SYSTEM DESIGN
Cooling design is developed to provide:
• Uniform heat extraction
• Reduced cycle time
• Thermal stability
• Consistent bottle dimensions
Cooling Features
• Dedicated cavity cooling circuits
• Balanced water flow design
• Turbulent flow optimization
• Temperature control analysis
Benefits
• Improved productivity
• Reduced dimensional variation
• Enhanced mould life
• Stable production performance
9. MOULD TESTING AND FACTORY ACCEPTANCE TESTING (FAT)
Prior to shipment, the mould undergoes:
Mechanical Verification
• Dimensional inspection
• Assembly verification
• Alignment checks
Functional Testing
• Vacuum integrity testing
• Cooling circuit testing
• Leak testing
• Mould movement verification
FAT : FAT is not available as every tooling is made for the specific machine.
10. VALIDATION AND QUALIFICATION SUPPORT
• Material certificates
11. INSTALLATION AND COMMISSIONING SUPPORT
Friscohn provides:
• Installation & commissioning supervision
Remote and on-site support options are available.
12. RECOMMENDED SPARE PARTS
Few critical spares are supplied with the mould. The complete spare parts list will be included with the proposal.
13. PREVENTIVE MAINTENANCE
Recommended Maintenance Intervals
Daily
• Cleaning
• Visual inspection
Weekly
• Vacuum inspection
• Cooling inspection
Monthly
• Dimensional verification
• Wear assessment
Annual
• Comprehensive overhaul inspection
Preventive maintenance significantly extends mould service life.
14. PROJECT TIMELINE
Typical Project Schedule : One Month.
15. WARRANTY AND PERFORMANCE GUARANTEE
Warranty Period
12 months from commissioning or 18 months from delivery, whichever occurs first.
Warranty Scope
• Manufacturing defects
• Material defects
• Workmanship defects
Performance Guarantee
Subject to approved operating conditions, qualified raw materials, and machine condition, the mould will meet agreed bottle dimensional specifications and production performance targets.
16. CORRECTIVE ACTION AND TECHNICAL SUPPORT
Should any issue arise, Friscohn follows a structured CAPA process:
• Root cause investigation
• Technical assessment
• Corrective action implementation
• Preventive action recommendations
• Follow-up verification
Response Targets
Remote Support:
24–48 hours
Urgent Technical Review:
Immediate prioritization
On-Site Support:
As mutually scheduled
17. AFTER-SALES SERVICE
Our after-sales services include:
• Remote diagnostics
• Spare parts supply
• Mould refurbishment
• Process optimization
• Preventive maintenance support
• Emergency technical assistance
18. INFORMATION REQUIRED FROM CUSTOMER
To initiate engineering evaluation and prepare a detailed proposal, we request:
Machine Information
• OEM machine Model and serial number
• Existing mould specifications
• Current process parameters
Exiting Mould Information
• Drawings
• Filling Nozzle pitch...
MOULD GALLERY
Engineering Better BFS Performance
Trademark Disclaimer
Rommelag, Weiler and Brevetti Angela are trademarks of their respective owners. Friscohn is an independent company and is not affiliated with, sponsored by, authorized by, or endorsed by these manufacturers, unless expressly stated. All other trademarks and brand names referenced on this website remain the property of their respective owners.
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