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Case Study · Haripur, Pakistan

FDL: Integrated Plastic-Bottle IV Production

A connected IV manufacturing solution bringing filling, pharmaceutical water, nitrogen purging, sterilisation, cleaning and downstream packaging into one coordinated line.

100 mL IV BottleFour-Head FillingAutoclaveEDI Water System
ClientFDL
LocationHaripur, Pakistan
Reference Container100 mL Plastic IV Bottle
StatusReported in Production
01 · Project Overview

An IV Line Is More Than the Filler

Reliable IV production depends on the systems surrounding the filling machine. The project links filling, water, nitrogen, sterilisation, cleaning and packaging into one architecture.

01

The Production Need

A plastic-bottle IV line required clean pharmaceutical water, controlled filling, nitrogen handling, terminal sterilisation, cleaning systems and downstream packing.

02

The Integrated Approach

Project records connect the four-head filler with EDI water, nitrogen purging, autoclave sterilisation, CIP/SIP and labeling and flow-packing layouts.

02 · Technical Scope

The Systems Around the Filling Line

01

Four-Head Filling

IV filling nozzle and four-filling-head drawings documented.

02

100 mL Layout

Production-line layout reference around the 100 mL format.

03

EDI Water System

Pharmaceutical water design supporting production.

04

Nitrogen Purging

Nitrogen generators incorporated before and after filling.

05

Autoclave

Terminal sterilisation design for plastic IV bottles.

06

CIP / SIP

Cleaning-in-place and sterilisation-in-place design.

07

Labeling

Labeling layouts integrated into the downstream flow.

08

Flow Packing

Packing-hall and flow-packing layout integration.

03 · Production Route

The Connected IV Manufacturing Process

01Water & Raw Materials
02Solution Preparation
03Filling
04Nitrogen Purge & Closure
05Autoclave Sterilisation
06Inspection
07Labeling & Flow Packing
08Finished Goods
04 · Plastic Bottle Advantage

Where Plastic Can Reduce IV Line Costs

The actual economics depend on bottle size, production volume, local pricing and line configuration rather than one fixed saving.

Lower Freight

Lighter containers can reduce transport and handling costs.

Less Breakage

Reduced losses compared with fragile glass bottles.

Reduced Storage

Preforms require less space than finished empty bottles.

Integrated Forming

Container production can form part of the manufacturing line.

Simpler Handling

Some routes eliminate separate bottle washing stages.

Configuration Dependent

Final economics depend on the selected technology.

05 · After-Sales

Support Beyond Handover

Operator Training

Training for operating, maintenance and quality teams.

Technical Assistance

Support with operating questions and troubleshooting.

Maintenance Support

Routine servicing and maintenance planning.

Spares & Consumables

Relevant replacement components and consumables.

Planning a Plastic-Bottle IV Line?

Engineer the Systems Around the Filler as One Production Line

From water systems and filling to nitrogen, sterilisation, validation and after-sales support.

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