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Aseptic Packaging - Basics
Aseptic Filler and Sealer
Aseptic packaging can be defined as the filling of a commercially sterile product into a sterile container under aseptic conditions and hermetically sealing the containers so that reinfection is prevented. This results in a product, which is shelf-stable at ambient conditions.The term “aseptic” is derived from the Greek word “septicos” which means the absence of putrefactive micro-organisms.
In practice, generally there are two specific fields of application of aseptic packaging technology:-
Packaging of pre-sterilised and sterile products.Examples are milk and dairy products, puddings, desserts, fruit and vegetable juices, soups, sauces, and products with particulates.
Packaging of non-sterile product to avoid infection by micro-organisms. Examples of this application include fermented dairy products like yoghurt.
Aseptic packaging technology is fundamentally different from that of conventional food processing by canning.
Advantages of Aseptic Packaging Technology:-
The three main advantages of using aseptic packaging technology are:-
1.Packaging materials, which are unsuitable for in-package sterilisation can be used.
2. Sterilisation process of high-temperature-short time (HTST) for aseptic packaging is thermally efficient and generally gives rise to products of high quality and nutritive value compared to those processed at lower temperatures for longer time.
3.Extension of shelf-life of products at normal temperatures.
Elements of Aseptic Packaging:-
Aseptic packaging is a complex process composed of four elements, all of which must be entirely present in order to achieve long-term, ambient sterility:-
1. Sterile Product
2. Sterile Packaging
3. Sterile Filling Environment
4. Hermetically Sealed Package – impervious to the outside environment until opened by consumer
Aseptic Processing – Methodology:-
Aseptic processing comprises the following:-
• Sterilisation of the products before filling
• Sterilisation of packaging materials or containers and closures before filling
• Sterilisation of aseptic installations before operation (UHT unit, lines for products, sterile air and gases, filler and relevant machine zones)Conventional Process Flow Aseptic Process Flow
• Maintaining sterility in this total system during operation; sterilization of all media entering the system, like air, gases, sterile water
• Production of hermetic packages
A great variety of packages may be aseptically filled...
• Carton Boxes
• Bags and Pouches
• Cups and Trays
• Bottles and Jars
• Metal Cans
• Plastic Jars and Cans
• Composite Cans
Aseptic Packaging Materials
Packaging materials must meet following factors:-
The packaging material must be compatible with the product intended to be packed and must comply with applicable material migration requirements.
Physical integrity of the package is necessary to assume containment of the product and maintenance of sterility.
The package material must be able to withstand sterilization and be compatible with the methods of sterilization.
The package must protect the product from oxygen, also package must retain the aroma of the products.
Aseptic packaging for fresh products:-
Increased demands from consumers and retail outlets require products which offer extended shelf life (ESL), while at the same time maintaining freshness.The growth of markets requires the distribution of products over ever increasing distances, so that continuous refrigeration cannot always be guaranteed. Furthermore, legislators have imposed product liability laws, which make it essential to develop the highest packaging standards for quality assurance.These factors affect fresh products such as dairy products, fruit drinks, desserts, baby food, soups, sauces, cooking fats and delicatessen salads.To achieve extended shelf-life, they have to be bottled or filled under hygienically perfect conditions.
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