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    Prathamesh Ghorpade
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    Aseptic packaging is a revolution in the packaging industry that allows filling of sterile products into sterile containers under aseptic conditions and hermetically sealing to prevent reinfection. It provides advantages over traditional canning like being energy efficient, sustainable, improving food safety and quality while allowing longer shelf life without refrigeration. Key aspects of aseptic packaging include sterilization of products and packaging materials using techniques like HTST, UHT, steam or radiation. The sterile product is then filled into packaging materials like various types of aseptic cartons and sealed tightly in a continuous process to prevent contamination. Common applications include fruit juices, milk, cream and other dairy and food products.

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    Aseptic packaging is a revolution in the packaging industry that allows filling of sterile products into sterile containers under aseptic conditions and hermetically sealing to prevent reinfection. It provides advantages over traditional canning like being energy efficient, sustainable, improving food safety and quality while allowing longer shelf life without refrigeration. Key aspects of aseptic packaging include sterilization of products and packaging materials using techniques like HTST, UHT, steam or radiation. The sterile product is then filled into packaging materials like various types of aseptic cartons and sealed tightly in a continuous process to prevent contamination. Common applications include fruit juices, milk, cream and other dairy and food products.

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    377 views26 pages

    Aseptic Packaging

    Uploaded by

    Prathamesh Ghorpade
    Aseptic packaging is a revolution in the packaging industry that allows filling of sterile products into sterile containers under aseptic conditions and hermetically sealing to prevent reinfection. It provides advantages over traditional canning like being energy efficient, sustainable, improving food safety and quality while allowing longer shelf life without refrigeration. Key aspects of aseptic packaging include sterilization of products and packaging materials using techniques like HTST, UHT, steam or radiation. The sterile product is then filled into packaging materials like various types of aseptic cartons and sealed tightly in a continuous process to prevent contamination. Common applications include fruit juices, milk, cream and other dairy and food products.

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    of 26

    Aseptic Packaging Revolution in Packaging Industry

    Indian Packaging Industry


    Indian Packaging Industry sector wise

    Distribution of packaging material

    (www.npes.com, 2009)

    Need for Revolution


    Traditional processing operations are
    Energy intensive Require heavy packaging Impact the taste, appearance, healthfulness Examples - a hot-fill/retort process or chemical process

    Drivers of Revolutions
    Cost Sustainability Food safety Technology enablers

    Aseptic Packaging
    The filling of a commercially sterile product into a sterile
    container under aseptic conditions and hermetically sealing the containers so that reinfection is prevented

    Aseptic derived from the Greek word Septicos which means the absence of putrefactive micro-organisms.

    The first aseptic filling plant for milk was presented in

    Switzerland in 1961

    Contd....

    Aseptic Packaging

    Conventional Canning v/s Aseptic Packaging

    Methodology
    Sterilization of products Sterilization of aseptic packaging materials and equipment Filling

    Seals and closures

    Sterilization of Products
    Pre sterilization of product by HTST or UHT for prescribed time A fast heat exchange rate is desired for better quality Important methods used commercially are Microwaves Electrical resistance heating High voltage discharge Ultra high pressure

    Characteristics of the heat exchange systems used for aseptic processing of liquids

    Dinnage (1983)]

    Sterilization of aseptic packaging materials and equipment


    Non-sterile

    Heat, chemicals, electron beam and radiation can be used single or in combination

    Steam

    Chemical sterilisation

    Electron beam

    Heat
    Moist heat or dry heat in the form of superheated steam is used Time temperature requirement is higher in dry heat as

    compare to moist heat


    Moist heat - 121C to 129C

    Dry heat - 176C to 232C


    Highly energy intensive

    Chemicals
    Hydrogen peroxide of 30 to 35% as a sterilant for packaging materials followed by hot air 60C to 125C to dissipate residual hydrogen peroxide

    Various acids, ethanol, ethylene oxide and peracetic


    acid etc. are used

    Uses significant energy and water


    Less expensive than other

    Radiation
    Gamma radiation 1.5 Megaradians (Mrad) used for containers of acid food Highly effective Expensive and not inline technology

    Electron beam
    Energy Efficient No Water No Chemicals Minimum Package Weight Equipment size, speed and costs are limiting factors

    Filling
    Sterilised product is accumulated in an aseptic surge tank Positive pressure monitored and controlled to protect contamination Airtight sealing paramount importance in packaging

    Longitudinal system, a flat web of packaging


    material is used

    Sealing

    Sealing cont..... Constantly moving sealing and pressure jaws Pressure applied from outside packaging material The polyethylene layer is heated Melted and pressed together between a pair of jaws The melted plastic layer cools down

    Bonding is effectuated between the two opposite packaging material surfaces they are sealed transversally Produced are sufficiently tight to prevent re-infection of the product

    Types of Aseptic Packs

    Type of Package Forms available in India


    TBA: Tetra Brik Aseptic

    TCA: Tetra Classic Aseptic


    TFA: Tetra Fino Aseptic

    TWA: Tetra Wedge Aseptic

    Composition of Tetra Pak Aseptic Cartons

    Properties of Aseptic Packaging Material

    Advantages of Aseptic package


    Higher degree of safety, hygiene and nutrient retention Preserving taste and freshness Can be kept for months with no need for refrigeration Light-weight Product quality

    Applications
    Fruit Juices, concentrates, purees Tomato Products Milk and Cream Coconut Products Jam

    Thank you

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