PA C K A G I N G
THE ADVANTAGES OF COLD ASEPTIC FILLING
In recent years, aseptic technology has become well established in the food and drink sector as
a filling technique. Yet some businesses are still unaware of its benefits or do not believe that it
can be used with their products.
As consumers have become more
health conscious, the demand for
food and drink products without
preservatives has increased.
However, traditional methods
combining sterilisation with hot filling have
not been suitable for products which are
increasingly sold on their ‘fresh’ and ‘natural’
characteristics, due to the effect on product
quality.
In most cases, hot filling sterilises the container
as the product (which is still hot from cooking or
sterilising) is filled. However, the temperatures
required often have unwanted effects on the
quality of the product, and the heat imposes
restrictions on the type of container which can
be used: for example, hot filling of lightweight
plastic drinks bottles can lead to distortion of
the plastic.
Consequently, cold aseptic filling has become
a common technique with drinks manufacturers
for products including UHT milk, fruit juices, and
sports and energy drinks. Its flexibility means
that it is suitable for a wide range of products
from fresh fruit dices and purees to marinades
and dairy products. This diversity has also seen
the development of a wide range of fillers and
packaging types, from pouches and lidded trays
through to bulk bags and intermediate bulk
containers (IBCs).
Aseptic filling systems generally combine a
number of elements into a single integrated
production line. This integrated approach helps
to ensure microbiological safety throughout
the process from initial treatment through
to the sealing of the finished product. The
steps included in an integrated aseptic filling
line (such as the HRS Asepticblock) typically
include:
1. Thermal treatment
Although in theory this can be any thermal
treatment which reduces harmful bacteria
(pasteurisation, sterilisation or cooking), in
practice the types of product which are most
likely to benefit from aseptic filling are those
which are pasteurised or sterilised. This step
usually comprises a suitable tubular heat
exchanger, such as the HRS MI, DTA or AS
Series.
2. Cooling (where necessary)
Depending on the product, the production
process and the packaging used, it may
be necessary to cool the product following
pasteurisation or sterilisation. In some situations
(such as the production of cooked items like
soups and sauces), this step may actually form
the first part of the integrated aseptic line,
receiving hot cooked product from elsewhere
in the factory. In such cases another heat
exchanger will be used, such as the AS Series.
If cooling the product is likely to increase its
viscosity, then a scraped-surface unit, such
28 FEBRUARY 2020