PA C K A G I N G
(Left to right) 1. Aseptic filling can be used with a range of packaging from small pouches to barrels and bulk containers; 2. The aseptic
process ensures that both food and packaging materials are free of harmful bacteria when the product is packaged; 3. The HRS
Aseptic Block Series is a packaged steriliser (or pasteuriser) and aseptic filler.
as the patented Unicus Series or R Series heat
exchanger, may be used.
3. Sterilisation of the packaging
Prior to filling, packaging is normally sterilised
using thermal or chemical methods (such
as peroxyactic acid or hydrogen peroxide),
although in many production environments the
packaging is supplied pre-sterilised in aseptic
packaging that can be put into the filling line
without contamination. However the packaging
is sterilised, it is vital that aseptic conditions are
maintained between sterilisation and sealing,
and this is another reason for adopting an
integrated aseptic processing solution.
4. Filling and sealing under
aseptic conditions
There are numerous systems of aseptic filler
on the market, but all try to balance speed,
accuracy of operation and flexibility of filling
(for example, working with different products
and containers), while maintaining the microbial
integrity of the product and the sterility of the
containers – including suitable cleaning-inplace
(CIP) systems before, during and after
production.
Depending on the product and how it is
packaged, filling may be based on weight or
volume and appropriate sensors (such as weigh
cells of flow meters) and control systems will be
included in the filler machinery. The AF Series of
aseptic fillers meets all of these criteria and is
suitable for both high and low acidity products.
Once filled, there are many ways that aseptic
packaging can be sealed; from screw-capping
bottles to heat sealing pouches or putting lids
on bulk containers. These mechanisms may also
include some form of tamper-evident system to
alert customers or consumers if the pack has
been opened since filling.
The business case for aseptic
filling
There is of course a financial investment required
to install aseptic filling technology, but when
conducting a cost/benefit analysis, some of the
factors to consider include:
- Volume: Aseptic filling lines normally operate
on a continuous basis and therefore are much
faster than batch cooling operations.
- Quality: Probably the biggest driver towards
aseptic filling is the improvement in product
quality. Any heat treatments can be driven
by product requirements, rather than the
need to sterilise the container, making high
temperature, short time (HTST) pasteurisation
feasible in many cases. This preserves key
quality characteristics such as taste, nutrient
content and colour.
- Flexibility: Most aseptic filling lines can be
configured to supply a range of products and
fill a range of containers including PET, HDPE,
LDPE, glass, cans, foil etc. Not only does this
increase flexibility, but also helps to futureproof
installations.
- Packaging: Although there may be an increase
in costs associated with the need to purchase
sterile packaging, many packaging types
used in aseptic filling are generally lighter
(and therefore cheaper) than their hot-fill
equivalents.
When considering aseptic filling, companies need
to weigh up the safety of the proposed solution
with capital and operating costs, operational
safety considerations and the effect on product
quality. In most situations, the business case to
adopt cold filling quickly becomes apparent.
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