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Complete Overview Of Aseptic Packaging

A package is the “face” of the product contained inside and often is only product exposure that consumers experience prior to purchase. Generally, we have seen that efficient packaging boosts sales in the market. But have you ever thought about what is this packaging all about, what is needed for it, and why the food companies are much more concerned about it? So, this article will answer all your questions.

Food packaging plays a very crucial role in protecting food products from outside influences and damage. The principal role of food packaging is to protect the food products from microbial attack, exposure to gases(mainly oxygen), and moisture so as to extend the shelf life of the commodity. Let’s go through Aseptic Packaging.

Aseptic Packaging | Discoverfoodtech.com

What Is Aseptic Packaging?

There are many methods of food packaging under which the most significant packaging is Aseptic packaging. The term aseptic is derived from the Greek word “septics” which means the absence of putrefactive microorganisms. Aseptic packaging is the filling of sterile containers with a commercially sterile product under aseptic conditions and then hermetically (strict airtight condition) sealing the product so that reinfection is prevented. The purpose of aseptic packaging is to produce a food item that can be stored without refrigeration for 6 months or more while maintaining chemical and sensory properties.

Aseptic Packaging Flow Chart | Discoverfoodtech.com

Examples Of Aseptic Packaging

1. Aseptic Milk

Milk is heated to 275- 300 degrees Fahrenheit for 2-15 seconds. It is then cooled to a temperature suitable for filling. This is now called UHT Milk(Ultra-high temperature). Packaging materials are sterilized through a heated hydrogen peroxide bath which is then removed from packaging material using pressure rollers, hot and sterile air.

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2. Aseptic juice

The fruit juice is heat-treated, chilled and then packed in a sterile environment on an aseptic filling machine into pre-sterilized packaging.

Applications Of Aseptic Packaging

  • Packaging of Presterilized and sterile products.

Example-Milk and dairy products, puddings, desserts, fruits, and vegetables.

  • Packaging of non-sterile products to avoid infection by microorganisms

Example-Fermented dairy products like yogurt.

Basic Requirements For Aseptic Packaging System

An aseptic packaging system should meet 4 criteria:

  • It should be able to connect to a processing system so that the system enables the aseptic transfer of products.
  • Effective sterilization of the food product, as well as the packaging before use, should be possible.
  • It should be able to carry out the filling, sealing, and critical transfer operations in a sterile environment.
  • It should be able to be cleaned after use.

Advantages of Aseptic Packaging

  • Aseptic packages are portable and lightweight.
  • It ensures that the food product inside is free from harmful bacteria and contaminants.
  • No refrigeration is required.
  • Long shelf life.
  • Products retain natural color, taste, and texture
  • Packaging to product ratio is very less such that 90% of the product and 10% of packaging material is present.

Disadvantages Of Aseptic Packaging-

  • Since the entire system is very complicated therefore cost of production is high resulting in a high cost of the product.
  • Presence of overcooked flavor in some products.

Processes Used For Sterilization In Aseptic Packaging

Broadly there is 3 main sterilization process that is used either individually or in combination.

These are Irradiation, heat, and chemical treatments.

1. IRRADIATION

a.Ionising Radiation-Irradiation techniques using gamma rays from Co-60 or Cs- 135
b.Pulsed light-Use of short pulses in the form of electrical energy to kill pathogens.
c.UV-C Radiation-UV Radiation has a wavelength of 200-315 nm.UV Radiation is commercially used in combination with hydrogen peroxide.

2. CHEMICAL TREATMENTS

In chemical methods, hydrogen peroxide is used as a sterilizing agent.

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Minimum temperature of 70 degrees Celsius, a minimum concentration of 30% for 6 seconds is necessary to cause destruction of most microbial spores within seconds. The U.S.Food and drug administration has ruled that the concentration of Hydrogen peroxide used for sterilization of packaging material should not be greater than 50 parts per billion(50 ppb) at the time of filling and should fall to 1 ppb within 24 hours. To increase the efficiency of sterilization by hydrogen peroxide number of methods have evolved which use heat, radiant or irradiant energy along with hydrogen peroxide.

3. HEAT

  1. Saturated Steam-It is used under pressure in plastic containers.
  2. Super-heated steam-The cans are passed continuously through 220-225 degrees Celsius saturated steam under normal pressure for 36-45 seconds depending upon the material used.
  3. Hot air
  4. Hot air and steam-Mixture of hot air and steam is used to sterilize the inner surfaces of cups and lids.

ASEPTIC PACKAGING EQUIPMENT’S

  • CARTON SYSTEMSIt consists of layers of unbleached or bleached paperboard which is coated internally and externally with polyethylene. Thus the carton becomes impermeable to liquids in which internal and external surfaces may be sealed with heat. There is also a thin layer of aluminum that acts as an oxygen and light barrier.
  • CAN SYSTEMSThis system uses superheated steam at 225 degrees Celsius for up to 40 seconds to sterilize the cans as well as to maintain a vacuum in the cans. When the cans are filled with a cold and sterile product they are sealed using a conventional can sealer.
  • BOTTLE SYSTEMThe bottles are sterilized either by saturated steam under pressure or by dry heat. Two types of bottles can be used glass and plastic bottles. Glass bottles have not gained widespread acceptance. A plastic bottle is a better alternative than glass bottles. HDPE and PP are the two most thermoplastics used sometimes with pigments added so that the contents are protected from light. Nowadays aseptic PET bottles are widely used which are capable of packaging a variety of products like milk, juice, water, etc.
  • SACHET AND POUCH SYSTEMSCompared to other systems, this system is claimed to offer lower environmental impacts in terms of energy consumption and waste generation. Generally, it is a form-fill-seal system.UV rays may be used to sterilize the film. The bags may be made from either a reeled or flat film. The popular laminate is black or brown(to exclude ultraviolet light.)
  • CUP SYSTEMMade of paper with wax or plastic coating on the inside. Used for frozen and coagulated products. The cups are sprayed with 35% hydrogen peroxide and after 3 seconds at 400 degrees Celsius, the solution is removed with compressed hot air.
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