Aseptic Packaging

Content

• Introduction• What is Aseptic?• Aseptic Packaging• Advantages• Limitations

Why Foods are processed?

Introduction

Increase Shelf life of product Availability of commodity throughout

year Wide range of products can be

produce Convenience for consumer

How Foods products are processed ?

Introduction

Methods Of Processing

By Application of heat – Aseptic packaging

By Removal of heat By Irradiation By Addition of sugar / salt / Additive Minimal Processing By Altering surrounding of product

Aseptic Packaging

What is Asepsis?

Hermetic Vs Aseptic

A condition in which contamination or infection of microorganisms are prevented and also ingress or out gress of mass is 100% prevented. This is carried out by air tight sealing

A procedure consisting of sterilization of the packaging material or container, filling of a commercially sterile product in sterile environment and producing containers which are hermetically sealed which results in product which is shelf stable under ambient condition.

Components of Aseptic Packaging

Commercial Sterile Product Sterile Packaging material Sterile Environment

Aseptic Packaging

Commercial Sterile Product

On basis of pH, Foods are categorized as follows

Low Acid Foods (pH > 4.5) Acid Foods (pH 4 to 4.5) High Acid Foods (pH < 4.0)

pH Affects on Processing temperature and time

Presence of acid decreases heat resistance of microorganisms.

Clostridium Botulinum is considered as most heat resistant from the studies.

It can not grow at pH below 4.8 Bssychalmus fulva (Mold) can grow at acidic pH

SN Fruit Products pH

1 Acidified Banana Puree 4.0-4.5

2 Acidified Banana Puree Concentrate 4.0-4.5

3 Alphonso Mango Puree 3.5-4.3

4 Totapuri Mango Puree 3.5-4.3

5 Kesar Mango Puree 3.5-4.3

6 Raspuri Mango Puree 3.5-4.0

7 Totapuri mango Puree Concentrate 3.5-4.0

8 Mango Puree & Concentrate Natural < 4.5

9 Pink Guava Puree < 4.0

10 White Guava Puree < 4.0

11 Pink Guava Puree Concentrate < 4.0

12 White Guava Puree Concentrate < 4.0

13 Red Papaya Puree < 4.5

14 Yellow Papaya Puree < 4.5

15 Red Papaya Puree Concentrate < 4.5

16 Yellow Papaya Puree concentrate < 4.5

17 Tomato puree / paste < 4.4

18 Amla Puree & Concentrate < 3.0

Thermobacteriology

D Value – Time required to kill 90% microorganisms under study

Z value – Temperature required for TDT curve to pass through one log cycle

F value – Time required at reference temperature to reduce the microbial population to desired sterility level

Recommended Schedule by NCA

PH Fo VALUE (VALUE AT 250 DEGREE FAHRENHEIT) Minutes

3.9 or LESS 0.1

3.9 to 4.1 1

4.1 to 4.2 2.5

4.2 to 4.3 5

4.3 to 4.4 10

4.4 to 4.5 20

• Water - decreasing moisture increases resistance

• Fat, protein and carbohydrate - Presence in solution tends to increase resistance of some micro-organisms

• Salts - Effect is variable

• pH - Microbes are most heat-resistant at optimum pH

• Number of organisms - Larger numbers lead to higher degree of resistance

• Age of organisms - Most resistant in stationary phase, least resistant in exponential phase

Sterility - Factors affecting heat resistance of micro-organisms

Sterilization Equipment

Heat transfer data of Heat Exchanger High Pressure withstanding ability MOC should withstand with acidic and basic conditions

Heating Methods Direct heating methods Indirect heating methods

• Plate heat exchanger

• Tubular heat exchanger

• Scraped surface heat exchanger

Aseptic Plant sections

Preparatory Section / Blending Section (Raw material to intermediate product)

Processing Section (Intermediate product to Commercial sterile Product)

Aseptic Filler Section (Commercial sterile product filling in sterile package in sterile environment)

“Prevention is better than Cure”

Cleaning & Sanitation – SOP Regular CIP of pipeline Preventive Maintenance Schedule Skilled and Qualified Manpower Strict Monitoring over production line Team spirit

We can achieve better Hygiene in Processing plant

Aseptic Environment

Aseptic FillerScholleAsepsystem

Aseptic environment is created near Filler head by maintaining positive pressure of steam

Aseptic Packaging Material

Packaging material is sterilized by application of the following or in combination

Irradiation UV light treatment Steam Water By Hot air By use of chemicals like H2O2

Aseptic Packaging Material

Primary packaging Material Tetrapack – LD / Al foil / LD / Paperboard Aseptic Bulk pack – LD / EVOH / Al foil / LD Glass bottle FFS cartons Secondary packaging Material Tetrapack – pack in corrugated tray with shrink

wrapping Aseptic Bulk pack – CFB boxes (25 kg) – Bag in box Aseptic Bulk pack – Plastic Drums (50 kg) Aseptic Bulk pack – MS Drum (225 kg)

Integrity Check for Aseptic Packaging material

Teardown test – Sealing strength Electrolytic Test – Pinhole testing Dye test – For pinholes in laminated

cartons Sterility check

ConvenienceAseptic packages are portable, lightweight, and shatterproof and easily transportable Food SafetyThe aseptic process and carton together ensure that the liquid food or beverage inside is free from harmful bacteria and contaminants. No refrigeration required Long shelf life More nutritionCompared with canning, products can retain more nutrients as well as natural taste, colour and texture Low Packaging to product ratio

Advantages of Aseptic Packaging

Limitations Plant Installation cost is high as compare to canning Gas transmission rate of Aseptic bag/ package Overcooked flavour in some products Lack of equipment for particulate sterilization, due

especially to settling of solids and thus over processing

Thanks

Canning Vs Aseptic

Types of Tetra pack

Vitamin Loss

UHT Milk Processing

Test organisms UHT – Spores of B. subtilis or B. stereothermophilus