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ADVANCES IN ASEPTIC

PROCESSING

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12 for bulk systems- bag-in-box or bag-in-drum

Basic principle : aseptic transfer of sterilised

materials into sterile containers.

Food is subjected to rapid heating in a heat exchanger,

held for sufficient time to achieve commercial sterility

and then cooled before filling into a decontaminated

container within an aseptic filling zone.

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Avoidance of reinfection:

Food contact surfaces

Maintaining over pressure within the processing

storage and the filling system

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Regulatory effects

For meat and poultry processes USDA has added

aseptic process systems to their plants

Chemical sterilant packaging systems could not be

used at one period for commercial processing andaseptic packaging of foods

1981-Hydrogen peroxide is permitted as a

sterilising agent for polyethylene surfaces ofcontainers

Application to homogeneous products

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Aspects of good manufacturing

practice

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Food preparation

Packagethermoform

Package erection

Package

preformed

Warehouse

Steriliser Direct

heating

Steriliser Indirect

heating

Steriliser/ cooler

batch

Package

sterilisation

Package materialsterilisation

Palletisation

Flash evaporator

(1st stage cooler)

Coolers

Aseptic tank

Aseptic fillers

Package- asepticformation

Aseptic sealing,

Lidding

Secondary packaging

Food

Processing

Aseptic

packaging

Final

product

ASEPTIC FLOW DIAGRAM

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GMP guidelines

Low acid foods- Cl.botulinum

Commercial sterility

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Design and development

1. Food Contact Surfaces

2. Food Process

3. Non-food Contact Surfaces

4. Decontamination of packaging

5. Aseptic filling zone

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Food description

Consider product transport and

capacity of plant for product and

services

Define thermal process

requirement by hazard

analysis

Design-stage candidates:Identify critical control

points

Pumps

Pipework

Heat exchangers

Holding section

ValvesPackaging

Product fillers

Control system

Aseptic tanks

Proposed installation

Establish scheduled processes

1. Pre-production sterilisation of food contact

surfaces2. Food thermal process

3. Decontamination of packaging

4. Decontaminated air or gas

a. Aseptic filling environments

b. Aseptic tanks

5. Decontamination of non-food contact

surfaces in filling machines

Commissioning tests1. Performance of on-line control

system

2. Incubation and destructive analysis

3. Secondary packaging

4. Handling practices

5. Transport tests

6. CIP requirements

7. Aseptic seals

e.g.

Re-assess

Stages in system development

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Commissioning tests

1.Packaging

Compatibility- no breakdown of packaging mtrls

Package structurefree from defects

Sealing method- microbiological barrier

2. Storage

Identification- product referable to records

Protection- adequate for handling and stacking3. Transportation- package integrity has to be

maintained by correct handling

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