Aseptic Packaging. Content Introduction What is Aseptic? Aseptic Packaging Advantages Limitations.

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Aseptic Packaging

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  • Aseptic Packaging

  • Content Introduction What is Aseptic? Aseptic Packaging Advantages Limitations

  • Why Foods are processed?Introduction

  • Increase Shelf life of productAvailability of commodity throughout yearWide range of products can be produceConvenience for consumer

  • How Foods products are processed ?

    Introduction

  • Methods Of ProcessingBy Application of heat Aseptic packagingBy Removal of heatBy IrradiationBy Addition of sugar / salt / AdditiveMinimal ProcessingBy Altering surrounding of product

  • Aseptic PackagingWhat 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 sealingA 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 PackagingCommercial Sterile ProductSterile Packaging materialSterile EnvironmentAseptic Packaging

  • Commercial Sterile ProductOn basis of pH, Foods are categorized as followsLow Acid Foods (pH > 4.5)Acid Foods (pH 4 to 4.5)High Acid Foods (pH < 4.0)

  • pH Affects on Processing temperature and timePresence 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 4.8Bssychalmus fulva (Mold) can grow at acidic pH

  • SNFruit ProductspH1Acidified Banana Puree4.0-4.52Acidified Banana Puree Concentrate4.0-4.53Alphonso Mango Puree3.5-4.34Totapuri Mango Puree3.5-4.35Kesar Mango Puree3.5-4.36Raspuri Mango Puree3.5-4.07Totapuri mango Puree Concentrate3.5-4.08Mango Puree & Concentrate Natural< 4.59Pink Guava Puree< 4.010White Guava Puree< 4.011Pink Guava Puree Concentrate< 4.012White Guava Puree Concentrate< 4.013Red Papaya Puree< 4.514Yellow Papaya Puree< 4.515Red Papaya Puree Concentrate< 4.516Yellow Papaya Puree concentrate< 4.517Tomato puree / paste< 4.418Amla Puree & Concentrate< 3.0

  • Thermobacteriology

    D Value Time required to kill 90% microorganisms under studyZ value Temperature required for TDT curve to pass through one log cycleF value Time required at reference temperature to reduce the microbial population to desired sterility level

  • Recommended Schedule by NCA

    PHFo VALUE (VALUE AT 250 DEGREE FAHRENHEIT) Minutes3.9 or LESS0.13.9 to 4.114.1 to 4.22.54.2 to 4.354.3 to 4.4104.4 to 4.520

  • 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 EquipmentHeat transfer data of Heat ExchangerHigh Pressure withstanding abilityMOC should withstand with acidic and basic conditions

    Heating MethodsDirect heating methodsIndirect heating methods Plate heat exchanger Tubular heat exchanger Scraped surface heat exchanger

  • Aseptic Plant sectionsPreparatory 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 CureCleaning & Sanitation SOPRegular CIP of pipelinePreventive Maintenance ScheduleSkilled and Qualified ManpowerStrict Monitoring over production lineTeam spirit

    We can achieve better Hygiene in Processing plant

  • Aseptic EnvironmentAseptic FillerScholleAsepsystem

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

  • Aseptic Packaging MaterialPackaging material is sterilized by application of the following or in combinationIrradiationUV light treatmentSteamWaterBy Hot airBy use of chemicals like H2O2

  • Aseptic Packaging MaterialPrimary packaging MaterialTetrapack LD / Al foil / LD / PaperboardAseptic Bulk pack LD / EVOH / Al foil / LDGlass bottleFFS cartonsSecondary packaging MaterialTetrapack pack in corrugated tray with shrink wrappingAseptic Bulk pack CFB boxes (25 kg) Bag in boxAseptic Bulk pack Plastic Drums (50 kg)Aseptic Bulk pack MS Drum (225 kg)

  • Integrity Check for Aseptic Packaging materialTeardown test Sealing strengthElectrolytic Test Pinhole testingDye test For pinholes in laminated cartonsSterility check

  • Convenience Aseptic packages are portable, lightweight, and shatterproof and easily transportable Food Safety The 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 nutrition Compared 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 canningGas transmission rate of Aseptic bag/ packageOvercooked flavour in some productsLack 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 ProcessingTest organisms UHT Spores of B. subtilis or B. stereothermophilus