What is aseptic packaging of food?
Aseptic packaging of foods can be defined as a process where a pre-sterilized food product is filled and hermetically sealed in sterile packaging materials under an aseptic environment without reheating for sterilization. Aseptic processing requires (Buchner, 1993 ):
How are products made clean and safe through aseptic packaging?
These products are made clean and safe through the technology and process of aseptic packaging. What is Aseptic Packaging? Aseptic packaging is a manufacturing method in which pharmaceutical and various food products are sterilized separately and then combined and sealed under a sterilized environment.
What is aseptic processing equipment sterilization?
Aseptic processing equipment sterilization procedures often use steam or hot water under pressure. Packaging equipment and packaging materials are sterilized with various medium or combination of mediums (i.e., saturated steam, superheated steam, hydrogen peroxide and heat and other treatments).
Why is polyethylene used in aseptic packaging?
Polyethylene is used as a barrier on the inner and outer sides of aseptic packaging. These layers protect against moisture entering or exiting the container. Film foil helps preserve the product by keeping light and oxygen out.
What is aseptic packaging give example?
Aseptic filling works by introducing a pre-sterilized product into a pre-sterilized container. Items are sterilized using ultra-high temperatures for a few seconds at a time. Some examples of items that are commonly packaged using aseptic technology are milk, coffee, and fruits and vegetables.
What does aseptically packaged mean?
Aseptic packaging is a procedure consisting of sterilization of the packaging material or container, filling with a commercially sterile product in a sterile environment, and producing containers that are tight enough to prevent recontamination (hermetically sealed).
What is a major advantage of aseptic packaging?
Not only are they shelf-stable for up to 18 months — aseptic packaging means that they also don't require refrigeration and can still stay fresh during their shelf life. Refrigeration is typically used to slow down bacteria, but when there are no germs in the first place, there's nothing to slow down.
Why is aseptic technique used?
In the microbiology lab we use aseptic technique to: Prevent contamination of the specific microorganism we are working with. Prevent contamination of the room and personnel with the microorganism we are working with.
Is aseptic packaging safe?
Yes. There are no health concerns associated with aseptic packaging. The inside layer of an aseptic package, which touches the product, is polyethylene (plastic). There is no leaching of aluminum or aluminum components through the polyethylene layer.
What is the principle of aseptic packaging?
Aseptic processing involves three primary steps: thermal sterilization of the product, sterilization of the packaging material, and conservation of sterility during packaging.
What are the advantages and disadvantages of aseptic packaging?
less energy is required - less energy to heat and sterilise the product and the container. protection of nutritional content - the food product contains more nutrients due to less heat damage; preservatives do not need to be added. low packaging to product ratio - there is more than 90% food product to 10% package.
Does aseptic packaging need to be refrigerated?
Products that are aseptically processed are commercially sterilized to kill harmful microorganisms. These products are filled into a sterilized package using a sterile filler. Since both the product and package have been sterilized, the sealed package is shelf-stable and refrigeration is not required.
What is in aseptic packaging?
Aseptic packaging is the process by which microorganisms are prevented from entering a package during and after packaging. During aseptic processing, a sterilized package is filled with a commercially sterile food product and sealed within the confines of a hygienic environment.
Does aseptic packaging need to be refrigerated?
Products that are aseptically processed are commercially sterilized to kill harmful microorganisms. These products are filled into a sterilized package using a sterile filler. Since both the product and package have been sterilized, the sealed package is shelf-stable and refrigeration is not required.
What is difference between sterile and aseptic?
In the context of medicine, aseptic and sterile both mean germ-free. Aseptic is most commonly applied in the context of techniques and procedures, while sterile is most commonly used to describe environments and instruments that have been cleaned (sterilized). Sterile also means “incapable of producing offspring.”
What does aseptic literally mean?
1 : preventing or not involving infection aseptic techniques. 2 : free or freed from pathogenic microorganisms an aseptic wound an aseptic operating room. Other Words from aseptic.
Why do manufacturers use aseptic packaging?
Manufacturers don’t need to use preservatives with the use of aseptic packaging because the sterilization process protects against bacteria. This allows manufacturers to use real ingredients that consumers prefer. Aseptic packaging is a sustainable method that can contribute to a manufacturer’s “Go Green” initiative.
Why is aseptic packaging important?
Aseptic packaging also requires less energy to manufacture. The high-tech aseptic packaging process helps preserve the overall quality of most food products. That means taste, smell, and even nutritional value will not be compromised and consumers can be confident that the product they purchase will be of high quality.
What is the layer of aseptic packaging?
Several materials are layered together to provide the level of protection required for aseptic packaging standards, including: Polyethylene is used as a barrier on the inner and outer sides of aseptic packaging. These layers protect against moisture entering or exiting the container.
How long does aseptic packaging last?
Increased shelf life. Aseptic packaging helps increase shelf life for select products by an estimated six to 12 months without refrigeration.
What temperature can aseptic packaging be stored at?
With the unique materials used in aseptic packaging, select products can be stored at ambient temperatures (approximately 68-77 degrees Fahrenheit). Additionally, aseptic packaging is lightweight and compact when compared to more traditional packaging types.
How does film foil help preserve products?
Film foil helps preserve the product by keeping light and oxygen out. Aseptic packaging has been growing in popularity amongst manufacturers in recent years. In fact, The Freedonia Group reported that the demand for aseptic packaging is expected to rise at a 6.8% rate annually, reaching $6.4 billion by year 2020.
What is aseptic packaging?
Aseptic packaging is the filling of a commercially sterile product into sterile containers under sterile conditions and sealing the containers so that reinfection is prevented. The three main processes used commercially, either individually or in combination, to sterilize packaging materials prior to aseptic filling are irradiation (gamma rays, pulsed light, UV lasers, or plasma), heat (either steam or dry heat), and chemical treatments (either hydrogen peroxide or peroxyacetic acid). Packaging materials for aseptic packaging are composed of either paperboard laminates or plastics. Four major categories of aseptic packaging systems are available for dairy products: cartons, plastic bottles, sachets and pouches (including bag-in-box), and plastic cups. Their major features and characteristics are described. Finally, integrity testing of aseptic packages is discussed, including recent developments in nondestructive or noninvasive methods for assessing package integrity.
When was aseptic packaging first used?
The first aseptic packaging of food (specifically milk in metal cans) was carried out in Denmark by Nielsen prior to 1913 and a patent for this process (termed aseptic conservation) was granted in 1921. In 1923, aseptically packaged milk from South Africa reached a trade fair in London, England, in perfect condition.
What is Martin's aseptic process?
Martin's aseptic process overcame many of the obstacles that prevented the success of the HCF unit. The use of superheated steam at atmospheric pressure eliminated the need for rotary valves for passing empty cans into the system and finished cans out of the system. Also, the use of atmospheric pressure negated the need for high-pressure construction. This early unit was the forerunner of the Dole Aseptic Canner still in use today. The first commercial units were installed in 1951 for Andersen Pea Soup, and sterilized milk at the Med-O-Milk plant started in 1951 by Ralph Graves and associates in East Stanwood, Washington. Real Fresh Inc. was established in 1952 by Robert Graves and associates at Visalia, California ( David et al., 1996 ). In 1962 Martin patented an improvement for use in aseptic canning systems containing suspended solids such as vegetable soup and beef stew (US patent 3,041,185). Although the Martin-Dole Aseptic Canning System worked well for packaging liquids in metal cans, industry explored possibilities for aseptic packaging in other containers. The first commercial successes with other packages were in Europe, especially through the development by Tetra Pak of machines for packaging milk aseptically in cartons.
What is the most common method of sterilization?
The common methods of sterilization include chemical methods, thermal methods, and radiation methods. Hydrogen peroxide sterilization followed by hot air is the most common method used in aseptic packaging. Sterilization of packaging materials using hydrogen peroxide followed by ultraviolet ...
What is UHT in aseptics?
Aseptic systems use ultrahigh-temperature (UHT) sterilization, a fast heating treatment at temperatures higher than pasteurization temperatures. Paper and plastic packaging materials are sterilized, formed, filled, and sealed in a continuous operation at the end of the processing line.
Where was the Avoset process invented?
In 1942, at the Avoset plant in Gustine, California, George Grindrod developed the Avoset process based on his 1939 patent (US patent 2,170,196). Whipping cream was sterilized by steam injection and packed in cans, and later in glass bottles. Containers were sterilized in retorts using saturated steam. The retort method of sterilization was eventually abandoned and replaced by a continuous hot-air system, utilizing ultraviolet lamps to protect the filling and closing area. Like the HCF process, the Avoset process is no longer in operation, but it served as a stepping-stone in the evolution of aseptic processing and packaging technology.
When was hydrogen peroxide approved for sterilization?
In the 1960s chlorine was used as the sterilizing agent for aseptic packaging material, but in 1981 the FDA approved the use of hydrogen peroxide as the sterilant. This approval provided a real boost to this technology.
Aseptic packaging
Microorganisms are prevented from entering a product during and after packing by using aseptic packaging. A sterilized package is filled with a commercially sterile food product and sealed inside the constraints of a sanitary environment during aseptic processing.
Composition of aseptic packaging
To meet aseptic packaging criteria, many components are stacked together, including:
Increasing demand for Aseptic Packaging
According to research by the Freedonia Group, pharmaceuticals had the largest market for aseptic packaging in 2015, accounting for 61% of the overall demand in the US. However, aseptic packaging for food and beverage has experienced an increase in popularity in recent years, and demand for it continues to grow.
Top benefits of Aseptic Packaging
Aseptic packing extends the shelf life of certain foods for at least 6 to 12 months even when they are not refrigerated. Manufacturers and merchants have more time to sell their products before they expire or lose their flavor and health advantages with a longer shelf life.
Applications of aseptic packaging
There are primarily two fields to consider: Pre-sterilized and sterile product packaging is the first field. Milk and dairy products, puddings, sweets, fruit and vegetable juices, soups, sauces, and particulate-containing goods are all included in this category.
Characteristics of Aseptic packaging
The low water-vapor transfer rate is a characteristic of aseptic packing. Gas transmission rates are low, particularly when it comes to oxygen. This is important for preserving the food’s color, taste, and nutritional components.
Aseptic packaging by Custom Crating and Logistics
Custom Crating and Logistics provide aseptic packaging for the maintenance of the hygiene of the product. Our company provides aseptic packaging for medical products and various preserved products so that they would not be harmed by any bacterial attack.
What is aseptic packaging?
Aseptic packaging is the process in which the filling and sealing of the sterilized product is done in the sterilized packaging material in a totally hygienic environment which protects the food contents from micro-organisms improving its shelf life while retaining its original test, texture, colour, and nutrition.
Why is aseptic packaging important?
As medicines and drugs need strong protection from external weather factors, aseptic packaging is the best option as it offers very strong barrier protection from temperature changes. Also as aseptic packaging offers stiffness and rigidity to the package, it offers the easy transportation of pharmaceutical products across long distances while retaining its effectiveness.
Why do food products need aseptic packaging?
But after the innovation of Aseptic packaging technology, food industries have started packing these food items in aseptic packaging as it provides more nutrition retention as compared to canned packaging.
How much will the aseptic packaging market grow in 2024?
Due to all these benefits, based on the market research, by 2024, the aseptic packaging market is supposed to grow to around USD 85.5billion.
How is retort packaged?
On the other hand, in retort packaging, the product is first packed and sealed in a metal can or a pouch, and then it is sterilized by heating it at an extremely high temperature.
Do you need refrigeration for aseptic food?
1) No refrigeration of the food is required as the aseptic packaging material itself protects the contents from any variation in the outer temperature.
How are aseptic bags sterilized?
The bags are stabilized by an outer carton during filling and shipping. The outer carton may be reused several times, however, the bags and filler valves are used only once. Each bag is equipped with a fitment or valve which, when matched with the correct filler will allow for aseptic filling and emptying of the bag. Depending upon the system the filler nozzle may be sterilized by using chemicals (i. e., hydrogen peroxide) or steam.
What is used for aseptic sterilization?
Aseptic processing equipment sterilization procedures often use steam or hot water under pressure. Packaging equipment and packaging materials are sterilized with various medium or combination of mediums (i.e., saturated steam, superheated steam, hydrogen peroxide and heat and other treatments).
What is aseptic inspection?
Inspections of aseptic processing and packaging systems for Low Acid Canned Food (LACF) are some of the most complex inspections of food manufacturing operations. The major difference between aseptic processing and the more "conventional" types of LACF processing is that a process authority (s) must establish a process that ensures commercial sterility not only of the product but also for:
What is an aseptic pump?
Aseptic processes are based on a continuous flow of product through a holding tube. This continuous flow relies on pumps, and as such, these pumps are critical in the design of the system. 21CFR 113.40 (g) (i) (f) states "A metering pump shall be located upstream from the holding tube and shall be operated to maintain the required rate of product flow". A positive displacement pump is used as the metering (sometimes called the timing) pump because they are less sensitive to pressure drops and slippage than centrifugal pumps. The product characteristics may determine the type of positive displacement pump used. When the pressure drop in the system is low (less than 150 lbs.) and the product contains only small particles or is homogenous, a rotary positive displacement pump may be used. At higher-pressure drops and for large particulates, a reciprocating piston pump is normally the pump of choice.
How to determine if a sterile filter is used?
If a sterile filter is used, determine the specifications of the filter, filter location and number of filters. Determine if the firm changes the filter at intervals recommended by the manufacturer or process authority for their method of use. Filter changes should be documented on the processing records.
Why do you need to change filters for sterile air?
Filters for sterile air providing overriding air pressure during processing operations must be changed after a specified number of uses because they are in contact with incinerated air during the pre-sterilization cycle. Determine how often filters are changed to comply with that specified in the scheduled process and how the firm documents this.
Why is product formulation critical to the process?
The conductivity and electrical resistance of the product influences the heating rate. Because of this, product formulation becomes critical to the process. Food products, which are not good conductors of electrical current, are not good candidates for ohmic heating.
