ADVANCES IN ASEPTIC PROCESSING

Aseptic technology

Aseptic technology- shelf stable products UHT milk & Pasteurised fruit juices plastics, paper board and aluminium foil.
Adv: economical, convenient and light

38 types of commercially available aseptic filling & packaging system for retail pack sizes
Metal,

laminate cans, plastic pots, laminate cartons, sachets and plastic or glass bottles or jars.

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.

Avoidance of reinfection:
Food

contact surfaces Maintaining over pressure within the processing storage and the filling system

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 and aseptic packaging of foods 1981-Hydrogen peroxide is permitted as a sterilising agent for polyethylene surfaces of containers Application to homogeneous products

Aspects of good manufacturing practice

Steriliser Direct heating

Flash evaporator (1st stage cooler)

Food Processing

Food preparation

Steriliser Indirect heating Steriliser/ cooler batch

Coolers

Aseptic tank

Package thermoform

Aseptic packaging

Package erection

Package sterilisation

Aseptic fillers

Aseptic sealing, Lidding

Package preformed

Package material sterilisation

Package- aseptic formation

Final product

Warehouse

Palletisation

Secondary packaging

ASEPTIC FLOW DIAGRAM

GMP guidelines

Low acid foods- Cl.botulinum Commercial sterility

Design and development

1. Food Contact Surfaces 2. Food Process 3. Non-food Contact Surfaces 4. Decontamination of packaging 5. Aseptic filling zone

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

e.g.

Re-assess

Pumps Pipework Heat exchangers Holding section Valves Packaging Product fillers Control system Aseptic tanks

Proposed installation

Establish scheduled processes 1. Pre-production sterilisation of food contact surfaces 2. 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 tests 1. 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

Stages in system development

Commissioning tests
1.Packaging Compatibility- no breakdown of packaging mtrls Package structure free from defects Sealing method- microbiological barrier 2. Storage Identification- product referable to records Protection- adequate for handling and stacking 3. Transportation- package integrity has to be maintained by correct handling

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