ASEPTIC PROCESSING AND PACKAGING OF FOODS PRESENTED BY- JIGISHA PARGI COLLEGE OF FPT & BE, AAU, ANAND

1.INTRODUCTION 2.HISTORY 3.ASEPTIC PROCESSSING METHODOLOGY 4.PACKAGING MATERIAL 5.ADVANTAGES 6.CONCLUSION 7.REFERENCES

Aseptic processing is the process by which a sterile (aseptic) product is packaged in a sterile container in a way that maintains sterility Sterility is achieved with a flash-heating process (temperature between 195 to 295 °F, which retains more nutrients and uses less energy than conventional sterilization techniques

Sterile processing includes use of clean rooms, bacteria retaining filters, dry or steam heat Aseptic food preservation methods allow processed food to keep for long periods of time without preservatives, as long as they are not opened Aseptic packaging technology is fundamentally different from that of conventional food processing by canning

 Process by which a sterile product is packaged in sterile environment  Ensures the containers for food also sterilized continuously and inserted into completely sterile environment container  Often called “drink boxes”  Used for food such as: Dairy products Fruit & Vegetable juice soups

In 1914, sterile filters for filtering wines were fully developed. In 1917, Dunkley in the USA received a patent for sterilizing cans and lids with saturated steam and subsequent aseptic filling. In the early 1940s, Dole Martin process was developed by Dr. Martin, USA. FIRST ASEPTIC PLANT (IN 1961,SWITZERLAND,for MILK) Introduced to us in 1980s BAG-IN-BOX TECHNOLOGY

Consists of paper (70%), polyethylene (LDPE) (24%), and aluminum (6%), with a tight polyethylene inside layer. eliminating the need for refrigeration.

First layer Seals in the liquid Adhesion layer Aluminum foil Oxygen, flavor and Light barrier Adhesion layer Paper For stability and strength Top layer Protects against outside moisture

1. Sterilization of the products before filling. 2. Sterilization of packaging material or containers and closures before filling 3. Sterilization of aseptic installations before operation (UHT unit lines for products, sterile air, and gases, filters and relevant machine zones) 4. Maintaining sterility in this total system during operation; sterilization of all media entering the system, like air, gases, sterile water, production of hermetic packages.

Pre-sterilizaton- It is the heating the product to the desired UHT temp. In order to achieve the desired degree of sterility, with subsequent cooling (usually to ambient temp and sometimes to an elevated temp) To achieve the right viscosity for filing Heating and cooling are performed so rapidly as possible to achieve the best quality dependent upon the nature of the product. Fast heat exchange rate is desired for cost reasons

Microbial count of film and packing the level of microbial contamination of packaging material with extruded plastic upper layer/with heat seal lacquer which is then heated for drying is low Despite the fact that it was shown that microorganisms may survive extrusion condition. Although glass bottles and jars are sterile, when manufactured, during the last step of cooling, however infection may occur by airborne microorganism. The infection rate is dependent on size of the opening of the bottle, level of contamination of air and the use of mechanical precaution. Arrangement on pallet has to be done under good conditions.

It includes- a.Sterilization of packaging machine (steam or hydrogen peroxide) b.Sterilizing of filling lines and fillers (steam) c.Sterilization of air (by using air filters)

A. METHODS OF DECONTAMINATION OF PACKAGING MATERIAL 1.HYDROGEN PEROXIDE AND PERACIDS- Generally 0.2% is used. can be used as a sterilant at 15-30% on inanimate objects. 2. ULTRAVIOLET IRRADIATION- Ultraviolet light has wavelength between 328 and 210 nm but has maximum antimicrobial effect between 280 and 250 nm 3. IONISING RADIATIONS- Ionizing radiation, such as gamma rays, have been used for the sterilization.

4. THERMAL TREATMENT Moist or dry heat can be used. Dry heat requires very high temperature; for example, glass bottles have been sterilized at C within 12 s Moist heat at C C has more applications High pressure steam has been used to create a sterile environment around the filling head during filling and sealing to ensure an aseptic environment.

B. FILLING LINES AND FILTERS Filers have to handle the product gently They must be suitable for CIP and SIP (sterilize in place) Piston and valves are redrawn to allow access for cleaning and sterilizing media to all surfaces

PRODUCT CAN BE PACKED IN- 1. Carton box 2.Bags and pouches 3. Cups and Trays 4.Bottles and jars 5. Metal cans 6. Plastic cans 7. composite cans

Quality of aseptically treated foods may be higher due to UHT sterilization This is valid with large packs, because heat penetration in retorting is time consuming and consequently quality suffers from overheating UHT process involves faster heating and followed by cooling

If filled and sealed effectively, no control is necessary for possible interruptions of the chilled chain, which, in the case of short life of pasteurized products, creates a cost penalty As aseptic products do not need refrigeration storage and distribution are cheaper and selling path may be longer and permit more variation.

Advantages of dried product are longer shelf and absence of microbiological risk, weight reduction by drying and low cost packs. Quality preservation by drying, however, is limited to foods suitable for drying. Quality and consistency of dried products may suffer by drying process. In contrast to aseptic products, dried products, need to be reconstituted for consumption and so their convenience is lower.

Frozen foods demonstrates disadvantages; for example they require cooking whereas aseptic products are generally ready to eat or drink. Where products are heated for consumption little time is needed for aseptic products in contrast to frozen foods. Aseptic products may also be distributed to countries with a poor cold infrastructure.

Aseptic packaging of foods and beverages generally has gained greatly in economic importance, mainly for milk and fruit juices Its application is spreading in areas with inadequate refrigeration options Packaging particulars in liquids and pastes into consumer packs is still a very young field of application and continue to be developed, improved, and adapted to the special requirements

1.Aseptic Processing and Packaging of Particulate Food, Edited by Edward M.A. Willhoft 2. Aseptic Packaging of Food, Edited by H. Reuter 3. Tetrapak Company Magazine No The Wiley Encyclopedia of Packaging Technology 5. Modern Food Packaging, IIP Publication, Aseptic Packaging by Dr. Bern Hard Von Bookelmann, A. B. Tetra Pak, Lund, Sweden