1. Aseptic Packaging

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

3. Why Foods are processed?
Introduction
Why Foods are processed?

4. Increase Shelf life of product
Availability of commodity throughout year
Wide range of products can be produce
Convenience for consumer

5. How Foods products are processed ?
Introduction
How Foods products are processed ?

6. Methods Of Processing By Application of heat – Aseptic packaging
By Removal of heat
By Irradiation
By Addition of sugar / salt / Additive
Minimal Processing
By Altering surrounding of product

7. Aseptic Packaging
What is Asepsis?

8. 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 sealing
A 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.

9. Components of Aseptic Packaging
Commercial Sterile Product
Sterile Packaging material
Sterile Environment

10. Commercial Sterile Product
On basis of pH, Foods are categorized as follows
Low Acid Foods (pH > 4.5)
Acid Foods (pH 4 to 4.5)
High Acid Foods (pH < 4.0)

11. pH Affects on Processing temperature and time
Presence 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 4.8
Bssychalmus fulva (Mold) can grow at acidic pH

12. SN
Fruit Products pH 1
Acidified Banana Puree 2
Acidified Banana Puree Concentrate 3
Alphonso Mango Puree 4
Totapuri Mango Puree 5
Kesar Mango Puree 6
Raspuri Mango Puree 7
Totapuri mango Puree Concentrate 8
Mango Puree & Concentrate Natural
< 4.5 9
Pink Guava Puree
< 4.0 10
White Guava Puree 11
Pink Guava Puree Concentrate 12
White Guava Puree Concentrate 13
Red Papaya Puree 14
Yellow Papaya Puree 15
Red Papaya Puree Concentrate 16
Yellow Papaya Puree concentrate 17
Tomato puree / paste
< 4.4 18
Amla Puree & Concentrate
< 3.0

13. Thermobacteriology
D Value – Time required to kill 90% microorganisms under study
Z value – Temperature required for TDT curve to pass through one log cycle
F value – Time required at reference temperature to reduce the microbial population to desired sterility level

14. Recommended Schedule by NCAPH
Fo VALUE (VALUE AT 250 DEGREE FAHRENHEIT) Minutes
3.9 or LESS
0.1
3.9 to 4.1 1
4.1 to 4.2
2.5
4.2 to 4.3 5
4.3 to 4.4 10
4.4 to 4.5 20

15. Sterility - Factors affecting heat resistance of micro-organisms
• 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

16. Sterilization Equipment
Heat transfer data of Heat Exchanger
High Pressure withstanding ability
MOC should withstand with acidic and basic conditions
Heating Methods
Direct heating methods
Indirect heating methods
• Plate heat exchanger
• Tubular heat exchanger
• Scraped surface heat exchanger

17. Aseptic Plant sections
Preparatory 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)

18. “Prevention is better than Cure”
Cleaning & Sanitation – SOP
Regular CIP of pipeline
Preventive Maintenance Schedule
Skilled and Qualified Manpower
Strict Monitoring over production line
Team spirit
We can achieve better Hygiene in Processing plant

19. Aseptic Environment Aseptic Filler Scholle Asepsystem
Aseptic environment is created near Filler head by maintaining positive pressure of steam

20. Aseptic Packaging Material
Packaging material is sterilized by application of the following or in combination
Irradiation
UV light treatment
Steam
Water
By Hot air
By use of chemicals like H2O2

21. Aseptic Packaging Material
Primary packaging Material
Tetrapack – LD / Al foil / LD / Paperboard
Aseptic Bulk pack – LD / EVOH / Al foil / LD
Glass bottle
FFS cartons
Secondary packaging Material
Tetrapack – pack in corrugated tray with shrink wrapping
Aseptic Bulk pack – CFB boxes (25 kg) – Bag in box
Aseptic Bulk pack – Plastic Drums (50 kg)
Aseptic Bulk pack – MS Drum (225 kg)

24. Integrity Check for Aseptic Packaging material
Teardown test – Sealing strength
Electrolytic Test – Pinhole testing
Dye test – For pinholes in laminated cartons
Sterility check

25. Advantages of Aseptic Packaging
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

26. Limitations Plant Installation cost is high as compare to canning
Gas transmission rate of Aseptic bag/ package
Overcooked flavour in some products
Lack of equipment for particulate sterilization, due especially to settling of solids and thus over processing

27. Thanks

28. Canning Vs Aseptic

29. Types of Tetra pack

30. Vitamin Loss

31. UHT Milk Processing
Test organisms UHT – Spores of B. subtilis or B. stereothermophilus