ASEPTIC PACKAGING

EQUIPMENTS , ASEPTIC
TANK , MICRO – PROCESSOR
CONTROLLED SYSTEM
EMPLOYED FOR ASEPTIC
PACKAGING
SUBMITTED TO: SUBMITTED BY:
Dr.Rekha Rani Jeffy Kuriakose Thomas
Assistant Professor 17dtech004
Dept Of Dairy Technology Btech DairyTechnology
Warner College Of Dairy technology Warner College Of Dairy

technology
 Aseptic Packaging
Aseptic packaging is a specialized manufacturing process in which food, pharmaceutical, or
other contents are sterilized separately from packaging. The contents are then inserted into
the container in a sterile environment. This method uses extremely high temperatures to
maintain the freshness of the contents while also ensuring that it’s not contaminated with
microorganisms. It is used for various food products and beverages, including milk, soup,
tomatoes, pudding and several others. It’s also used in the pharmaceutical industries to ensure
that medications aren’t polluted with harmful bacteria. The packaging material or container is
sterilized prior to filling and sealing in a sterile environment. Both the packaging material and
seal are of sufficient strength and function to prevent recontamination of the product during
storage and transport.
 ADVANTAGES OF ASPECTIC
PACKAGING
• Increased shelf life
• Reduced shipping and distribution costs
• No preservatives required
• Eco-friendly
• Maintains quality of contents
• Low water-vapour transmission rate.
• Capability to fit into automatic fabricating and filling equipment.
• Low gas transmission rates, especially to oxygen. This is important to preserve the colour,
flavour and nutritional constituents in the products.
 Categories of Aseptic Packaging Systems

• Can system: It includes hermetically sealed cans.

• Bottle systems: Glass containers and plastics bottles fall into this category. The bottles can further
be divided into; a) Non-sterile bottles; b) Sterile blown bottles; c) Single station blowing, filling &
sealing.
• Sachet and pouch systems: This system is classified into Form-fill-seal systems and Lay flat
tubing.
• Cup systems: The aseptic packaging of food into cups can be into; Pre-formed plastic cups and
Form-fill and seal cups.
• Carton systems: This type of aseptic packaging system includes Form-fill-seal cartons and
Prefabricated cartons.
• Bulk packaging systems: This type of system classified into; Metal drum and Bag-in-box
Packaging Lines for Aseptic Processing.
 Types of aseptic packaging

• Film & Seal: Pre-formed containers made up of thermoformed plastic, glass or metal are sterilized,
filled in aseptic environment and sealed.
• Form, Fill & Seal: Roll of material is sterilized, formed in sterile environment, filled and sealed.
e.g. Ex tetra packs Erect, Fill & seal: Using knocked, down blanks, erected, sterilized, filled sealed.
e.g. Ex. Gable-top cartons, Cambri-block.
• Thermoform, Fill, sealed roll stock, sterilized, thermoformed, filled, sealed aseptically. e.g. Ex.
Creamers, plastic soup cans.
• Blow, Mold, Fill & Seal. e.g. Different package forms used in Aseptic UHT processing are cans,
paperboards/plastic/foil/plastic laminates/flexible pouches, thermoformed plastic containers, bag in
box, bulk totes.
 Functions of aspetic packaging
1. Low water-vapour transmission rate.
2. Low gas transmission rates, especially to oxygen. This is important to preserve
the colour, flavour and nutritional constituents in the products.
3. Good physical or mechanical strength, sufficient to resist any physical damage
during manufacture, handling and distribution.
4. Good sealing characteristics to prevent entrance of external contaminants.
5. Capability to fit into automatic fabricating and filling equipment.
6. Resistance to withstand the temperatures encountered during filling of the
product as well as during storage and distribution.
7. Chemically resistant to the product packed and ability to withstand sterilisation
packing material with gas, liquid radiation.
8. Resistance to microbes, insects and other types of biological hazards.
9. Compatibility with the milk packed. The constituents and additives etc. of thepackage
material should be inert with low migration levels in accordance with the appropriate codes
of practice and standards of the country.
10.Economical in cost in comparison to the packaged product and readily available in the
market.
 Aseptic packaging equipment's
• Semi-automatic UTH Plant For Aseptic Packaging
UTH Plant For Aseptic Packaging is designed for aseptic packaging of beverages and food products
in an ultra high-temperature environment. The environment of the whole unit is maintained for
hygienic atmosphere by keeping it contamination free. It helps in filling and sealing food items in
hygienic condition.
• Preserves the nutritional value of product for long duration
• Needs no refrigeration
• Sterile Packaging of products
• Maintain Hygienic condition
• Manufactured using quality material
• Aseptic packaging machine
The packaging design and material of this machine are such that can not be tampered with. The whole
packaging takes place in an isolated environment. These machines are generally fully automatic. The
machinery is designed so as to inhibit any growth of microorganisms. These highly sophisticated
machines ensure highest packaging standards.
• sterilization of the products before filling
• sterilization of the packaging materials or containers and closures before filling
• maintaining sterility in the total system during operation – sterilization of all media entering the
system, air, gases, sterile water
• production of hermetic packages.
• Aseptic Processing And Packaging System
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).
• Heating the product to sterilization temperatures (140-150°C for 0-few seconds).
• Maintaining the sterility of the products till they are cooled/packed.
• Filling into sterile containers and sealing aseptically.
• Uht Htst Aseptic Packaging Machine
UHT treatment requires both a sterilizer and an aseptic unit (for packaging the product). It is used for low
acid (above pH 4.6) products such as UHT milk, UHT flavoured milk, UHT creams, soya milk and other
dairy alternatives. The same process is also used to sterilize prepared food, such as soups, sauces,
desserts, tomato and fruit preparations, and baby food. the process requires relatively high energy
consumption compared to indirect UHT treatment. With indirect heating, the product does not come into
direct contact with the heat source, but is instead heated using heat exchangers.
• Tetra pack cartons
Tetra Pak group of Sweden had launched various types of cartons and Tetra Hedron cartons were
the first type introduced in fifties, which required the development of heavy weight paper
board/aluminium/polyethylene and have proved to be quite successful for UHT milk packaging.
The Tetra Pak Company had gradually replaced these Tetra Hedron cartons with Tetra Brick cartons
as the former posed problems of col¬lating and stacking and short shelf life. These cartons are
primarily made from paper. 75% of the tetra pack carton is made from paperboard, 20% of
polyethylene and 5% of aluminium. These three materials are layered together using heat and
pressure to form a six layered armour which protects the contents from light, oxygen, air, dirt and
moisture.
 Aseptic Tank
The aseptic tank is used for intermediate storage of UHT treated dairy products. It can be used in
different ways in UHT lines, depending on plant design and the capacities of the various units in the
process and packaging lines. The aseptic tank is first filled with one product, sufficient to last for a
full shift of packaging. Then the UHT plant is switched over to another product which is packed
directly in the line of packaging machines. Direct packaging from a UHT plant requires recirculation
of a minimum extra volume of 300 litres per hour to maintain a constant pressure to the filling
machines. Products which are sensitive to overtreatment cannot tolerate this and the required
overcapacity must then be fed from an aseptic tank.
 MICRO-PROCESSOR CONTROLLED SYSTEMS
EMPLOYED FOR ASEPTIC PACKAGING
Microprocessor-based aseptic packaging has capability of monitoring one or more process variables
simultaneously.It was first used in packaging machines for the first time in 1973. Microprocessor-
controlled packaging machinery were first commercially used in 1978.
Objectives of micro processors
• Feeding of film to the machine
• Converting of film into required shape of specific dimensions
• Filling the product with specific volume of product
• Heat sealing
• Collecting up of specific no of packs and shrink wrapping them into one single pack.
 REFERENCE

• https://dir.indiamart.com/impcat/aseptic-packaging-machines.htm
• http://ecoursesonline.iasri.res.in/course/view.php?id=122
• https://
www.iaritoppers.com/2019/06/packaging-of-dairy-products-icar-ecourse-pdf-book-downlo
ad.html