2.aseptic System.6
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Aseptic Filling Machine
Aseptic Zone Sleeve feed
Sleeve Base forming activation
Base folding
SIG Combibloc
Base Peroxide pressing sterilization
Drying
Filling
Top sealing
Panich Choenthanomwong Training and Quality Department
Top forming 6 June, 2013
Conveying
Page 1
Aseptic system What is the meaning of “Aseptic”
Aseptic means “working under germ-free condition. Or the summary of all measures guaranteeing the absence of any reproductive micro-organism. Or free from or keeping away.
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 2
Preservation of foodstuffs by heat treatment
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 3
Preservation of foodstuffs by heat treatment
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 4
Aseptic system comparison of processing method Microorganisms (bacteria)
Microorganisms (Bacteria)
Product
Product Packaging
Filling and sealing
Sterilisation Filling and sealing
Packaging Sterilisation Aseptic Zone
Sterilisation of sealed packs
Packed, sterilised product
SIG Combibloc
Aseptically packed product
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 5
Aseptic
Factors of influence on the aseptic process:
Quality of the nonsterile product
Aseptic filling of beverages, dairy and food products into carton packs
Human
Product
factor
heating
ASEPTIC Sterilisation liquid/
Filling machine sterilisation
Package sterilisation
Aseptically packaged product
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 6
Factors affecting the sterility rate of an aseptic production 1. The Microbiological load of the raw material 2. Sterilization effect of UHT process 3. Cleanliness and sanitary conditions of plant 4. Maintenance of aseptic conditions during production 5. Microbiological contamination of carton’s surface (inner) 6. Efficiency of sterilization of carton’s surface 7. Packages integrity 8. Cleaning and sterilization of filling machine (Aseptic zone) 9. Care and diligence of operating staffs 10. The service and preventive maintenance of the aseptic processing and packaging system 11. Plant hygiene.
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 7
Aseptic Filling Machine
Three main processes are used for the decontamination processes: Steam sterilisation H202 vapour sterilisation
Filtration of air Filtration of Nitrogen and pressurised air for tank overpressure (Options)
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 8
Aseptic Filling Machine
1.Steam sterilisation Product pipe system, Product tank,
Product valves, Filling valves
Air (Pall) filters for product tank pressure Nitrogen filters for Nitrogen injection SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 9
Aseptic Filling Machine 2. H2O2 vapour sterilization. - Pocket chain - Drying zone - Filling zone - Steam injection - etc
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 10
Aseptic Filling Machine
3. Filtration of air HEPA (high efficiency particulate air filter) filtration of the air for the aseptic zone Filtration of pressurised air for product tank pressure Filtration of Nitrogen for Nitrogen injection
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 11
Combibloc filling machine operation.
Conclusion. Condition for aseptic operation of the combibloc filling machine 1. Operator 2. Filling machine
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 12
Combibloc filling machine operation.
1.Operator (5 important rule of Hygiene) 1.Personal cleanliness (wash hands ) 2.Clean working clothes and hat
3.Clean environment (walls, floors,ceilings) 4.Do not work at machine with open wounds (even small wounds must be taken care of)
5.Any consumption of food at the filling machine is prohibited SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 13
Combibloc filling machine operation.
2. The filling machine 1.The parts of filling machine must be cleaned ,sterilized for each start of production: - Product-holding lines(pipelines, filling station etc) - Aseptic zone 2. Spray sterilization of hands and possibly of parts installed into the aseptic zone. (All parts must be cleaned and dried) SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 14
Combibloc filling machine operation.
3. The filling machine must be cleaned immediately after the end of production (manual cleaning, pocket chain cleaning and CIP cleaning) 4. No leakage at aseptic zone , product pipe. 5. Keep sterile air pressure condition 6. The carton must be sterilized during production and check cartons for leaks.
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 15
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 16
Aseptic Filling Machine
Decontamination processes used within a combibloc system: Steam sterilisation for product pipe system, product tank, product valves, filling valves and air (Pall) filters for product tank pressure and Nitrogen filters for Nitrogen injection H2O2 sterilisation for aseptic zone surfaces and HEPA air filter system H2O2 sterilisation of the package during production HEPA (high efficiency particulate air filter) filtration of the air for the aseptic zone Filtration of pressurised air for product tank pressure Filtration of Nitrogen for Nitrogen injection Additional options not available for all formats: Dedusting unit (to remove dust particles out of the package before it enters the aseptic zone) Pocket chain desinfection unit (normally potable water is used for chain cooling) SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 17
Aseptic Filling Machine
Decontamination processes used within a combibloc system: Steam sterilisation for product pipe system, product tank, product valves, filling valves and air (Pall) filters for product tank pressure and Nitrogen filters for Nitrogen injection H2O2 sterilisation for aseptic zone surfaces and HEPA air filter system H2O2 sterilisation of the package during production HEPA (high efficiency particulate air filter) filtration of the air for the aseptic zone Filtration of pressurised air for product tank pressure Filtration of Nitrogen for Nitrogen injection Additional options not available for all formats: Dedusting unit (to remove dust particles out of the package before it enters the aseptic zone) Pocket chain desinfection unit (normally potable water is used for chain cooling) SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 18
Aseptic Filling Machine
Decontamination processes used within a combibloc system: Steam sterilisation for product pipe system, product tank, product valves, filling valves and air (Pall) filters for product tank pressure and Nitrogen filters for Nitrogen injection H2O2 sterilisation for aseptic zone surfaces and HEPA air filter system H2O2 sterilisation of the package during production HEPA (high efficiency particulate air filter) filtration of the air for the aseptic zone Filtration of pressurised air for product tank pressure Filtration of Nitrogen for Nitrogen injection Additional options not available for all formats: Dedusting unit (to remove dust particles out of the package before it enters the aseptic zone) Pocket chain desinfection unit (normally potable water is used for chain cooling) SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 19
Product
Sterilisation
The liquid food is commercially sterilised.
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 20
Product
Sterilisation
Packaging
Sterilisation
The sleeves are sterilised.
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 21
Product
Sterilisation Filling and sealing
Packaging
Sterilisation Aseptic Zone
The sterile product is filled into sterile sleeves under sterile conditions in aseptically. SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 22
Product
Sterilisation Filling and sealing
The product is "commercially sterilised" using a concept called "aseptic processing" SIG Combibloc
Packaging
Sterilisation Aseptic Zone
Aseptically filled product
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 23
Aseptic Filling Machine
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 24
Aseptic and aseptic filling system
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 25
UHT and “Commercial sterility”
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 26
Making Milk Last Longer We have 2 containers of milk. • Bottle of milk - fresh or pasteurised • Pack of UHT milk - closed
• Which one will last longest ? • Why ? • What is the difference between the two ?
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 27
Question : Which will remain fresher longer ?
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 28
Question : Which will remain fresher longer ?
The UHT milk can remain fresh for up to 6 months, or even longer, :• without refrigeration and • without using preservatives.
(The fresh milk will deteriorate in hours at ambient temperatures, or days if refrigerated.) SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 29
Why does the UHT milk last so very long ??
• The bacteria in the milk are either killed, or prevented from growing, by high temperature treatment.
• This is called “commercially sterilising” the milk.
• The treatment is called “Ultra High Temperature” - UHT.
• It is then aseptically filled into a sterile pack - ie no bacteria.
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 30
Definition - Commercial Sterility “ A commercially sterile product is free from micro organisms which grow under normal conditions of storage.”
Same meaning - different words.
UHT milk does not contain any bacteria capable of multiplication under normal conditions of storage and distribution.
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 31
No bacterial growth = long shelf life
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 32
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 33
Aseptic system What is commercial sterility ?
Commercial sterility means: * The product is free from micro-organism which grow
under normal conditions of distribution and storage OR
UHT milk does not contain any bacteria capable of multiplication under normal conditions of storage and distribution. SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 34
Aseptic system Commercial Sterility -Purpose or target of commercial sterility -No Poisons or Toxins -No Pathogens -No Enzyme -No growth of bacteria under room temperature (transportation and shelf stable)
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 35
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 36
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 37
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 38
Aseptic system Why UHT product can keep long time in room
temperature ? 1.UHT equipment ,product line and CFA are cleaned and sterilization before production. 2.Product sterilized by UHT system. 3.Package sterilized by H2O2
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 39
Aseptic system
4. Product filled into package under aseptic condition 5. Integrity of the package to prevent post contamination.
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 40
Aseptic Zone Sleeve feed
Sleeve Base forming activation
Base folding
SIG Combibloc
Base Peroxide pressing sterilization
Drying
Filling
Top sealing
Panich Choenthanomwong Training and Quality Department
Top forming 6 June, 2013
Conveying
Page 1
Aseptic system What is the meaning of “Aseptic”
Aseptic means “working under germ-free condition. Or the summary of all measures guaranteeing the absence of any reproductive micro-organism. Or free from or keeping away.
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 2
Preservation of foodstuffs by heat treatment
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 3
Preservation of foodstuffs by heat treatment
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 4
Aseptic system comparison of processing method Microorganisms (bacteria)
Microorganisms (Bacteria)
Product
Product Packaging
Filling and sealing
Sterilisation Filling and sealing
Packaging Sterilisation Aseptic Zone
Sterilisation of sealed packs
Packed, sterilised product
SIG Combibloc
Aseptically packed product
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 5
Aseptic
Factors of influence on the aseptic process:
Quality of the nonsterile product
Aseptic filling of beverages, dairy and food products into carton packs
Human
Product
factor
heating
ASEPTIC Sterilisation liquid/
Filling machine sterilisation
Package sterilisation
Aseptically packaged product
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 6
Factors affecting the sterility rate of an aseptic production 1. The Microbiological load of the raw material 2. Sterilization effect of UHT process 3. Cleanliness and sanitary conditions of plant 4. Maintenance of aseptic conditions during production 5. Microbiological contamination of carton’s surface (inner) 6. Efficiency of sterilization of carton’s surface 7. Packages integrity 8. Cleaning and sterilization of filling machine (Aseptic zone) 9. Care and diligence of operating staffs 10. The service and preventive maintenance of the aseptic processing and packaging system 11. Plant hygiene.
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 7
Aseptic Filling Machine
Three main processes are used for the decontamination processes: Steam sterilisation H202 vapour sterilisation
Filtration of air Filtration of Nitrogen and pressurised air for tank overpressure (Options)
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 8
Aseptic Filling Machine
1.Steam sterilisation Product pipe system, Product tank,
Product valves, Filling valves
Air (Pall) filters for product tank pressure Nitrogen filters for Nitrogen injection SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 9
Aseptic Filling Machine 2. H2O2 vapour sterilization. - Pocket chain - Drying zone - Filling zone - Steam injection - etc
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 10
Aseptic Filling Machine
3. Filtration of air HEPA (high efficiency particulate air filter) filtration of the air for the aseptic zone Filtration of pressurised air for product tank pressure Filtration of Nitrogen for Nitrogen injection
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 11
Combibloc filling machine operation.
Conclusion. Condition for aseptic operation of the combibloc filling machine 1. Operator 2. Filling machine
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 12
Combibloc filling machine operation.
1.Operator (5 important rule of Hygiene) 1.Personal cleanliness (wash hands ) 2.Clean working clothes and hat
3.Clean environment (walls, floors,ceilings) 4.Do not work at machine with open wounds (even small wounds must be taken care of)
5.Any consumption of food at the filling machine is prohibited SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 13
Combibloc filling machine operation.
2. The filling machine 1.The parts of filling machine must be cleaned ,sterilized for each start of production: - Product-holding lines(pipelines, filling station etc) - Aseptic zone 2. Spray sterilization of hands and possibly of parts installed into the aseptic zone. (All parts must be cleaned and dried) SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 14
Combibloc filling machine operation.
3. The filling machine must be cleaned immediately after the end of production (manual cleaning, pocket chain cleaning and CIP cleaning) 4. No leakage at aseptic zone , product pipe. 5. Keep sterile air pressure condition 6. The carton must be sterilized during production and check cartons for leaks.
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 15
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 16
Aseptic Filling Machine
Decontamination processes used within a combibloc system: Steam sterilisation for product pipe system, product tank, product valves, filling valves and air (Pall) filters for product tank pressure and Nitrogen filters for Nitrogen injection H2O2 sterilisation for aseptic zone surfaces and HEPA air filter system H2O2 sterilisation of the package during production HEPA (high efficiency particulate air filter) filtration of the air for the aseptic zone Filtration of pressurised air for product tank pressure Filtration of Nitrogen for Nitrogen injection Additional options not available for all formats: Dedusting unit (to remove dust particles out of the package before it enters the aseptic zone) Pocket chain desinfection unit (normally potable water is used for chain cooling) SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 17
Aseptic Filling Machine
Decontamination processes used within a combibloc system: Steam sterilisation for product pipe system, product tank, product valves, filling valves and air (Pall) filters for product tank pressure and Nitrogen filters for Nitrogen injection H2O2 sterilisation for aseptic zone surfaces and HEPA air filter system H2O2 sterilisation of the package during production HEPA (high efficiency particulate air filter) filtration of the air for the aseptic zone Filtration of pressurised air for product tank pressure Filtration of Nitrogen for Nitrogen injection Additional options not available for all formats: Dedusting unit (to remove dust particles out of the package before it enters the aseptic zone) Pocket chain desinfection unit (normally potable water is used for chain cooling) SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 18
Aseptic Filling Machine
Decontamination processes used within a combibloc system: Steam sterilisation for product pipe system, product tank, product valves, filling valves and air (Pall) filters for product tank pressure and Nitrogen filters for Nitrogen injection H2O2 sterilisation for aseptic zone surfaces and HEPA air filter system H2O2 sterilisation of the package during production HEPA (high efficiency particulate air filter) filtration of the air for the aseptic zone Filtration of pressurised air for product tank pressure Filtration of Nitrogen for Nitrogen injection Additional options not available for all formats: Dedusting unit (to remove dust particles out of the package before it enters the aseptic zone) Pocket chain desinfection unit (normally potable water is used for chain cooling) SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 19
Product
Sterilisation
The liquid food is commercially sterilised.
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 20
Product
Sterilisation
Packaging
Sterilisation
The sleeves are sterilised.
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 21
Product
Sterilisation Filling and sealing
Packaging
Sterilisation Aseptic Zone
The sterile product is filled into sterile sleeves under sterile conditions in aseptically. SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 22
Product
Sterilisation Filling and sealing
The product is "commercially sterilised" using a concept called "aseptic processing" SIG Combibloc
Packaging
Sterilisation Aseptic Zone
Aseptically filled product
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 23
Aseptic Filling Machine
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 24
Aseptic and aseptic filling system
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 25
UHT and “Commercial sterility”
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 26
Making Milk Last Longer We have 2 containers of milk. • Bottle of milk - fresh or pasteurised • Pack of UHT milk - closed
• Which one will last longest ? • Why ? • What is the difference between the two ?
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 27
Question : Which will remain fresher longer ?
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 28
Question : Which will remain fresher longer ?
The UHT milk can remain fresh for up to 6 months, or even longer, :• without refrigeration and • without using preservatives.
(The fresh milk will deteriorate in hours at ambient temperatures, or days if refrigerated.) SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 29
Why does the UHT milk last so very long ??
• The bacteria in the milk are either killed, or prevented from growing, by high temperature treatment.
• This is called “commercially sterilising” the milk.
• The treatment is called “Ultra High Temperature” - UHT.
• It is then aseptically filled into a sterile pack - ie no bacteria.
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 30
Definition - Commercial Sterility “ A commercially sterile product is free from micro organisms which grow under normal conditions of storage.”
Same meaning - different words.
UHT milk does not contain any bacteria capable of multiplication under normal conditions of storage and distribution.
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 31
No bacterial growth = long shelf life
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 32
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 33
Aseptic system What is commercial sterility ?
Commercial sterility means: * The product is free from micro-organism which grow
under normal conditions of distribution and storage OR
UHT milk does not contain any bacteria capable of multiplication under normal conditions of storage and distribution. SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 34
Aseptic system Commercial Sterility -Purpose or target of commercial sterility -No Poisons or Toxins -No Pathogens -No Enzyme -No growth of bacteria under room temperature (transportation and shelf stable)
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 35
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 36
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 37
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 38
Aseptic system Why UHT product can keep long time in room
temperature ? 1.UHT equipment ,product line and CFA are cleaned and sterilization before production. 2.Product sterilized by UHT system. 3.Package sterilized by H2O2
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 39
Aseptic system
4. Product filled into package under aseptic condition 5. Integrity of the package to prevent post contamination.
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
6 June, 2013
Page 40
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