Advances In Aseptic Processing

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

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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.

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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.

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Avoidance of reinfection:  Food

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

Regulatory effects 

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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

Food Processing

Food preparation

Flash evaporator (1st stage cooler)

Steriliser Indirect heating

Coolers

Steriliser/ cooler batch

Aseptic tank

Package thermoform

Aseptic packaging

Final product

Package sterilisation

Aseptic fillers

Package preformed

Package material sterilisation

Package- aseptic formation

Warehouse

Palletisation

Package erection

ASEPTIC FLOW DIAGRAM

Secondary packaging

Aseptic sealing, Lidding

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:

e.g.

Re-assess

Identify critical control points

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

Proposed installation

Establish scheduled processes

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

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

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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