International Journal of Trend in Scientific Research and Development (IJTSRD)

Volume: 3 | Issue: 3 | Mar-Apr 2019 Available Online: www.ijtsrd.com e-ISSN: 2456 - 6470

Aseptic Packaging – A Novel Technology to the Food Industry

Sanjana M. C.1, Hemegowda R.2, Sushma R. E.3
1,2Researcher, 3PhD Student
1Department of Veterinary and Animal Science, University Degli Studi Di Milano, Milano, Italy
2Department of Clinical Research and Regulatory Affairs, Sikkim Manipal University, Gangtok, Sikkim, India
3Department of Veterinary Medicine, KVAFSU, Bengaluru, Karnataka, India

How to cite this paper: Sanjana M. C. | ABSTRACT

Hemegowda R. | Sushma R. E. "Aseptic Aseptic packaging is very well accepted in food and beverage applications
Packaging – A Novel Technology to the worldwide as a safe and high-quality packaging option. Aseptic processing is the
Food Industry" Published in process by which a sterile (aseptic) product (typically food) is packaged in a
International Journal of Trend in sterile container in a way which sustains sterility. Aseptic processing sterilizes
Scientific Research and Development food products by destroying the harmful bacteria and pathogenic micro-
(ijtsrd), ISSN: 2456- organisms through a tightly controlled thermal process and combines the sterile
6470, Volume-3 | product with the sterile packaging material in a sterile environment. Thus, the
Issue-3, April 2019, shelf-stable product requires no refrigeration. Basic operations in aseptic
pp.307-310, URL: packaging are heating the product to sterilization temperatures (140-150°C for
http://www.ijtsrd.co few seconds), maintaining the sterility of the products till they are
m/papers/ijtsrd227 cooled/packed and filling into sterile containers and sealing aseptically.
79.pdf IJTSRD22779 Packaging materials play a very important role in packaging the products so 1st
generation materials are paper board/plastic/foil/plastic laminates and 2nd
Copyright © 2019 by author(s) and generation materials are plastic containers. Aseptic Packaging offers the
International Journal of Trend in important advantages they are food safety, convenience, affordability, cost-
Scientific Research and Development effective in transport and storage with minimal environmental impact, no need
Journal. This is an Open Access article for a cold chain. Innova Database analysis indicates that the dairy and soft drinks
distributed under markets most readily utilize aseptic packaging. More recently aseptic packaging
the terms of the has been applied for wine, small particle foods like soups and salsas, waters like
Creative Commons natural spring water, vitamins and energy water drinks and customized
Attribution License (CC BY 4.0) functional waters. New product applications in aseptic packaging are in
(http://creativecommons.org/licenses/ traditional core segments like Juices, Iced teas, Dairy-based beverages, and Low
by/4.0) acid foods.

Keywords: Aseptic process, Food, Sterilization, Materials, and Packaging

INTRODUCTION
The production of a commercially sterile product by Pak system, following the growth of the UHT process for
continuous UHT (Ultra-high temperature) processing milk.
requires a means of packing which will ensure continued
product sterility with the attainment of expected shelf-life. According to David (2013), Aseptic packaging can be defined
Such a requirement is fulfilled by aseptic packing. Aseptic as the filling of a commercially sterile product into a sterile
processing and packaging denotes the filling commercially container under aseptic conditions and hermetically sealing
sterilized and cooled product into pre-sterilized containers the containers so that reinjection is prevented. This
under aseptic conditions and sealing in an atmosphere free development in a product, which is shelf-stable at ambient
of micro-organisms (Ansari and Datta, 2003). conditions. The term “aseptic” is derived from the Greek
word “septicos” which aids the absence of putrefactive
Aseptic packaging is a packaging approach where the micro-organisms.
product is packed under aseptic conditions. The history of
aseptic packaging abandons to the early 20th century. A Methodology
patent was filed for a process, termed as aseptic Aseptic processing comprises the sterilization of the
conservation process in Denmark, prior to 1913 by J. products before filling. Sterilization of packaging materials
Nielson-following Orla Jensen which was obtained in 1921. and closures previously filling. Sterilization of aseptic
The first aseptic filling plant was commercialized in the establishments before operation (UHT unit, lines for
market by Dole which used superheated steam at 210ºC for products, sterile air and gases, filler and relevant machine
sterilization. The first aseptic filling plant for milk was zones). Maintaining sterility in this complete system during
presented in Switzerland in 1961 (FDA, 2018). The most operation; sterilization of whole media entering the system,
significant development in this field is the development of a like air, gases, sterile water. Production of hermetic packages
commercially viable packaging plant for milk, i.e. the Tetra (Fellows, 2000).

@ IJTSRD | Unique Paper ID - IJTSRD22779 | Volume – 3 | Issue – 3 | Mar-Apr 2019 Page: 307
 International Journal of Trend in Scientific Research and Development (IJTSRD) @ www.ijtsrd.com eISSN: 2456-6470
Forms of Aseptic packaging are Tetra pack cartons - Tetra hydrogen peroxide. Gamma-radiation has been used for
Pak group of Sweden had launched various types of cartons decades to decontaminate packaging materials for use in
and 'Tetra Hedron' cartons were the first type introduced in aseptic systems for packing acid and acidified food. Aseptic
the fifties, which required the growth of heavyweight paper packages are evaluated in bulk at commercial irradiators due
board/aluminium/polyethylene and have proved to be quite to the penetrating powers of gamma-radiation. Other types
successful for UHT milk packaging. The Tetra Pak Company of radiation are not widely used in aseptic systems. To
had gradually replaced these Tetra Hedron cartons with decontaminate food contact surfaces Ultraviolet (UV-C) light
Tetra Brick cartons as the former posed problems of has been used. The low penetration and problems associated
collating and stacking and short shelf life (Smolin, 2017). with ‘shadowing’, limit the use of UV-C for aseptic systems
packaging of low acid food (Handbook of food safety
Characteristics of Aseptic packaging are low water-vapor engineering, 2011).
transmission rate. Low gas transmission rates, especially to
oxygen. This is valuable to preserve the color, flavor and Properties of aseptic packaging: a higher degree of safety,
nutritional constituents in the products. Good physical or hygiene and nutrient retention in food. Preserving taste and
mechanical strength, adequate to resist any physical damage freshness, which can be kept for months with no need for
during manufacture, handling, and distribution. Good sealing refrigeration or preservatives. Efficient (a filled package
characteristics to forbid the entrance of external weight is 97% product and only 3% packaging material),
contaminants and ability to perform into automatic using a small number of materials necessary to achieve a
fabricating and filling equipment. Resistance to withstand given function. A good example of resource efficiency is its
the temperatures encountered during filling of the product light-weight (among the lightest packages available).
as well as during storage and distribution. Chemically
resistant to the product packed and ability to endure Applications of Aseptic packaging
sterilization packing material with a gas, liquid radiation. Mainly, there are two specific fields: First field in the
Resistance to microbes, insects and other types of biological packaging of pre-sterilized and sterile products. It includes
hazards. Compatibility with the milk packed. The milk and dairy products, puddings, desserts, fruit and
constituents and additives etc. of the packaging material vegetable juices, soups, sauces, and products with
should be inert with low migration levels in accordance with particulates. Secondly, in the packaging of the non-sterile
the suitable codes of practice and standards of the country. product to avoid infection by micro-organisms. Examples are
Economical in cost in comparison to the packaged product fermented dairy products like yogurt.
and readily available in the market (Fellows, 2016).
Aseptic packaging of milk: Aseptic or long-life milk was
Aseptic package contains structure and composition that not originally introduced in Sweden called the “Tetra-pack”
only to protect the product but also to maintain the quality of system. It consumes a laminate pre sterilizer and a filling
the product. Hence the structure as well as the composition environment heater. Aluminium foil is an integral part of the
of aseptic packaging are greater complex and alter flexible laminate in order to provide a barrier against light
depending on product application, package size, and package and gas. In UHT processing, milk is preheated to 73– 850C
type. Components such as seal strength and integrity, then rapidly raised to 135°C for fraction of second and then
package shape, stiffness, and durability, as well as hurdle suddenly cooled by flashing into a vacuum chamber. It must
properties determine the choice and/or combination of be packed under completely sterile conditions. No
materials required. Generally, to achieve all required refrigeration is necessary for at least 3-6 months. If kept
properties, aseptic packages includes more than one under refrigeration a shelf life of up to one year is possible.
material in the structure that is put together by lamination In the distribution system, the pouches are maintained in
or co-extrusion process. The packaging material must be reusable multi-trip plastic crates. Tetra Pak aseptic cartons
agreeable with the product intended to be packed and must are formed of three basic materials that together result in a
adhere with applicable material migration requirements. very efficient, safe and light-weight package. Each material
The physical integrity of the package is necessary to assure gives a specific function. Aseptic containers may extend in
containment of the product and supply of sterility. The size from a few fluid ounces to a nearly 8-million-gallon
packaging material must be able to endure sterilization and aseptic tank on an ocean-going ship. Worldwide export and
be compatible with the methods of sterilization. The package import of new, economical and safe food products done by
must protect the product from oxygen, also package must aseptic processing. Other common package types are drink
retain the aroma of the product (Hargreaves, 2018). boxes and pouches (Hersom, 2009).

Sterilization of Aseptic packaging materials and equipment: Consumer packages: A great variety of packages may be
Sterilization agents are Heat, Chemicals, and Radiation. The aseptically filled now as Carton Boxes: Some of the existing
heat was used as the sterilant for aseptic systems as a aseptic carton boxes may now be filled with particulates,
natural extension of thermal processing. Product supply also aseptically. Bags and Pouches: Pillow pouches are
lines and fillers are mainly sterilized by ‘moist’ heat in the mainly used for packaging of milk; three-sided sealed pouch,
form of hot water or saturated steam under pressure. To however, is advisable also for aseptic packaging of
sterilize equipment ‘Dry’ heat, in the form of superheated particulates up to particle sizes of 12μ and bag sizes from 1-5
steam or hot air is used. Hydrogen peroxide is using as a liters. Cups and Trays: These are either used pre-made or
chemical sterilant. Other chemicals which have been used as formed, closed and sealed in thermoform/fill/seal machines.
sterilants, mainly for use in systems for acid food, include Both types of machines endure for filling particulates and
various acids, ethanol, ethylene oxide, and per acetic acid. also in packs advisable for microwave heating. Bottles and
Most aseptic packaging systems use hydrogen peroxide (at Jars: Glass bottles may be aseptically filled with food
concentrations of 30 to 35%) as a sterilant for packaging containing small particles, for instance for baby food. Jars
materials than by hot air (60°C to 125°C) to expend residual may be filled with larger particles -12mm cube size or larger

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 International Journal of Trend in Scientific Research and Development (IJTSRD) @ www.ijtsrd.com eISSN: 2456-6470
-if one dimension is smaller (Nelson, 1993). In a recent flat until ready to be used (unlike glass or cans). A standard
development, returnable bottles are filled aseptically, which semi-trailer truck can transport 1.5 million empty drink
up to now be applied only for UHT – treated milk. Mainly, the boxes versus only 150, 000 glass bottles. Space efficient in
same products can be filled into plastic bottles and jars as transport when filled. The brick shape allows more product
into glass containers. Closing is usually done by heat-sealing able to be stacked in the truck (Smith, 2004).
aluminium lids. So, much attention has to be paid to avoid
contamination of heat-sealing rims. Plastic Cans: Two-piece Safety due to the steam sterilization of spout and
plastic cans, ‘gourmet cans’, was recently developed in an sterilization effect can be controlled and recorded. No
aseptic machine for filling and closing. Cans and lids with chemical sprays used to sterilize the chamber. The spout is
easy opening feature exist of PP/EVOH/PP. They are tamperproof. Safer sterilization and easier to monitor. No
sterilized with hydrogen peroxide, UV radiation and heat- risk of adding chemicals to the product. No risk of laminate
sealed inductively (Smith, 2004). material relating to chemicals. Reliability, because: The
filling machine is uncomplicated as there is no sterile
Special need for plastics in aseptic packaging: Plastic chamber (Smolin, 2017). The filling is controlled by weight.
material is so important to aseptic packaging; it is useful to This gives accuracy as no adjustments for specific gravity
discuss some special properties demanded of plastics by the need to be made.
aseptic process itself. They are chemical resistance and
wettability, thermal stability, low levels of contaminating Environmental impact: Renewable raw material - aseptic
microorganisms and resistance to ionizing radiations cartons are based on a renewable resource paperboard from
(Stevenson, and Chandarana, 1999). wood. Lightweight, transportation efficiency, storage
without cooling, energy efficient productions are resource
Bulk Aseptic Packaging: ‘Aseptic Bag-In-Box’ system caters efficiency. Aseptic cartons are the recyclable material which
to the packaging of ‘High’ as well as ‘Low’ acid products and is easy to recycle and are being recycled where respective
products containing particles for filling range from 25 liters collection systems exist. Aseptic cartons have a good
up to 1140 liters. Applications are in fruit juices, performance in fossil resource. Consumption and
concentrates, purees, tomato products, milk and cream, greenhouse gas effect which impacts global warming
coconut products and jam. Advantages of bulk aseptic (Willhoft, 1993).
packaging are safety, reliability, extended shelf-life and
product quality. Safety due to the steam sterilization of Conclusion
spout, and sterilization effect can be controlled and Aseptic packaging has very well occurred in food service
recorded, no chemical sprays used to sterilize the chamber, applications worldwide as a safe and high-quality packaging
the spout is tamperproof, safer sterilization and easier to option. Aseptic processing sterilizes food products by
monitor, no risk of adding chemicals to the product and no destroying the harmful bacteria and pathogenic micro-
risk of laminate material relating with chemicals. Reliability, organisms through a tightly controlled thermal process and
because of the filling machine is uncomplicated as there is no combines the sterile product with the sterile packaging
sterile chamber, the filling is controlled by weight this material in a sterile environment; the final result is a shelf-
ensures accuracy as no adjustments for specific gravity need stable product requiring no refrigeration. Packaging for
to be made and the customer will have one partner with aseptic was particularly demanding of the long shelf-life,
worldwide service organizations and long experience in high seal integrity, and consumer appeal. The use of plastics
processing and packaging technology. Extended shelf-life in the aseptic packaging mainly increases the non-
due to the high oxygen barrier of the laminate, the laminate refrigerated shelf life and need of many perishable products.
is less susceptible to flex cracking, secure spout with limited Today, this is primarily being used in the innermost contact
possibility of oxygen permeation and there is no headspace layers of the package, thereby protecting the quality of food.
in the bag. A bulk aseptic bag is several layered structures More recently aseptic packaging has been applied for wine,
consisting of an outer barrier laminate and an inner bag in soup, baby food, and water products.
contact with the product. Most of the bags are pre-sterilized
using gamma irradiation and supplied flat. The level of References
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