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Aseptic Packaging
Content
• Introduction• What is Aseptic?• Aseptic Packaging• Advantages• Limitations
Why Foods are processed?
Introduction
Increase Shelf life of product Availability of commodity throughout
year Wide range of products can be
produce Convenience for consumer
How Foods products are processed ?
Introduction
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
Aseptic Packaging
What is Asepsis?
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.
Components of Aseptic Packaging
Commercial Sterile Product Sterile Packaging material Sterile Environment
Aseptic Packaging
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)
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
SN Fruit Products pH
1 Acidified Banana Puree 4.0-4.5
2 Acidified Banana Puree Concentrate 4.0-4.5
3 Alphonso Mango Puree 3.5-4.3
4 Totapuri Mango Puree 3.5-4.3
5 Kesar Mango Puree 3.5-4.3
6 Raspuri Mango Puree 3.5-4.0
7 Totapuri mango Puree Concentrate 3.5-4.0
8 Mango Puree & Concentrate Natural < 4.5
9 Pink Guava Puree < 4.0
10 White Guava Puree < 4.0
11 Pink Guava Puree Concentrate < 4.0
12 White Guava Puree Concentrate < 4.0
13 Red Papaya Puree < 4.5
14 Yellow Papaya Puree < 4.5
15 Red Papaya Puree Concentrate < 4.5
16 Yellow Papaya Puree concentrate < 4.5
17 Tomato puree / paste < 4.4
18 Amla Puree & Concentrate < 3.0
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
Recommended Schedule by NCA
PH 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
• 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
Sterility - Factors affecting heat resistance of micro-organisms
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
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)
“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
Aseptic Environment
Aseptic FillerScholleAsepsystem
Aseptic environment is created near Filler head by maintaining positive pressure of steam
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
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)
Integrity Check for Aseptic Packaging material
Teardown test – Sealing strength Electrolytic Test – Pinhole testing Dye test – For pinholes in laminated
cartons Sterility check
ConvenienceAseptic packages are portable, lightweight, and shatterproof and easily transportable Food SafetyThe 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 nutritionCompared with canning, products can retain more nutrients as well as natural taste, colour and texture Low Packaging to product ratio
Advantages of Aseptic Packaging
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
Thanks
Canning Vs Aseptic
Types of Tetra pack
Vitamin Loss
UHT Milk Processing
Test organisms UHT – Spores of B. subtilis or B. stereothermophilus
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