Aseptic Packaging Revolution in

Packaging Industry

Indian Packaging Industry

Indian Packaging Industry sector wise

Distribution of packaging material

(www.npes.com, 2009)

Need for Revolution

• Traditional processing operations are

– Energy intensive

– Require heavy packaging

– Impact the taste, appearance, healthfulness– Examples - a hot-fill/retort process or chemical

process

Drivers of Revolutions

• Cost

• Sustainability

• Food safety

• Technology enablers

Aseptic Packaging

“ The filling of a commercially sterile product into a sterile

container under aseptic conditions and hermetically sealing the

containers so that reinfection is prevented ”

“Aseptic” derived from the Greek word “Septicos” which

means the absence of putrefactive micro-organisms.

The first aseptic filling plant for milk was presented in

Switzerland in 1961

Contd....

Aseptic Packaging

Conventional Canning v/s Aseptic Packaging

Methodology

• Sterilization of products

• Sterilization of aseptic packaging materials

and equipment

• Filling

• Seals and closures

Sterilization of Products

• Pre sterilization of product by HTST or UHT for

prescribed time

• A fast heat exchange rate is desired for better quality

• Important methods used commercially are –Microwaves– Electrical resistance heating– High voltage discharge– Ultra high pressure

Characteristics of the heat exchange systemsused for aseptic processing of liquids

Dinnage (1983)]

Sterilization of aseptic packaging materials and equipment

• Heat, chemicals, electron beam and radiation can be used single or in combination

Electron beam Steam Chemical sterilisation

Sterile

Non-sterile

Heat

• Moist heat or dry heat in the form of superheated

steam is used

• Time temperature requirement is higher in dry heat as

compare to moist heat

• Moist heat - 121°C to 129°C

• Dry heat - 176°C to 232°C

• Highly energy intensive

Chemicals

• Hydrogen peroxide of 30 to 35% as a sterilant for

packaging materials followed by hot air 60°C to

125°C to dissipate residual hydrogen peroxide

• Various acids, ethanol, ethylene oxide and peracetic

acid etc. are used

• Uses significant energy and water

• Less expensive than other

Radiation

• Gamma radiation

• 1.5 Megaradians (Mrad) used for containers of acid

food

• Highly effective

• Expensive and not inline technology

Electron beam

• Energy Efficient

• No Water

• No Chemicals

• Minimum Package Weight

• Equipment size, speed and costs are limiting factors

Filling

• Sterilised product is accumulated in an aseptic surge

tank

• Positive pressure monitored and controlled to protect

contamination

• Airtight sealing paramount importance in packaging

• Longitudinal system, a flat web of packaging

material is used

Sealing

Sealing cont.....

• Constantly moving sealing and pressure jaws

• Pressure applied from outside packaging material

• The polyethylene layer is heated

• Melted and pressed together between a pair of jaws

• The melted plastic layer cools down

• Bonding is effectuated between the two opposite packaging material surfaces they are sealed transversally

• Produced are sufficiently tight to prevent re-infection of the product

Types of Aseptic Packs

Type of Package Forms available in India

• TBA: Tetra Brik Aseptic

• TCA: Tetra Classic Aseptic

• TFA: Tetra Fino Aseptic

• TWA: Tetra Wedge Aseptic

Composition of Tetra Pak Aseptic Cartons

Properties of Aseptic Packaging Material

Advantages of Aseptic package

• Higher degree of safety, hygiene and nutrient retention

• Preserving taste and freshness

• Can be kept for months with no need for refrigeration

• Light-weight

• Product quality

Applications

• Fruit Juices, concentrates, purees

• Tomato Products

• Milk and Cream

• Coconut Products

• Jam

Thank you