Jean-Pierre Orenge is the global leader in the Synerlink bottle line; Which is a packaging company called Barry-Wehmiller. Since 1999, the company has supported liquid and beverage processors with expertise and professional packaging solutions. Recently, Orenge has shared extensive knowledge of the challenges and solutions available for several products, including milk, juice, tea, bottled water and other non-carbonated beverages.
Here’s what we need to know about the aseptic filling process, provided by Jane Piraeus Arrange.
As the COVID-19 pandemic continues, we are facing supply chain disruptions and increasing consumer pressure to provide safe and stable packaging products, as well as increasing interest from beverage processors in aseptic bottle filling solutions. In part, this is due to a positive feature of the products that are going to be on the shelf (shelf-stable), Including lower energy costs for retailers, lower shipping costs for manufacturers, and longer food safety. So I wanted to answer some of the most commonly asked questions about aseptic bottle solutions.
But before I dive into the Q&A, I believe that it is important to define the aseptic bottle process. I like to describe this process as filling a sterile product into a sterile bottle, closed by a sterile cap (or lid), all in a sterile process environment. This process can lead to better storage and less food waste, especially in areas where refrigerators are not widely available.
1) What is the process for aseptic beverage filling?
Creating an aseptic product and eliminating the risk of contamination throughout the bottling process; It usually requires a fully integrated approach with several applications working in harmony – including fillers, caps, and other sanitary equipment.
To understand this for clients, I compare the aseptic filling process to a hurdle race. Each machine or application has its own hurdles that you must put in place and monitor to ensure food safety for the end user. These hurdles may be additional light or oxygen to the product. In any case, these barriers are essential to ensure that your final product is suitable for consumption during the shelf-life.
2)What is UHT sterilization?
To make liquid products aseptic, beverage processors use a technique called ultra-high temperature (UHT) sterilization. This involves rapid heating of the liquid to a very high temperature. The beverage is then allowed to cool before filling.
3) What are the advantages of aseptically bottled milk?
To be considered aseptic (or shelf-stable), milk must be pasteurized by UHT, which must be heated to 150-138 ° C (280-302 ° F) for one or two seconds. This kills harmful bacteria before you fill the product is filled or milk jug or bottle. Product stability combined with repackaging capability provides perfect fit for consumers and excellent marketability for producers.
4) What are the benefits of fully integrated aseptic bottle lines?
As I mentioned before, the aseptic bottle filling process requires several machines (fillers, cappers, etc.) to work in harmony. For this reason, it may be helpful to select an equipment partner who can provide fully integrated packaging line solutions.
5) When are aseptic conditions necessary for bottled products?
Often beverage processors already have an opinion on whether aseptic filling technology is necessary or useful for their product when they meet with original equipment manufacturers (OEMs). These customers, who seek approval, usually fall into two groups:
- A group that wants to justify investing in aseptic technology, so the manufacturers of this original equipment are looking for; To help them at cost.
- Other people who want to avoid it because they expect aseptic technology to have higher operating costs and more difficult technology integration and monitoring.
Since each product is presented in a set of unique parameters (brand owner standards, market competition, type of distribution, end-user environmental conditions, etc.), there is no solution for everyone. Because of this, manufacturers (OEMs) can help customers and provide resources to see the impact of the proposed solutions on their customers.
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