Paper No.

: 02

Paper Title: Principles of The food processing & preservation

Module – 11: Aseptic Processing & Packaging

Paper Coordinator: Dr. P. Narender Raju,

Scientist, National Dairy Research Institute, Karnal, Haryana
Content Writer: Dr. Kuna Aparna,
Asst. Professor, Prof. Jayashankar Telangana State Agricultural
University, Hyderabad
 Module 11

ASEPTIC PROCESSING
 Introduction
• Aseptic processing is a high--temperature, short-time (HTST)
process which results in products with improved texture, color,
flavor, and nutritional value, compared to conventional
canning.

• Aseptic processing is the process in which a sterile product

(typically food or pharmaceutical) is packaged in a sterile
container in a way that maintains sterility.

• Sterility is achieved with a flash-heating

flash process (temperature
between 195 and 295 °F (91 91 to 146 °C)), which retains
more nutrients and uses less energy than conventional
sterilization techniques.
• High Temperature Short Time (HTST) processes are
possible if the product is sterilised before it is filled
into pre-sterilised containers in a sterile atmosphere.

• This forms the basis of aseptic processing, also

known as ultra-high temperature (UHT) processing.

• Aseptic processing is used to sterilise a wide range of

liquid foods, including milk, fruit juices and
concentrates, cream, yoghurt, salad dressings, egg
and ice cream mix.
Heating equipment for aseptic processing includes the
following:
• Direct systems:
– steam injection
– steam infusion
• Indirect systems:
– plate heat exchangers (including tube-in-tube)
– tubular heat exchangers (concentric tube or shell-and-
tube)
– scraped surface heat exchangers.
exchangers
 Table.1.1. Direct and indirect heating systems
Direct heating systems
Steam injection Steam infusion
Advantages Limitations Advantages Limitations
One of the fastest methods · The method is only suitable · Almost instantaneous · The method is only suitabl
of heating and the fastest for low viscosity products heating of the food to the for low viscosity products
method of cooling and is · There is relatively poor temperature of the steam, · There is relatively poor contro
Therefore suitable for control over processing and very rapid cooling over processing conditions
more heat sensitive foods conditions which results in high · There is a requirement fo
Volatile removal is an · A requirement for potable retention of sensory potable steam which is mor
advantage with some steam which is more characteristics and expensive to produce than
foods (for example milk) expensive to produce than nutritional properties normal processing steam
normal processing steam · Greater control over · Regeneration of energy is les
· Regeneration of energy is processing conditions than than 50% compared with mor
less than 50% compared steam injection than 90% in indirect systems
with more than 90% in · Lower risk of localized · Flexibility for changing to
indirect systems overheating of the product different types of product i
· Flexibility for changing to · The method is more suitable low
different types of product is for higher viscosity foods · Blockage of the spray nozzles
low compared to steam injection · Separation of components in
some foods
 Table.1.2. Direct and indirect heating systems
In direct systems
Steam injection Steam infusion
Advantages Limitations Advantages Limitations
· Relatively inexpensive · Limited to low viscosity · Few seals and easier cleaning · Limited to relatively low
· Economical in floor space liquids (up to 1.5Nsm-2) and maintenance of aseptic viscosity foods (up to 1.5Nsm-2)
and water consumption · Operating pressures limited conditions · Lower flexibility to changes in
· Efficient in energy use by the plate gaskets to · Operation at higher pressures production capacity
(>90% energy approximately 700kPa (7,000-10,000 kPa) and · Larger diameter tubes cannot be
regeneration) · Liquid velocities at higher liquid flow rates (6ms- used because higher pressure
· Flexible changes to relatively low pressure also 1) than plate heat exchangers needed to maintain the liquid
production rate, by varying low (1.5-2ms-1) · Turbulent flow at tube walls velocity and large diamete
the number of plates · Low flow rates can cause due to higher flow rates hence pipes have a lower resistance to
· Easily inspected by uneven heating and solids more uniform heat transfer pressure
opening the plate stack deposits on the plates which and less product deposition · Any increase in production rate
require more frequent requires duplication of the
cleaning equipment
· Gaskets susceptible to high · Difficulty in inspecting hea
temperatures and caustic transfer surfaces for food
cleaning fluids and are deposits
replaced more regularly than
in pasteurisation
· Careful initial sterilisation of
the large mass of metal in
the plate stack is necessary
for uniform expansion to
prevent distortion and
damage to plates or seals
· Liable to fouling
• Recent developments in the heating system technologies
include tube-in-tube heat exchangers, a development of
plate heat exchangers, in which the thin-walled plates are
formed into a tube and corrugations or twists in the tubes
are introduced to promote turbulent flow.
• This system is relatively low cost and is widely used,
although it suffers from some drawbacks such as:
– The equipment is restricted to relatively low viscosity liquids that
do not cause
– Significant fouling
– Seal integrity is critical to prevent mixing of incoming material,
sterilised
– Product or heating and cooling media
– The seal strength limits the pressure that can be used
– Seals may be difficult to clean.
• A major challenge lies in aseptic processing of particulate-containing foods,
especially at particle sizes of 5–10mm or more.

• The major problem is that of ensuring sterility of the fastest moving particle
without heat damage to the slower moving ones.

• To reduce this problem, processes have been designed where liquid and
particles are processed separately and mixed again before the aseptic packaging
stage, or where liquid and particles are moved through the heating zone at
different rates.

• The ‘Twintherm’ system is a semi-continuous

continuous process in which particulate food
is heated by direct steam injection in a pressurised, horizontal, cylindrical vessel
that rotates slowly.

• This method of aseptic processing is now used for foods such as soups, baby
foods, fruit and vegetables.
Semi-aseptic processes
• There are a number of other similar processes to aseptic
processing which may be labelled minimal processing
compared to conventional canning, in that heat treatment
is done in direct contact between heating medium and
food.

• One example is the old Flash-18

Flash process, in which people
actually worked inside a pressure vessel in which food was
heat sterilised in open cookers and packed hot inside the
vessel.

• A modern, automated version of this is the Pressure-Pac

system.
• For bulk pasteurisation of vegetables in combination with
semi-aseptic modified atmosphere packaging, two
interesting methods are claimed to be in commercial use.

• Pasteurisation by heat or other means in combination

with packaging under clean room conditions known as
semi-aseptic processing is attracting increasing interest
today.

• Interesting new process equipment that can be used in

such applications are spiral steam heaters and coolers,
also using impingement steam jets, and microwave and
short-wave infrared tunnels..
• High heat infusion is used mainly for dairy products such as
UHT milk, lactose reduced milk, flavoured milks, various sauces
and dressings.
• The advantages and disadvantages of high heat infusion are
summarised in Table below.
Table 2. High heat infusion
Advantages Disadvantages
· Its capacity to kill heat-resistant spores · Products undergo more severe chemical damage
· Longer operating times, due to reduced fouling compared to the normal infusion process
· Increased safety, because the flash chamber (and · In milk production the process also requires
in some cases the homogeniser) is placed prior to downstream homogenisation for the longest
UHT treatment possible shelf-life to be obtained
· Increased cost efficiency, especially in energy
costs and the cost of maintenance, inspection, etc.
· The possibility of aseptic flavour addition, giving
the technology an advantage in the production of
flavoured milk or ice cream mixes, for example
· The capacity to manufacture a wider range of
products
Aseptic Packaging
• UHT-treated products have to be packaged under conditions
which prevent microbiological contamination, i.e. aseptically
packaged.

• With some high-acid foods (pH<4.5),

(pH< it may be sufficient to
cool the product after UHT treatment to just below 100°C, fill
it into a clean container, seal the container and hold it at that
temperature for some minutes before cooling it.

• This procedure will inactivate microorganisms that may have

been in the container or entered during the filling operation
and which might grow in the product.
product
• In the case of rigid metal containers, superheated steam
may be used to sterilize the empty containers and maintain
a sterile atmosphere during the filling and sealing
operations.
• Superheated steam, at a temperature of approximately
260°C, is introduced into the tunnel to sterilise the cans.
• The filled and seamed cans then exit from the tunnel.
• The whole system has to be pre-sterilised and the
temperatures adjusted to the appropriate levels before
filling commences.
• This aseptic filling procedure is known as the Dole process.
• Form-fill-seal systems
are available as
shown in the figure
to fill processed food
materials aseptically.

Figure.1: Principle of aseptic packaging system

Conclusion
• Aseptic processing has been a boon to the food processing sector,
enabling both growth and innovation.
innovation

• In aseptic processing, food is stored at ambient temperatures in

sterilized containers free of spoilage organisms and pathogens.

• The results of this food technology come in all shapes and sizes, from
the consumer packages of milk on the shelves of the supermarket to
the huge containers full of orange juice transported around the world
by cargo ships.

• The construction of new aseptic facilities continues around the world,

and an up-to-date understanding of the technology is essential for a
new generation of food scientists and engineers alike.
 Glossary of terms
• Aseptic - Aseptic means sterile or free of bacterial contamination. Aseptic is
commonly used to describe food processing and packaging techniques for non-
refrigerated storage or long-life products.
products
• Contamination - Any objectionable matter found in food or a food environment.
• Critical control point (CCP) - A step in a process where a hazard can be controlled
and the control measures in place at that step are essential to protect food safety.
• Critical limit - A criterion which separates acceptability from unacceptability.
• Cross-contamination - A common term for the way in which harmful bacteria
(pathogens) are passed from unsafe to safe foods.
• Pasteurization: a technology that uses heat to kill harmful microorganisms.
• Sterilization - A process that destroys all living organisms.
• Temperature - a critical measurement for ensuring the safety and quality of many
food products.
 Suggested readings
• Earle, R.L. Unit Operations in Food Processing.
Processing 2nd Ed. Pergamon Press. 207 pp., 1983.
• Henderson, S.M. and R.L. Perry. Agricultural Process Engineering. 3rd Ed. The AVI Publishing
Co., Inc., 442 pp., 1976.
• Toledo, R.T. Fundamentals of Food Process Engineering. The AVI Publishing Co., Inc., 409 pp.,
1980.
• Heldman, D.R. and R.P. Singh Food Process Engineering.
Engineering 2nd Ed. Van Nostrand Reihold, 414
pp., 1981.
• Other Recommended readings:
– PIC/S Recommendation on the Validation of Aseptic Processes
– FDA Guidance for Industry- Sterile Drug Products Produced by Aseptic Processing - Current Good
Manufacturing Process
– ISO 13408 Aseptic Processing of Health Care Products
• Part 1: General Requirements
• Part 2: Filtration
• Part 3: Lyophilization
• Part 4: Clean-In-Place Technologies
• Part 5: Sterilization-In-Place
• Part 6: Isolator Systems