Aseptic processing
Encyclopedia
Aseptic processing is the process by which a sterile (aseptic) product (typically food
or pharmaceutical) is packaged in a sterile container in a way that maintains sterility
. Sterility is achieved with a flash-heating process (temperature between 195° and 295°F (91° to 146°C)), which retains more nutrients and uses less energy than conventional sterilization techniques such as retort
or hot-fill canning
. Aseptic food preservation
methods allow processed food
to keep for long periods of time without preservative
s, as long as they are not opened. The aseptic packages are typically a mix of paper
(70%), polyethylene
(LDPE) (24%), and aluminum (6%), with a tight polyethylene inside layer. Together the materials form a tight seal against microbiological organisms, contaminants, and degradation, eliminating the need for refrigeration
.
The first aseptic filling plant for milk
was presented in Switzerland
in 1961. The Tetra Pak
company later became one of the leading suppliers of processing and packaging equipment for dairies
. Aseptic techniques were common in Europe and Asia before they were introduced in the United States in the 1980s.
Aseptic containers may range in size from a few fluid ounces to a nearly 8 million USgals (30,283.3 m³) aseptic tank on an ocean-going ship. Aseptic processing makes worldwide export and import of new, economical and safe food products possible. Bag-In-Box
technology is commonly used because it provides strong containers that are light weight and easy to handle prior to being filled. Other common package types are drink boxes and pouches.
In 1991, the Institute of Food Technologists
rated the top 10 innovations in food technology
. Aseptic processing and packaging ranked No. 1, ahead of juice concentrates, safe canning processes, freeze-drying and food fortification. In 2007 Dr. Philip E. Nelson
received the World Food Prize
in recognition for his pioneering work in aseptic processing and bulk storage.
In 1940s, Martin developed process in which empty metal cans were sterilized by treatment with superheated steam at 2100C prior to being filled with cold, sterile product. In 1950, the Dole Company bought the first commercial aseptic filling plant on the market. At the end of 1940, a dairy enterprise and machinery manufacturers in Switzerland (Alpura Ag, Bern, and Sulzer Ag, Winterthur) combined to develop UHT-sterilized, aseptically canned milk, which was marketed in Switzerland in 1953. However, this system was not economical mainly because of cost of the cans. Long shelf life milk packaged in this manner was first sold in Switzerland in October, 1961.
, a notable company in the industry, has launched an initiative to increase the recycling of aseptic containers. A 1995 book on recycling notes that aseptic containers were not widely recycled. In 1993, aseptic packages could be recycled in 19 US states. Confusion over whether aseptic packages can be recycled led to a 1990 ban on them in Maine.
Food
Food is any substance consumed to provide nutritional support for the body. It is usually of plant or animal origin, and contains essential nutrients, such as carbohydrates, fats, proteins, vitamins, or minerals...
or pharmaceutical) is packaged in a sterile container in a way that maintains sterility
Asepsis
Asepsis is the state of being free from disease-causing contaminants or, preventing contact with microorganisms. The term asepsis often refers to those practices used to promote or induce asepsis in an operative field in surgery or medicine to prevent infection...
. Sterility is achieved with a flash-heating process (temperature between 195° and 295°F (91° to 146°C)), which retains more nutrients and uses less energy than conventional sterilization techniques such as retort
Retort
In a chemistry laboratory, a retort is a glassware device used for distillation or dry distillation of substances. It consists of a spherical vessel with a long downward-pointing neck. The liquid to be distilled is placed in the vessel and heated...
or hot-fill canning
Canning
Canning is a method of preserving food in which the food contents are processed and sealed in an airtight container. Canning provides a typical shelf life ranging from one to five years, although under specific circumstances a freeze-dried canned product, such as canned, dried lentils, can last as...
. Aseptic food preservation
Food preservation
Food preservation is the process of treating and handling food to stop or slow down spoilage and thus allow for longer storage....
methods allow processed food
Food processing
Food processing is the set of methods and techniques used to transform raw ingredients into food or to transform food into other forms for consumption by humans or animals either in the home or by the food processing industry...
to keep for long periods of time without preservative
Preservative
A preservative is a naturally occurring or synthetically produced substance that is added to products such as foods, pharmaceuticals, paints, biological samples, wood, etc. to prevent decomposition by microbial growth or by undesirable chemical changes....
s, as long as they are not opened. The aseptic packages are typically a mix of paper
Paper
Paper is a thin material mainly used for writing upon, printing upon, drawing or for packaging. It is produced by pressing together moist fibers, typically cellulose pulp derived from wood, rags or grasses, and drying them into flexible sheets....
(70%), polyethylene
Polyethylene
Polyethylene or polythene is the most widely used plastic, with an annual production of approximately 80 million metric tons...
(LDPE) (24%), and aluminum (6%), with a tight polyethylene inside layer. Together the materials form a tight seal against microbiological organisms, contaminants, and degradation, eliminating the need for refrigeration
Refrigeration
Refrigeration is a process in which work is done to move heat from one location to another. This work is traditionally done by mechanical work, but can also be done by magnetism, laser or other means...
.
The first aseptic filling plant for milk
Milk
Milk is a white liquid produced by the mammary glands of mammals. It is the primary source of nutrition for young mammals before they are able to digest other types of food. Early-lactation milk contains colostrum, which carries the mother's antibodies to the baby and can reduce the risk of many...
was presented in Switzerland
Switzerland
Switzerland name of one of the Swiss cantons. ; ; ; or ), in its full name the Swiss Confederation , is a federal republic consisting of 26 cantons, with Bern as the seat of the federal authorities. The country is situated in Western Europe,Or Central Europe depending on the definition....
in 1961. The Tetra Pak
Tetra Pak
Tetra Pak is a multinational food processing and packaging company of Swedish origin. It was founded in 1951 in Lund, Sweden, by Ruben Rausing. It was Erik Wallenberg who invented the tetrahedral package, today known as Tetra Classic...
company later became one of the leading suppliers of processing and packaging equipment for dairies
Dairy
A dairy is a business enterprise established for the harvesting of animal milk—mostly from cows or goats, but also from buffalo, sheep, horses or camels —for human consumption. A dairy is typically located on a dedicated dairy farm or section of a multi-purpose farm that is concerned...
. Aseptic techniques were common in Europe and Asia before they were introduced in the United States in the 1980s.
Aseptic containers may range in size from a few fluid ounces to a nearly 8 million USgals (30,283.3 m³) aseptic tank on an ocean-going ship. Aseptic processing makes worldwide export and import of new, economical and safe food products possible. Bag-In-Box
Bag-In-Box
In packaging, a bag-in-box or BiB is a type of container for the storage and transportation of liquids. It consists of a strong bladder , usually made of several layers of metallised film or other plastics, seated inside a corrugated fiberboard box. The bag is supplied to the 'filler' as an empty...
technology is commonly used because it provides strong containers that are light weight and easy to handle prior to being filled. Other common package types are drink boxes and pouches.
In 1991, the Institute of Food Technologists
Institute of Food Technologists
The Institute of Food Technologists or IFT is an international, non-profit professional organization for the advancement of food science and technology. It is the largest of food science organizations in the world, encompassing 22,000 members worldwide as of 2006. It is referred to as "THE Society...
rated the top 10 innovations in food technology
Food technology
Food technology, is a branch of food science which deals with the actual production processes to make foods.-Early history of food technology:...
. Aseptic processing and packaging ranked No. 1, ahead of juice concentrates, safe canning processes, freeze-drying and food fortification. In 2007 Dr. Philip E. Nelson
Philip E. Nelson
Philip E. Nelson is an American food scientist who is best known for his work in bulk aseptic processing and packaging of food and the use of chlorine dioxide gas and hydrogen peroxide liquid to commercially sterilize food products and food contact surfaces.He is Scholle Chair Professor in Food...
received the World Food Prize
World Food Prize
The World Food Prize is an international award recognizing the achievements of individuals who have advanced human development by improving the quality, quantity or availability of food in the world.-The Prize:...
in recognition for his pioneering work in aseptic processing and bulk storage.
Historical development
Nelson carried out the first aseptic packing of foods (especially milk in metal cans) in Denmark prior to 1913 and in 1921 patent for this process (termed aseptic conservation) was granted. In 1917, Dunkley in USA patented sterilization with saturated steam of cans and subsequent filling of pre-sterilized product. In 1923, aseptically packaged milk from South Africa reached a trade fair in London, England in perfect conditions. The American can company developed a filling machine in 1933, called the Heat-Cool-Fill (HCF) system which used saturated steam under pressure to sterilize the cans and ends. The sterile cans were filled with sterile product and the ends sealed on in a closed chamber, which was kept pressurized with steam or a mixture of steam and air. Three commercial plants were built and operated on this principle until 1945.In 1940s, Martin developed process in which empty metal cans were sterilized by treatment with superheated steam at 2100C prior to being filled with cold, sterile product. In 1950, the Dole Company bought the first commercial aseptic filling plant on the market. At the end of 1940, a dairy enterprise and machinery manufacturers in Switzerland (Alpura Ag, Bern, and Sulzer Ag, Winterthur) combined to develop UHT-sterilized, aseptically canned milk, which was marketed in Switzerland in 1953. However, this system was not economical mainly because of cost of the cans. Long shelf life milk packaged in this manner was first sold in Switzerland in October, 1961.
Common uses
Aseptic processing is commonly used for the packaging of milks, fruit juices, liquid whole eggs, gravies, and tomatoes. Fresh tomatoes are aseptically processed and packaged for year-round remanufacture into various food products.Recycling
Aseptic containers are recycled with a method called hydrapulping. Some plastics and aseptic packages come out looking "relatively good" in overall costs, however no packaging is always better. The major problem, however, is that the hydrapulping facilities are not that common, and thus the multimaterial packages are relatively difficult to recycle. Tetra PakTetra Pak
Tetra Pak is a multinational food processing and packaging company of Swedish origin. It was founded in 1951 in Lund, Sweden, by Ruben Rausing. It was Erik Wallenberg who invented the tetrahedral package, today known as Tetra Classic...
, a notable company in the industry, has launched an initiative to increase the recycling of aseptic containers. A 1995 book on recycling notes that aseptic containers were not widely recycled. In 1993, aseptic packages could be recycled in 19 US states. Confusion over whether aseptic packages can be recycled led to a 1990 ban on them in Maine.
See also
- Blow fill sealBlow fill sealBlow-Fill-Seal technology refers to the manufacturing technique used to produce small, and large volume, liquid filled containers...
- CosmeticsCosmeticsCosmetics are substances used to enhance the appearance or odor of the human body. Cosmetics include skin-care creams, lotions, powders, perfumes, lipsticks, fingernail and toe nail polish, eye and facial makeup, towelettes, permanent waves, colored contact lenses, hair colors, hair sprays and...
- Dietary supplementDietary supplementA dietary supplement, also known as food supplement or nutritional supplement, is a preparation intended to supplement the diet and provide nutrients, such as vitamins, minerals, fiber, fatty acids, or amino acids, that may be missing or may not be consumed in sufficient quantities in a person's diet...
- Food and Bioprocess TechnologyFood and Bioprocess TechnologyFood and Bioprocess Technology: An International Journal is a peer reviewed scientific journal published by Springer Science+Business Media. It is available in print and online...
- Food chemistryFood chemistryFood chemistry is the study of chemical processes and interactions of all biological and non-biological components of foods. The biological substances include such items as meat, poultry, lettuce, beer, and milk as examples...
- Food engineeringFood engineeringFood engineering is a multidisciplinary field of applied physical sciences which combines science, microbiology, and engineering education for food and related industries. Food engineering includes, but is not limited to, the application of agricultural engineering, mechanical engineering and...
- Food fortificationFood fortificationFood fortification or enrichment is the process of adding micronutrients to food. It can be purely a commercial choice to provide extra nutrients in a food, or sometimes it is a public health policy which aims to reduce numbers of people with dietary deficiencies in a population.Diets that lack...
- Food microbiologyFood microbiologyFood microbiology is the study of the microorganisms that inhabit, create, or contaminate food. Of major importance is the study of microorganisms causing food spoilage. "Good" bacteria, however, such as probiotics, are becoming increasingly important in food science...
- Food packagingFood packagingFood packaging is packaging for food. It requires protection, tampering resistance, and special physical, chemical, or biological needs. It also shows the product that is labeled to show any nutrition information on the food being consumed....
- Food preservationFood preservationFood preservation is the process of treating and handling food to stop or slow down spoilage and thus allow for longer storage....
- Food rheologyFood rheologyFood rheology is the study of the rheological properties of food, that is, the consistency and flow of food under tightly specified conditions. The consistency, degree of fluidity, and other mechanical properties are important in understanding how long food can be stored, how stable it will...
- Food scienceFood scienceFood science is a study concerned with all technical aspects of foods, beginning with harvesting or slaughtering, and ending with its cooking and consumption, an ideology commonly referred to as "from field to fork"...
- Food storageFood storageFood storage is both a traditional domestic skill and is important industrially. Food is stored by almost every human society and by many animals...
- Food supplements
- Food safetyFood safetyFood safety is a scientific discipline describing handling, preparation, and storage of food in ways that prevent foodborne illness. This includes a number of routines that should be followed to avoid potentially severe health hazards....
- Food technologyFood technologyFood technology, is a branch of food science which deals with the actual production processes to make foods.-Early history of food technology:...
- Liquid packaging boardLiquid packaging boardLiquid packaging board is a multi-ply paperboard with high stiffness, strong wet sizing and a high barrier coating. Only virgin paper fibers are used. The barrier coating must hold the liquid and prevent migration of air and flavors through the paperboard....
- NutraceuticalNutraceuticalNutraceutical, a portmanteau of the words “nutrition” and “pharmaceutical”, is a food or food product that reportedly provides health and medical benefits, including the prevention and treatment of disease. Health Canada defines the term as "a product isolated or purified from foods that is...
- Nutrification (aka food enrichment or fortification)
- Pharmaceuticals
- Retort pouchRetort pouchA retort pouch is a type of food packaging created by aseptic processing, made from multiple layers of flexible laminate, allowing for the sterile packaging of a wide variety of food and drink, ranging from water to fully cooked, thermo-stabilized high-caloric meals such as Meals, Ready-to-Eat ...
- Ultra-high-temperature processingUltra-high-temperature processingUltra-high temperature processing, ultra-heat treatment , or ultra-pasteurization is the sterilization of food by heating it for an extremely short period, around 1–2 seconds, at a temperature exceeding 135°C , which is the temperature required to kill spores in milk...
- Tetra PakTetra PakTetra Pak is a multinational food processing and packaging company of Swedish origin. It was founded in 1951 in Lund, Sweden, by Ruben Rausing. It was Erik Wallenberg who invented the tetrahedral package, today known as Tetra Classic...