Aseptic processing, Still juice drink, PET bottle, H2O2

1. Manufacturing Process for an Aseptic Still
Juice Drink
Dr. Shahidul Islam

2. Main Objectives
1. Low production cost
•Minimise production losses
•Energy economy
•Fast processing
2. High quality products
3. High degree of automation and flexibility
4. High level of reliability

3. Main Specifications for Process Technology
• Product type: Still juice drink
• Acidity: Acidic or high-acid juice drink
• pH: <4.6
• Type of juice: Clear
• Viscosity: Low viscous
• Heat treatment: HTST pasteurization
• Filling capacity: 700 bpm
• Packaging: PET bottle-aseptic filling
• Packaging size: 330ml and 500ml
• Shelf life: 6 Months

4. Process flow diagram for still juice drink
Juice from Concentrate
In line Blending
Sugar
Dissolving
Filtration
Glucose Fructose Syrup
Other Ingredients
HTST Pasteurization
(Homogenization)
CPS1
Aseptic Filling &
Capping
CPS2
Shrink Labelling &
Packaging
Finished Product
Cap
Aseptic dry
Sterilization
PET Bottle
Aseptic wet
Sterilization
CPS2
CPS2
CPS3
CPS: Critical Process Step
Water
Aseptic
Tank

5. Blending (CPS3)
- In line blending unit (blending of concentrate, water, sugar and
other ingredients)
• Continuous
• High accuracy (Brix of the final product ±1°Brix)
• Automatic
- Advantage of in line blending unit
• Minimise waste and consumption of raw materials
• Reduce man power
• Improve product quality
-Controlling parameters for blending
- Brix or sweetness - Taste
- Acidity or pH - Small
- Colour

6. HTST Pasteurization (CPS1)
•This diagram shows that most of the bacteria will not grow when
the pH is lower than 4.6
Relation between growth-rate of micro-organism and pH

7. HTST Pasteurization (CPS1)
Heat resistant
micrococci
Peroxidase
Typhus bacteria
Coliform Bacteria Tubercle Bacilli
Phosphatase
The lethal effect of time/temperature for destruction of some micro-
organisms and enzymes
•Above diagram shows that heat at 90-95°C and holding time of
10-30 sec destroy the majority of the pathogenic micro-organisms

8. Return from
filling
HTST Pasteurization (CPS1)
Flow chart for indirect plate heat exchanger with homogenizer
Water
CIP
Product inlet
CIP return
Reject Product to filling
Steam
Condensate
Cooling
water
Cooling
water
3
9
6. Final heater
7. Holding tube
8. Regenerative cooler
9. cooler
10. Final cooler
Item list
1. Balance tank
2. Pre-heater
3. Temperature sensor
4. Homogenizer
5. Hot water circuit

9. HTST Pasteurization (CPS1)
Advantages of indirect plate heat exchanger
• Excellent for low viscosity product
• High regenerative effect and low energy consumption
• High heat transfer area in minimal space
• Easy inspection
• High degree of flexibility
• Relatively low investment
• Low CIP costs

10. Aseptic Packaging (CPS2)
Wet sterilization of PET bottles
• Low peracetic acid concentration for bottle and surface disinfections
• Filler and capper are blocked with only one rinser
• Possible isolator zone. Freely accessible
• High efficiency particulate air (HEPA) filtration
• Isolator is limited to open bottle transfer area
•High microbiological safety
Aseptic filling
• Electromagnetic induction flow metering. Exact filling volume.
Dry sterilization of caps
• H2O2 sterilization. Dry sterilization process. High output and low cost.

11. Aseptic Packaging (CPS2)
Flow Chart of PET Bottle Aseptic Packaging
(Sterilization, Filling & Capping)
Sterility of the aseptic operation:
Microbiological isolator of sterile air
Product
filling
Cap dry
sterilization
Sterile water
rinse
Sterile air
Peracetic
acid spray
Exterior
spray
Isolator
Rinser Filler Capper

12. Conclusions
• Food safety- Aseptic processing ensure that the juice drink is free from
harmful bacteria and contaminants.
• Long shelf life- Product has a longer shelf life.
• More nutrition- This products can retain more nutrients as well as
natural taste and colour.
• Energy- High regenerative effect and low energy consumption.
Thank you!