Aseptic processing is gaining importance in beverage production as it preserves products in their natural state without preservatives while ensuring a long shelf life. Aseptic filling involves bottling products at ambient temperature without heat treatment, allowing products to maintain their natural qualities. It has several advantages over other methods like hot-filling and extended shelf life processing, such as preserving flavor and quality while eliminating the need for preservatives. The initial investment is higher for aseptic technology but manufacturers can enjoy reduced packaging costs and benefits of smaller packaging sizes.

1. INSIGHT & OUTLOOK Aseptic technology
thermal impact than the hot-fill product. This means that the
product is more natural and the risk of destroying flavours does not
exist. On the other hand, for ESL products, it is essential to always
maintain the cold chain – this is often a challenge in countries,
where there is a problem of cold chain availability at the point
of sale.”
What is the difference?
In hot-fill process, the product is flash pasteurised at temperatures
(between 120ºC and 140ºC) and held for a few seconds. After this,
the product is cooled down to be filled in a container, which is then
laid on its sides to sterilise the cap. It is then erected and undergoes
rapid cooling down to about 40ºC in a cooling tunnel.
Aseptic filling involves bottling a product at ambient
temperature, ie without tunnel pasteurisation or hot-filling and
without the addition of preservatives, in such a way that it attains
a specified shelf-life. The products are only briefly heated before
filling. Aseptic filling is recommended for both still as well as
carbonated beverages. Basically, two processes of aseptic filling have
emerged, dry and wet sterilisation, both with specific advantages
and disadvantages. Kraus explains, “The most common applications
in aseptic technology for beverage filling are definitely wet bottle
sterilisation with Peracetic Acid (PAA) or dry bottle sterilisation
with Hydrogen Peroxide (H2O2). The aseptic technology is indeed
a strong growing market – the consumer these days expects a
natural product without any preservative. The product should be
‘low processed’ to be as inartificial as possible.”
Courtesy: Krones AG
A paradigm shift in
beverage production
While there are many technologies available in the market to process and pack beverages, aseptic processing is
gaining importance as it can preserve the products safely in a natural state. But beverage manufacturers will have
to work closely with the technology providers to extract maximum benefit from aseptic processing.
Rakesh Rao Refreshing technology
There is an increasing demand for more natural and healthier
N
on-carbonated drinks such as juice, tea, milk, flavoured products among the consumers; so aseptic packaging enables
water,etc need protection from microbial contamination to do away with preservatives, artificial colours etc. “Besides,
as they contain sugars. Beverage manufacturers use compared to hot-filling for high acid drinks and retort for the low
methods such as preservatives, hot-filling, extended acid ones, combined with respectively High Temperature Short
shelf-life (ESL), aseptic processing/filling, etc to eliminate microbes, Time (HTST) and Ultra-high Temperature (UHT) processing,
thus ensuring safe consumption of drinks. However, in recent times, aseptic technology allows to preserve the organoleptic quality of
aseptic processing is gaining importance in the developed countries. the products still securing a long shelf-life,” elaborates Roland
The advantage of the aseptic process compared with hot-fill is Nicolas, Dairy & Aseptic Business Development Director, Serac.
obvious, says Stefan Kraus, Product Manager-Filling Technology, Seconding this thought, V Gokuldas, Managing Director,
Krones AG, adding, “The aseptic product is not as highly processed HRS Process Systems, says, “One of the biggest advantages of
as the hot-fill product, and the aseptic product experiences less aseptic technology is preservation of naturalness of processed
46 Modern Food Processing | March 2012

2. Aseptic technology
product. Compared to other methods such and steam is much lower than that for the
as hot-fill, extended shelf-life wherein traditional technologies. “However, aseptic WHICH IS THE BEST?
preservatives or extenders need to be packaging requires a higher investment Here are some of the characteristics of
added, the same is not required in aseptic cost; so generally the more production the commonly used beverage processing
processing. Also, some of the hot-fill/ESL end-user expects, the easier it is to justify methods:
products need cold chain in the logistics the purchase of an aseptic line,” he adds. Hot-fill: It is normally filled in
of supply.” Moreover, aseptic technology requires glass (not a restriction, but one of
The aseptic technology is now a proven a minimum production capacity in order the most common), the container
and reliable technology, which guarantees that the fillers could be cost-effective. could be fragile and not easy to
to obtain microbiologically stable products. Cesar Rodriguez, CEO, MachinePoint transport, and additionally could
Nicolas says, “The market requires more Group, says, “This equipment need change the flavour characteristics
and more shelf-stable products with a additional care for specialised personnel as well as product properties
long, sometimes very long shelf-life. It in order to keep equipment working and ESL: It has less shelf-life than
also requires that food products must guarantee the product safety (all these aseptic product; the product
be kept safe in any conditions during safety requirements are necessary to quality would be similar
storage, transportation and distribution. guarantee the shelf-life of products).” Pasteurised or fresh milk: It
Aseptic packaging is suitable for all these Although the initial cost of installation requires refrigeration and the shelf-
requirements.” is high for aseptic technology, beverage life is shorter than aseptic products
In the beverage field, aseptic cold manufacturers can enjoy several benefits. Aseptic filling: It requires a
filling enables to use standard PET Gokuldas points out, “Smaller size packets minimum production capacity
bottles instead of heat-set PET bottles are cheaper in aseptic as compared to hot- to be cost-effective, and the
for hot-filling. “This provides a significant fill or ESL. Hence, aseptic processing technology would not be available
packaging material cost reduction and, in technology is as cost-effective as other for small single milk or food
addition, offers a wider choice of bottle methods of processing. However, actual producers, because of minimum
format, shape, label or sleeve decor as savings can vary from product to product production requirements
there is no temperature constraints on the and depending on the capacity of
Source: Cesar Rodriguez, CEO, MachinePoint Group
packaging,” explains Nicolas. the plant.”
Aseptic processing also follows a A superficial comparison of aseptic is towards low-cost recyclable packaging
general trend in the food industry to packages with other commonly used material, which is effective for an aseptic
upgrade the hygienic standard of the packaging material often leads laypersons environment. These are being evaluated
equipment and particularly in the dairies. to the conclusion that aseptic packaging for small as well as bulk packaging.”
He adds, “The aseptic technology features is a more expensive option. On the Another area of interest for aseptic
a high grade of machinery design and contrary, Rodriguez observes that a technology in the future will be processing
manufacture, complying with food quality deeper understanding of the material and of beverages with fruit particles. Kraus
standard for ultra-clean and aseptic its underlying technology clearly shows opines, “One trend is definitely the high line
equipment, the likes of EHEDG, 3A unmatched levels of cost-effectiveness. In flexibility with maximum line availability.
or FDA. This comes together with a set fact, according to him, aseptic technology During the last few years, another trend
of cleaning, sterilisation and disinfection offers a host of savings, some of came up: aseptic filling of particles. The
procedures, which have to be carefully which are tangible while others are consumer wants to experience the fruit
followed. Besides, this necessarily implies intangible (but highly significant in terms itself in the natural product. So there is
an improvement of raw food quality, like of their value). a significant growing demand in filling
fresh milk.” particles without damaging them.”
Customised solutions In future, the demand for aseptically
A cost-effective method? The growing demand for fruit-based processed products, which retain their
The comparison with other techniques, beverages is leading to evaluation of aseptic naturalness in taste and flavour, and contain
such as hot-filling, retort, etc, shows technology for different products with no additives, are expected to go up manifold
that specially for high-capacity lines, customisation. Gokuldas says, “Aseptic with growing number of health-conscious
aseptic technology is economically more technology for beverage processing is consumers. Hence, keeping in mind the
interesting. For example, Nicolas says, working in two areas – one is processing growing consumer demand as well as cost-
aseptic cold-filling enables to use standard and the other packaging. The trend is to effective technology benefits, the demand for
PET bottles instead of heat-set PET design units with low energy consumption aseptic processing is growing among beverage
bottles for hot-filling. Moreover, the and low product hold-up, with optimum manufacturers, sums up Gokuldas.
overall consumption of processed water processing capacity. In packaging, the trend Email: rakesh.rao@infomedia18.in
48 Modern Food Processing | March 2012