The document discusses aseptic processing, which is a technique for sterilizing liquid food or pharmaceutical products and packaging them in sterile containers to produce shelf-stable products without refrigeration. It describes various types of aseptic packaging materials like carton boxes, bags, pouches, cups, trays, bottles, jars, metal cans, plastic cans, and composite cans. It also outlines the key steps in aseptic processing like sterilization of products, packaging materials, and equipment to maintain sterility during filling and sealing. Benefits are listed as no refrigeration needed, protection of nutrients, and storage efficiency, while drawbacks include difficult recycling and higher production costs.

1. P. Karthika
Assistant Professor
Periyar University, Salem - 11

2. Aseptic processing is a processing technique
wherein commercially thermally sterilized
liquid products (typically food or
pharmaceutical) are packaged into previously
sterilized containers under sterile conditions
to produce shelf-stable products that do not
need refrigeration.

3.  Carton Boxes: Some of the existing aseptic carton boxes may now be
filled with particulates, also aseptically.
 Bags and Pouches: Pillow pouches are usually used for packaging of
milk; three-sided sealed pouch, however, is suitable also for aseptic
packaging of particulates up to particle sizes of 12µ and bag sizes
from 1-5 litres.
 Cups and Trays: These are either used pre-made or formed, filled
and sealed in thermoform/ fill/seal machines. Both types of
machines exist for filling particulates and also in packs suitable for
microwave heating.
 Bottles and Jars: Glass bottles may be aseptically filled with food
containing small particles, for instance for baby food. Jars may be
filled with larger particles - 12mm cube size or larger - if one
dimension is smaller. In a recent development, returnable bottles are
filled aseptically, which up to now were applied only for UHT –
treated milk.

4.  Metal Cans: The existing slit filler, however, limits
applications to liquids with very small particles, such
as rice. Fruits, Juices in Tetra Pack with and without
Spin Cap 316
 Plastic Cans: An aseptic machine for filling and closing
of two-piece plastic cans, ‘gourmet cans’, was recently
developed. Cans and lids with easy opening feature
consist of PP/ EVOH/PP. They are sterilized with
hydrogen peroxide, UV radiation and heat-sealed
inductively. The can is presently offered for liquids only
– for example coffee.
 Composite Cans: These may, at present, not be filled
with particulate food, but only with fruit juice with
long fibers.

6.  Sterilization of the products before filling
 Sterilization of packaging materials or
containers and closures before filling
 Sterilization of aseptic installations before
operation (UHT unit, lines for products, sterile
air and gases, filler and relevant machine zones)
Conventional Process Flow Aseptic Process Flow
311
 Maintaining sterility in this total system during
operation; sterilization of all media entering the
system, like air, gases, sterile water
 Production of hermetic packages

7.  convenience – it is portable and light
 food safety – the process ensures that the food is safe
from harmful bacteria
 no refrigeration is required – which saves energy in
the transportation and storage of the food product
 less energy is required – less energy to heat and
sterilise the product and the container
 protection of nutritional content – the food product
contains more nutrients due to less heat damage;
preservatives do not need to be added
 low packaging to product ratio – there is more than
90% food product to 10% package
 storage efficiency – brick shapes are easier to pack in
bulk than cans or jars

8.  recycling difficult
 production costs – due to a more complicated
system, production costs increase, resulting
in increased costs for the consumer

10. • Different materials - together
in a layered structure
•(usually 5-7) to provide an
adequate level of protection to
the product
•at an acceptable cost