Aseptic packaging involves filling commercially sterile products into sterile containers and hermetically sealing them to prevent reinfection, resulting in shelf-stable products. The process includes sterilizing the product and packaging materials before filling, often utilizing heat, chemicals, or radiation for sterilization. Aseptic packaging offers advantages such as no refrigeration requirements, long shelf life, and enhanced nutrition but presents challenges like high installation costs and potential flavor issues.

1. ASEPTIC PACKAGING
MUFASSIL USMAN
S7-FOOD ENGG
KCAET, Kerala

2.  It is defined as filling of commercially sterile
product into sterile container under aseptic
conditions and hermetically sealing the
container so the reinfection is prevented
 The results in a product , which is shelf life
stable under ambient conditions
 The term aseptic is derived from the Greek
word “septicos” which means absence of
putrefactive micro organism

3.  There are two specific fields of application of
aseptic packaging technology
1.Packaging of pre-sterilised and sterile products.
E.g. Milk and dairy products, puddings, desserts,
fruit and vegetables.
2.Packaging of non-sterile products to avoid
infection by micro-organism
E.g. Fermented dairy products like yoghurt

4.  Aseptic packaging technology is fundamentally
different from that of conventional food
processing by canning.
 In canning, the process begins with treating the
food prior to filling
 Initial operations inactivate enzymes so that
these will not degrade the product during
processing.
 Generally, air that can cause oxidative damage
is removed from the interior.

5.  In aseptic packaging, the package is
hermetically sealed and after subjected to
heating.
 Sterilization of the products before filling
 The package must be able to withstand heat up
to about 100°C for high acid products and up to
127°C for low acid products.

7. Aseptic processing comprises the following:
• Sterilisation of the products before filling
• Sterilisation of packaging materials or containers
and closures before filling
• Sterilisation of aseptic installations before
operation (UHT unit, lines for products, sterile air
and gases, filler and relevant machine zones)
• Maintaining sterility in this total system during
operation

8. 1.Microwaves
2. Electrical resistance heating
3. High voltage discharge
4. Ultra high pressure
5. Sterilization of air by incineration

9.  Heat , chemicals and radiation have been used
, alone or in combination , for sterilization of
aseptic equipment and packaging materials

10.  Systems employing moist heat are
frequently sterilized at temperatures
ranging from 121°C to 129°C, while 176°C
to 232°C is used for sterilization by dry
heat.
 Sterilization of air by incineration:
Temperature ranging from 260°C to 315°C

11.  Hydrogen peroxide (at concentrations of 30 to
35%) is the overwhelming choice for use as a
chemical sterilant.
 Some other chemicals are various acids,
ethanol,ethylene oxide and peracetic acid.

12.  Gamma-radiation has been used for decades to
decontaminate packaging materials for use in
aseptic systems for packing acid and acidified
food.
 A dose of approximately 1.5 Megaradians
(Mrad) is commonly used to decontaminate
containers for acid and acidified food.
 Ultraviolet (UV-C) light has been used to
decontaminate food contact surfaces

13. Carton Boxes, Bags and Pouches, Cups
and Trays, Bottles and Jars, Metal Cans,
Plastic Cans, Composite Cans are used for
packaging

14.  Convenience
Aseptic packages are portable, lightweight, and
shatterproof and easily transportable
 Food Safety
The aseptic process and carton together ensure that the
liquid food or beverage inside is free from harmful bacteria
and contaminants.
 No refrigeration required
 Long shelf life
 More nutrition
 Low Packaging to product ratio

15.  Plant Installation cost is high as compare to
canning
 Gas transmission rate of Aseptic bag/ package
 Overcooked flavour in some products
 Lack of equipment for particulate sterilization,
dueespecially to settling of solids and thus over
processing