This document discusses aseptic processing and packaging of fruits and vegetables. It describes the basic requirements and methodology for aseptic processing, including sterilizing the product, packaging materials, and aseptic installations while maintaining sterility. It then details various machines used in aseptic processing like blending tanks, heat exchangers, holding tubes, and aseptic filling machines. It provides information on sterilizing different components of the aseptic system as well as packaging machines.

1. ADVANCES IN FRUITS AND VEGETABLES
PROCESSING
(FT 510)
PRESENTED BY:
KRATIKA SINGHAM
INT FOOD TECHNOLOGY
MACHINES USED
IN
ASEPTIC PROCESSING

2. INTRODUCTION
Aseptic processing denotes the filling commercially sterilized and cooled product into
pre-sterilized containers under aseptic conditions and sealing in an atmosphere free of
micro-organisms
UHT PROCESS = (130–150 °C ) for 1–2 sec

3. BASIC REQUIREMENTS OF ASEPTIC PROCESSING
EQUIPMENTS
1.
• Sanitary design
2.
• Capable of being sterilized (steam,
chemical, water, media)
3.
• Free from cracks, crevices, dead
spots
4.
• Capable of maintaining sterile state
5.
• Capable of being operated at
constant mode
6.
• Confirm to design , state and
federal regulatory codes

4. ASEPTIC PROCESSING METHODOLOGY
Sterilization of the
product
Sterilization of
packaging material
Sterilization of
aseptic
installations
Maintaining
sterility of the total
system
Production of
hermatic packages

5. ASEPTIC PROCESSING EQUIPMENTS
• PRIMARY COMPONENETS
• BLENDING TANK
• METERING PUMP
• HEAT EXCHANGERS
• HOLDING TUBE
• AIR OPERATED VALVES
• CONTROL SYSTEM
• ASEPTIC SURGE TANK

6. STERILIZATION OF ASEPTIC MACHINES
• H202 spray (disinfectant)
• Hot air= 330- 350˚C , 30 min
• Water vapour = presterilization
• Low acid ( superheated steam), high acid (wet steam)
PACKAGING MACHINES
• Pressurized superheated steam= 130-135˚C
• Pressure= 2 Bar
• Polyalcohol mixture= 170˚C (rinsing)
FILLING LINERS & FILLERS
• Incineration= 300-350˚C
• Cartridge filters= pressurized steam
• Blown clean sterile air
AIR FILTERS

7. BLENDING TANK AND BALANCE SURGE
1
• Completely suitable for CIP& SIP
2
• Crevices and dead leg free contact surfaces
3
• Bottom Magnetic Mixer
4
• 100% Drainability
5
• Top or bottom Entry Mixing System with
Double Mechanical Seals
6
• Process Automaon with Piping and
Transferring Systems
7
• Electropolished from inside <0.5 Ra
finish
8
• Sterile Micron Filtraon System
9
• Aspetic Sampling facility

8. BALANCE SURGE

9. TIMING PUMP
Delivers constant and accurate flow
Creates strong suction to draw the
product
Fed continuously to produce a constant
flow
RECIPROCATING PISTON PUMP
Suitable for product containing distinct
food pieces with zero slip

10. HEAT EXCHANGERS
PARAMOUNT METHDS INCLUDES:
PLATE HEAT
EXCHANGER
DIRECT
STEAM
SCRAPPED
SURFACE
HEAT
EXCHANGER
TUBULAR
HEAT
EXCHANGER
MICROWAVE
HEATING
OHMIC
HEATING
DIRECT STEAM: INJECTION/INFUSION
 Reduces the sterilization temperature very quickly and
removes water from the product
 Burnt flavor & color loss is minimal
 Steam is injected in continuous flow

11. PLATE HEAT EXCHANGER OHMIC HEATING

12. CONTINUOUS HOLDING TUBES
The product is being holded for
specific temperature and time
Inactivate bacteria & enzymes
Burnt odor, caramelization , vitamin
and color loss

13. DEAERATOR
Removes
undesirable
air before
final
sterilization
and cooling
operations
Reduce
fouling &
Prevent
foaming
Maintains
constant
filling
conditions &
specific
volume

14. HOMOGENIZER
disintegrate or
finely distribute
the particles
particle size
reduction using
shear force
Maintains
uniformity &
stability
Improve shelf life,
quality & taste
Pressure range
500- 1000psig

15. FILTERS
Oil
water vapour
odors & particles
Borosilicate type elements
Filter Size:
25 -1 μm
GASES
Flavors
Vitamins
chemicals
Odors & enzymes
Size: 0.2,0.45,1μm
Temp-= 250˚F
(15psi)
LIQUIDS
1
• Very high volume filter
• High temp= >300˚F
2
• Laminar flow & continuously
operated
3
• Trap the contaminants & produce
sterile air
HEPA FILTER

16. ASEPTIC FILLING MACHINE
Low acid foods
Speed= 450 cans /min
Can size= 202x214 (small)
603x700 (large)
2 or 3 piece steel cans
Heat resistance coating
Lids- plastisol selant

17. COMPONENTS OF CANNING MACHINE
•Steam Temp= 550˚F (260˚C)
•Container surface = 435˚F ( 224˚C)
CAN STERILIZER
•Slit = ¼ inch (wide), 6 inch (long)
•Annulus =1/2 inch
FILLING UNIT
•Superheated steam contact= 80sec
•Al (20% less time) then steel lids
LID STERILIZER
SEALER
•Maintains sterility
•Creates positive pressure

18. ASEPTIC PAPER-BOARD FILLERS (TETRA PAK)
• Bath of 35%H2O2
• Temp= 130˚F
•laminates- paper, Al foil &
•polyethylene layers
• Fill size= 80ml to 2000ml
• Food &beverages

19. FILLING EQUIPMENTS FOR FOOD CONTAINING
PARTICULATES
•Eg: cream cups
•Soft and small (non- abrasive)
particulates
DIAPHRAGM
FILLER
•Measure flow velocity
•Eg: milk & fruit juices
•Large particulates gives variability
INDUCTION
FLOW METER

20. • Particulate size= 25mm
• Uniform flow
• No splashing & dripping
• Rotating & adjustable nozzles
PISTON FILLER
•coriolis Effect
•Mesaures filled volume
•Bag-in- box sysytem
MASS
FLOWMETER

21. FORM- FILL- SEAL MACHINE (FFS)
METHODS
•Paper based
•Thermoformed
•Blow molded
•Bag-in- box
pouches
MODE OF ACTION
1.Roll-fed
paper based system
2.Preformed cartons
Ex: sauces, Juices,
beverages
MULTILAYER
• Outside
• Structural
• Adhesive
• Barrier
• Adhesive
• Food contact

22. ASEPTIC BULK STORAGE EQUIPMENTS
BULK STORAGE CONTAINERS
High acid foods
Size= 200-300 gallons
material = 304 0r 316 S.S
Avoid O2 , light penetration
BULK STORAGE TANKS
Citrus products
Refrigerated= 35˚F
Space= 330 to 1.8 gallons
Inactivate= enzyme & microbes
Increase vit C retention