Professional Documents
Culture Documents
May, 2009
Special Need of Plastics in Aseptic Packaging Sealing of Aseptic Packaging Different types of Closures Types of Aseptic Packages Popular Aseptic Packs Typical packaging applications Advantages of Aseptic Packaging Technology Environmental Impact Extraction of Raw material Alternatives to aseptic packaging: New Product Applications in Aseptic Packaging
Section I
Aseptic Packaging
Aseptic packaging can be defined as the filling of a commercially sterile product into a sterile container under aseptic conditions and hermetically sealing the containers so that re-infection is prevented. This results in a product, which is shelf-stable at ambient conditions. Aseptic Packaging is the important development in the field of packaging The first aseptic filling plant for milk was presented in Switzerland in 1961.
Packaging of pre-sterilized and sterile products. Ex: milk and dairy products, puddings, desserts, fruit and vegetable juices, soups, sauces, and products with particulates. Packaging of non-sterile product to avoid infection by micro-organisms. Ex: fermented dairy products like yoghurt.
Source: www.gpap.ca
Source: www.envis-icpe.com
Aseptic Developments
Aseptic containers may range in size from a few fluid ounces to a nearly 8-million-gallon aseptic tank on an ocean-going ship. Aseptic processing makes worldwide export and import of new, economical and safe food products possible. Other common package types are drink boxes and pouches. In 1991, the Institute of Food Technologists rated the top 10 innovations in food technology. Aseptic processing and packaging ranked No. 1, ahead of juice concentrates, safe canning processes, freeze-drying and food fortification. In 2007 Dr. Philip E. Nelson received the World Food Prize in recognition for his pioneering work in aseptic processing and bulk storage. A child is using TetraPak in 1965
Dole Canning systems Drum fillers, e.g. Scholle, PranRica Dole hot air system Tetra Pak (Brik Pak) International Paper Combibloc LuquiPak Metal box AsePack Gasti Crosscheck Benco Asepack Bosch Servac Conoflast Thermoforming USA Scholle Liqui Box Asepak Prepac Prado pak Inpaco Bottlepack Serac ALP
5.Thermoform-fill-seal
c. Blow - moulded
Section II
PACKAGING DEVELOPMENTS
Source: www.envis-icpe.com
Twist Cap
Stream Cap
Source: www.tetrapak.com
Bags and Pouches Bottles and Jars Carton Boxes: Composite Cans Cups and Trays Metal Cans Plastic Cans
Source: www.tradeget.com
Advantages of Bulk Aseptic Packaging Safety Reliability Extended Shelf-life Product quality
Advantages in Protection
Food and drinks are optimally protected and keep their high quality for extended shelf life. - Protection from light - Light impairs the taste of milk and reduces the vitamin content in many beverages - Protection from oxygen - Oxygen causes juices to oxidize and spoil quickly - Protection from other odors and flavors - Other odors and flavors can impact natural product taste
Advantages in Logistics
Lower transport weight - A one liter beverage carton weighs only 28 grams verses a glass container which weighs up to 380 grams Lower storage costs - Warehousing Efficiency - Good stack ability - Improved pallet utilization configuration Empty packages are stored flat until ready to be used (unlike glass or cans). A standard semi-trailer truck can transport 1.5 million empty drink boxes versus only 150, 000 glass bottles. Space efficient in transport when filled. Brick shape = more product able to be stacked in the truck.
Advantages in general
Convenience portable, lightweight, shatterproof. Food Safety cooking and packaging process ensures that the liquid is free from harmful bacteria and contaminants. No refrigeration required saves energy both in transportation and in storage. Requires less energy to heat and sterilize the product than some other packaging methods. Nutrition benefits process places less heat stress on foods than canning therefore product can contain more nutrients as well as taste, color and texture. Low packaging to product ratio typically 96% product and only 4 % packaging.
Reliability, because:
The filling machine is uncomplicated as there is no sterile chamber. Filling is controlled by weight. This ensures accuracy as no adjustments for specific gravity need to be made. Customer will have one partner with worldwide service organizations and long experience in processing and packaging technology.
Environmental Impact
Renewable Raw Material
Aseptic cartons are based on a renewable resource-paperboard from wood.
Resource Efficiency
Lightweight Transportation Efficiency Storage without cooling Energy efficient production
Recyclable Material
Aseptic cartons are easy to recycle and are being recycled where respective collection systems exist
Distribution
conditions involve temperatures of 121 degrees for up to 30 minutes. Unlike the metal can, retort pouches and trays are susceptible to rupture or seal separation during retorting if the internal pressure exceeds the external process pressure.
shelf life, heavier to transport, breaks more easily than aseptic packaging, stacking not as efficient, may require refrigeration or preservatives to be added to the product, can be recycled.
Glass bottles may lack the oxygen and light barriers needed to increase
Plastic container can lack the oxygen and light barriers needed to
increase shelf life, stacking not as efficient, may require refrigeration or preservatives to be added to the product, can be recycled if local council provides the right facilities.
New Applications
- Wine - Small particle foods
- Soups - Salsas
- Waters
- Natural Spring Water - Vitamin and Energy Water drinks - Customized Functional Waters
ASEPTIC PACKAGING
Aseptic Packaging
Introduction Quick Stats of Aseptic Packaging Products Market Analysis Top 5 Markets Market Analysis Top 10 Market Categories Market Analysis: Top 15 Countries Market Analysis: Top 10 Companies Aseptic Packaging - Positioning Category Analysis Aseptic Packaging - Flavor Analysis: Flavor Group Dairy and Soya Drinks Juices and Drinks Baby Foods and Drinks Soups in TetraBrik Wines and Alcoholic Soft Drinks Vegetables and Fruits in Aseptic Packaging Summary
Introduction
This section focuses on Aseptic Packaging product launches globally from the Innova Database. Search for products where Packaging matches one of Tetra Brik, Tetra Fino, Tetra Pak, Tetra Pouch, Tetra Prisma, Tetra Rex, Tetra Top across all regions. The review contains information regarding new Aseptic Packaging product launches from January 2008 to December 2008. Market Analysis Company Analysis Positioning Analysis Flavour Analysis Aseptic Packaging Product Trends
Search for products where Packaging matches one of Tetra Brik, Tetra Fino, Tetra Pak, Tetra Pouch, Tetra Prisma, Tetra Rex, Tetra Top across all regions for Date Published between 01/1/2008 and 12/12/2008
Auchan Rik & Rik Batido Sabor Vanilla: Skimmed Milk with Vanilla Flavor Spain
Dukat Trajno Mlijeko + 7 Vitamina - Milk with 7 Added Vitamins Croatia Gogreen Soygurt Jordgubb: Soy Yogurt Drink in Strawberry Flavor Sweden
Frugo Pear Flavored Juice Drink - Chile El Corte Ingles Melocoton Original Orange Nectar Y uva - Peach & Grape Saudi Arabia Juice Drink - Spain
P'tit Souper Douceur Parmalat Len Liquid d'Artichaut Artichokes Formula Milk for 3Yrs Soup for Infants France Children - Colombia
Nutriben 8 Cereales Papilla Lista Para Tomar - 8 Cereal Baby Food Spain Nestle Junior Milk 2+ Switzerland
Semper Smoothie Banan och Agusha Reconstituted Mango - Banana and Mango Apple-Apricot Juice Flavor Smoothie for Babies - Cow & Gate Ready with Pulp - Russia Made Infant Milk for Sweden Hungrier Babies - UK
Soups in TetraBrik
Itoen Green Colored Knorr Vellutata Vegetable Soup Di Spinaci - Ready Japan Spinach Soup - Belgium
Del Monte Sweet Corn Cream Style - Indonesia Broja Banana Puree - China
Knorr Vegetable Puree: Vegetable puree made with 12 different vegetables - Spain
Source: www.tetrapak.ca
Source: pffc-online.com
Source: www.gpap.ca
Source: www.lanpak.ca/packaging.htm
Source: www.oakleaf-european.co.uk
Source: www.tetrapak.com
Source: www.asepticbaginbox.com
Source: www.packagingeurope.com
Source: www.thehealthywayfoods.com
Source: www.caspllc.com
Summary
The aseptic packaging is very well accepted in food product applications worldwide as a safe and high-quality packaging option. Aseptic processing sterilizes food products by destroying the harmful bacteria and pathogenic micro-organisms through a tightly controlled thermal process and combines the sterile product with the sterile packaging material in a sterile environment, the end result is a shelf-stable product requiring no refrigeration. Innova Database analysis indicates that Dairy & soft Drinks are the top markets for Aseptic packaging. Recently, wines, soups, baby foods and Water are added to aseptic packaging line.
Packaging must address the following Food Safety Convenience Affordability Convenience Cost-effective transport and storage with minimal environmental impact No need for cold chain Makes safe food available the whole year