Aseptic Filling Machine Processes

Aseptic Filling Machine
Aseptic Zone
Sleeve feed Sleeve Base forming activation Base folding Base Peroxide pressing sterilization Drying Filling Top sealing Top forming
6 June, 2013
Conveying
SIG Combibloc
Panich Choenthanomwong Training and Quality Department
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Aseptic system
What is the meaning of Aseptic
Aseptic means working under germ-free condition.

Or the summary of all measures guaranteeing the absence of any reproductive micro-organism. Or free from or keeping away.
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Preservation of foodstuffs by heat treatment
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Preservation of foodstuffs by heat treatment
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Aseptic system
comparison of processing method
Microorganisms (bacteria) Product Packaging Filling and sealing Sterilisation of sealed packs Product Sterilisation Filling and sealing Microorganisms (Bacteria) Packaging Sterilisation Aseptic Zone
Packed, sterilised product
Aseptically packed product
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Aseptic
Factors of influence on the aseptic process: Aseptic filling of beverages, dairy and food products into carton packs
Quality of the nonsterile product
Human factor
Product heating
ASEPTIC
Sterilisation liquid/ Package sterilisation Filling machine sterilisation
Aseptically packaged product
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Factors affecting the sterility rate of an aseptic production

1. The Microbiological load of the raw material 2. Sterilization effect of UHT process 3. Cleanliness and sanitary conditions of plant 4. Maintenance of aseptic conditions during production 5. Microbiological contamination of cartons surface (inner) 6. Efficiency of sterilization of cartons surface 7. Packages integrity 8. Cleaning and sterilization of filling machine (Aseptic zone) 9. Care and diligence of operating staffs 10. The service and preventive maintenance of the aseptic processing and packaging system 11. Plant hygiene.
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Three main processes are used for the decontamination processes:

Steam sterilisation H202 vapour sterilisation
Filtration of air
Filtration of Nitrogen and pressurised air for tank overpressure (Options)
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1.Steam sterilisation
Product pipe system,
Product tank,
Product valves,
Filling valves
Air (Pall) filters for product tank pressure

Nitrogen filters for Nitrogen injection
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Panich Choenthanomwong Training and Quality Department 6 June, 2013 Page 9

2. H2O2 vapour sterilization. - Pocket chain - Drying zone - Filling zone - Steam injection - etc
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3. Filtration of air
HEPA (high efficiency particulate air filter) filtration of the air for the aseptic zone
Filtration of pressurised air for product tank pressure Filtration of Nitrogen for Nitrogen injection
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Combibloc filling machine operation.
Conclusion.
Condition for aseptic operation of the combibloc filling machine
1. Operator 2. Filling machine
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1.Operator (5 important rule of Hygiene)

1.Personal cleanliness (wash hands )
2.Clean working clothes and hat
3.Clean environment (walls, floors,ceilings)

4.Do not work at machine with open wounds
(even small wounds must be taken care of)
5.Any consumption of food at the filling machine is prohibited

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2. The filling machine

1.The parts of filling machine must be cleaned ,sterilized for each start of production:
- Product-holding lines(pipelines, filling station etc) - Aseptic zone 2. Spray sterilization of hands and possibly of parts installed into the aseptic zone. (All parts must be cleaned and dried)
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3. The filling machine must be cleaned immediately after the end of production (manual cleaning, pocket chain cleaning and CIP cleaning) 4. No leakage at aseptic zone , product pipe. 5. Keep sterile air pressure condition 6. The carton must be sterilized during production and check cartons for leaks.
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Decontamination processes used within a combibloc system: Steam sterilisation for product pipe system, product tank, product valves, filling valves and air (Pall) filters for product tank pressure and Nitrogen filters for Nitrogen injection H2O2 sterilisation for aseptic zone surfaces and HEPA air filter system H2O2 sterilisation of the package during production HEPA (high efficiency particulate air filter) filtration of the air for the aseptic zone Filtration of pressurised air for product tank pressure Filtration of Nitrogen for Nitrogen injection Additional options not available for all formats: Dedusting unit (to remove dust particles out of the package before it enters the aseptic zone) Pocket chain desinfection unit (normally potable water is used for chain cooling)
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Product
Sterilisation
The liquid food is commercially sterilised.
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Product
Packaging
Sterilisation
Sterilisation
The sleeves are sterilised.
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Product
Packaging
Sterilisation Filling and sealing The sterile product is filled into sterile sleeves under sterile conditions in aseptically.
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Sterilisation Aseptic Zone
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Product
Packaging
Sterilisation Filling and sealing
Sterilisation Aseptic Zone
The product is "commercially sterilised" using a concept called "aseptic processing"

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Aseptically filled product
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Aseptic and aseptic filling system
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UHT and Commercial sterility
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Making Milk Last Longer

We have 2 containers of milk. Bottle of milk - fresh or pasteurised Pack of UHT milk - closed
Which one will last longest ? Why ? What is the difference between the two ?
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Question : Which will remain fresher longer ?
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Question : Which will remain fresher longer ?
The UHT milk can remain fresh for up to 6 months, or even longer, : without refrigeration and without using preservatives.
(The fresh milk will deteriorate in hours at ambient temperatures, or days if refrigerated.)
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Why does the UHT milk last so very long ??
The bacteria in the milk are either killed, or prevented from growing, by high temperature treatment.
This is called commercially sterilising the milk.
The treatment is called Ultra High Temperature - UHT.
It is then aseptically filled into a sterile pack - ie no bacteria.
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Definition - Commercial Sterility

A commercially sterile product is free from micro organisms which grow under normal conditions of storage.
Same meaning - different words.
UHT milk does not contain any bacteria capable of multiplication under normal conditions of storage and distribution.
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No bacterial growth = long shelf life
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Aseptic system
What is commercial sterility ?
Commercial sterility means:

* The product is free from micro-organism which grow
under normal conditions of distribution and storage

OR
UHT milk does not contain any bacteria capable of multiplication under normal conditions of storage and distribution.
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Aseptic system
Commercial Sterility -Purpose or target of commercial sterility -No Poisons or Toxins -No Pathogens -No Enzyme -No growth of bacteria under room temperature (transportation and shelf stable)
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Aseptic system
Why UHT product can keep long time in room
temperature ?
1.UHT equipment ,product line and CFA are cleaned and sterilization before production. 2.Product sterilized by UHT system. 3.Package sterilized by H2O2
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Aseptic system
4. Product filled into package under aseptic condition 5. Integrity of the package to prevent post contamination.
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Aseptic Filling Machine Processes

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Aseptic Filling Machine

Panich Choenthanomwong Training and Quality Department

Aseptic means working under germ-free condition.

Panich Choenthanomwong Training and Quality Department

Preservation of foodstuffs by heat treatment

Panich Choenthanomwong Training and Quality Department

Preservation of foodstuffs by heat treatment

Panich Choenthanomwong Training and Quality Department

Packed, sterilised product

Aseptically packed product

Panich Choenthanomwong Training and Quality Department

Quality of the nonsterile product

Aseptically packaged product

Panich Choenthanomwong Training and Quality Department

Factors affecting the sterility rate of an aseptic production

Panich Choenthanomwong Training and Quality Department