2.Aseptic System.6

7/28/2019 2.Aseptic System.6

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Panich Choenthanomwong

Training and Quality Department

6 June, 2013 Page 1SIG Combibloc

Aseptic Filling Machine

Sleeve

feed

Sleeve

forming

Base

activation

Base

folding

Base

pressing

Peroxide

sterilizationDrying Filling

Top

sealing

Top

formingConveying

Aseptic Zone






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.






Preservation of foodstuffs by heat treatment






Preservation of foodstuffs by heat treatment






Aseptic system

comparison of processing method

Packaging Product

Sterilisation

of sealed packs

Packaging Sterilisation

Aseptic Zone

Aseptically

packed product

Sterilisation

Packed,

sterilised product

Filling and

sealing

Microorganisms

(bacteria)

Microorganisms

(Bacteria)

Filling and

sealing

Product






Factors of influenceon the asepticprocess:

Aseptic filling

of beverages,dairy and foodproducts intocarton packs

Aseptically packaged

product

ASEPTIC

Sterilisation liquid/

Package sterilisation

Filling machine

sterilisation

Human

factor

Quality of the non-sterile product

Product

heating

Aseptic






Factors affecting the sterility rate of an aseptic production

1. The Microbiological load of the raw material

2. Sterilization effect of UHT process3. Cleanliness and sanitary conditions of plant

4. Maintenance of aseptic conditions during production

5. Microbiological contamination of carton’s surface (inner)

6. Efficiency of sterilization of carton’s surface

7. Packages integrity8. 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.







Three main processes are used for the decontaminationprocesses:

Steam sterilisation

H202 vapour sterilisation Filtration of air

Filtration of Nitrogen and pressurised air for tank overpressure

(Options)







1.Steam sterilisation

Product pipe system,

Product tank,

Product valves,

Filling valves

Air (Pall) filters for product tank pressure

Nitrogen filters for Nitrogen injection







2. H2O2 vapour sterilization.

- Pocket chain

- Drying zone

- Filling zone

- Steam injection

- etc







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






Combibloc filling machine operation.

Conclus ion.Condition for aseptic operation of the combiblocfilling machine

1. Operator 2. Filling machine






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 machineis prohibited


C bibl filli hi ti







2. The f il l ing m ach ine

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 partsinstalled into the aseptic zone.

(All parts must be cleaned and dried)

C bibl filli hi ti







3. The filling machine must be cleaned immediately after the end of production (manual cleaning, pocket chaincleaning 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.






A ti Filli M hi







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 asepticzone



Additional options not available for all formats:

Dedusting unit (to remove dust particles out of the package before it entersthe aseptic zone)

Pocket chain desinfection unit (normally potable water is used for chain

cooling)

A ti Filli M hi



















cooling)

A ti Filli M hi



















cooling)






Sterilisation

Product

The liquid food is commercially sterilised.






SterilisationSterilisation

Product Packaging

The sleeves are sterilised.







Product Packaging

Aseptic ZoneFilling and sealing

The sterile product is

filled into sterile

sleeves under sterile

conditions in

aseptically.







Product Packaging

Aseptic ZoneFilling and sealing

Aseptically filled product

The product is "commercially

sterilised" using a conceptcalled "aseptic processing"








Aseptic and aseptic filling system






Aseptic and aseptic filling system






UHT and “Commercial sterility”

Making Milk Last Longer






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 ?

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.)

Why does the UHT milk last so very long ??






y does t e U ast so e y o g

• 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.

Definition - Commercial Sterility






y

“ A commercially sterile product is free from micro organisms which grow under

normal conditions of storage.”

UHT milk does not contain any bacteria capable of multiplication under

normal conditions of storage and distribution.

Same meaning - different words.






No bacterial

growth

=long shelf life






Aseptic system






p y

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 multiplicationunder normal conditions of storage and distribution.

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)













Aseptic system






Why UHT product can keep long time in room

temperature ?

1.UHT equipment ,product line and CFA are cleanedand sterilization before production.

2.Product sterilized by UHT system.

3.Package sterilized by H2O2

Aseptic system






4. Product filled into package under aseptic condition

5. Integrity of the package to prevent post

contamination.

Aseptic system

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