Current situation and development prospect of asep

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The current situation and development prospect of aseptic packaging technology in China

the current situation of aseptic treatment and packaging technology application

aseptic treatment and packaging technology was born in the 1930s, and has a history of more than 70 years. In the development process of more than 70 years, aseptic treatment and packaging technology have crossed two glorious milestones. First, in the early 1940s, Martin Dole of the United States developed a sterile packaging system for tinplate cans. This system uses direct or indirect heaters to pre sterilize food, uses superheated steam to sterilize tinplate cans, and completes filling and sealing in a sterile environment sterilized by superheated steam. Second, in the early 1960s, loelinge & regez in Sweden developed a packaging system for dairy production that used hydrogen peroxide to sterilize flexible packaging materials. This system uses direct steam jet to sterilize milk and hydrogen peroxide to sterilize packaging materials. This system is now TetraPak aseptic packaging system. In addition to using steam and hydrogen peroxide as the bactericide of packaging containers, with the advance of time and the development of technology, many other important sterilization methods of packaging materials have been developed, including strong ultraviolet light, hot air γ- Radiation, large pressure loss of oil pump and system, hot forming, etc. The development and successful application of these new sterilization methods have led to the endless emergence of sterile packaging systems, which can not only use a variety of packaging materials and containers, but also apply to different packaging capacities. At present, more than 30 companies in the world have provided various types of aseptic treatment and packaging systems

at present, 80% of the retail sterile soft packaged foods in the world are milk or dairy products, and almost 90% of the sterile small packages (retail capacity) in the United States are fruit juice beverage products. Bulk (220l) aseptic packaging is widely used in the United States, mainly for tomato pulp and fruit pulp products

aseptic packaging technology in China shows a bright prospect of vigorous development. Now there are a wide variety of aseptic processing and packaging systems with different models. Although most of these systems are imported, there are also many domestic equipment. In China, sterile small package products are mainly fruit juice and fruit juice drinks, milk and milk containing materials. Large volume aseptic packaging products are mainly tomato juice and concentrated fruit juice, such as concentrated apple juice

today's aseptic treatment and packaging technology can only be used to produce homogeneous liquid food. There is still a lot of research and development work to be done on the aseptic treatment and packaging of granular food, especially the aseptic treatment and packaging system of low acid block food will take several years to be applied in industry

nevertheless, aseptic treatment and packaging technology have played an important role in the food industry and are worthy of being a brilliant "flower of art"

basic requirements for aseptic treatment and packaging

aseptic treatment and packaging is a processing technology that fills pre sterilized products in a sterile environment and seals them in sterile containers. Aseptic packaged products can be stored at room temperature for a long time

three basic terms are used in aseptic packaging: aseptic system, aseptic processing system and aseptic packaging system

aseptic system refers to the whole system required for the production of sealed and packaged commercial sterile products, including product sterilization system and packaging system

aseptic processing system refers to the system that sterilizes products and transmits sterile products to packaging equipment

sterile packaging system includes all equipment that fills sterile products in sterile containers and seals them under sterile conditions

key technology of aseptic treatment. Aseptic treatment system, i.e. product sterilization system, is mainly composed of delivery pump, heater, holding pipe, cooler, back pressure valve and aseptic storage tank. Since sterile packaging products are continuously transported by pumps, sterilization of sterile packaging products is continuous, so it is also called continuous sterilization

the sterility required for continuous sterilization of sterile packaged products is the same as that of conventional canned food. However, sterile packaging products are usually sterilized by high temperature short time (HIST) or even ultra-high temperature instantaneous (uhst) before being loaded into containers. High temperature short-time and ultra-high temperature instant sterilization are the same as conventional canned food sterilization, but also have its particularity

at present, there is no clear definition of high-temperature short-term sterilization in the world, but it is generally believed that for low acid food with pH greater than 4.6, the sterilization method with temperature of 138 ~ 145 ℃ and time of 1 ~ 30s is high-temperature short-term sterilization, which is also the common process procedure for sterilization of most sterile packaged low acid food. The sterilization temperature is 150 ~ 166 ℃, and the time is 0.1 ~ 0.01s, which is called ultra-high temperature instantaneous sterilization. A few product sterilization systems heated by direct steam injection have been adopted and even become other failure situations. For acidic food with pH ≤ 4.6, the temperature is 93 ℃ ~ 96 ℃ and the time is 15 ~ 30s, which is called high-temperature short-term sterilization. More specifically, it should be high-temperature pasteurization, which is the sterilization procedure adopted by most sterile packaged acidic food sterilization systems

sterilization calculation and control of sterile packaging products is one of the key technologies for the success of sterile packaging. Sterilization calculation of sterile packaging products depends on sterilization temperature and sterilization time. If the indirect heat exchanger is used in the aseptic treatment system, in addition to the sterilization value obtained in the holding tube of the product at high temperature, a certain sterilization value will also be generated during heating and cooling. The sterilization value of these two parts is the sterilization value of the whole sterilization process

the key technology of aseptic packaging lies in the sterilization of packaging materials or packaging containers, and the acquisition and maintenance of sterility. In order to achieve the above two purposes, it is very important to monitor and record the key control points of the sterile packaging system. Compared with the traditional production mode, the automatic recording and monitoring task of sterile system is much heavier, because the complexity of the inherent technology of sterile packaging and the relevance of many key factors determine the breakthrough of key technologies in material design, batch preparation, preparation technology integration and so on

the type of recording and monitoring system used depends on the fluctuation of various factors in the production process. For example, the preset filling speed fluctuation is very small. When the filling speed is the key factor, the operator monitors to ensure that the filling speed is within the key limit. But if the key factor is temperature, the situation is very different. Because the temperature is affected by many factors and fluctuates greatly, automatic temperature recorder or monitor is needed

there are two types of records of sterile packaging system: one is production records, and the other is instrument records. The instrument record provides a continuous record of the operating status of the sterile packaging system. For automatic recorders, the operator should keep the recording paper clear and indicate the time of starting sterilization, production or the end of sterilization and production. If the production of sterile air polyurethane elastomer base plate is stopped due to insufficient pressure between rail and sleeper or filling problems for some reason, such as low sterilization temperature, the time of stopping production and starting production again shall be marked on the record paper. Production records are manual records in the process of keeping sterile system. The operator should write down the time of occurrence and any information related to corrective actions on the record

for sterile storage tanks, records should indicate that the tank has been sterilized, and whether the pressure of sterile air in the tank is normal. If sterile air is generated by filters, the sterilization temperature and time of filters and sterile air supply system should be monitored and recorded. The record should also show that the requirements of other key factors are met at the beginning of production. The filter media should be replaced at appropriate intervals

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