The term “Aseptic” is frequently heard in the food industry. Aseptic is one technic for producing and packaging processes in food industries and is a pre-sterilization processing technic for liquid products (particularly food or medicines). The aseptic process can create the capability for a sustainable product in a way that does not require refrigeration. The aseptic process is an effective method based on the use of high temperature and the short time that the short process time helps to better maintain the quality of the processed food.
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What is aseptic definition in food industries?
Aseptic means disinfecting. Aseptic is an industrial process used for products packaging. The stability of the solution is increased through sterilization in various stages by this process. They can be stored for a long time by performing an aseptic process without the need to freeze food in the refrigerator. In the aseptic process, packaging containers and food products are usually sterilized in separate systems. In addition, the sterile containers are sealed with sterile processed products under aseptic conditions. This means that the sterilized products are filled in sterile containers under completely sterile conditions. Sterile space is a space that is free of microorganisms. The main difference between the aseptic process and conventional sterilization methods is that the thermal process takes place before food is packaged in the aseptic method. However, the product is first packaged and then sterilized in conventional sterilization methods. Therefore, aseptic is a continuous process.
Steps of aseptic packaging system
Aseptic has the following steps:
- Thermal sterilization of the product
- Packaging sterilization
- Maintaining sterilization during product packaging
- Equipment sterilization
- Capping in sterile conditions
- Storage and distribution in sterile conditions
If the food is first sterilized and the packaging is kept free of microorganisms through sterilization, then by maintaining sterile conditions during packaging, the possibility of the presence of microorganisms and the burden of contamination can be minimized. The type and material of packaging are important in the aseptic process.
The sterilizing technics in food industries aseptic
Sterilization of raw materials, packaging materials, and surfaces and equipment are done in the following ways:
- Using supersaturated steam
- Using hot dry air
- Using ultraviolet rays
- Using radiation method (gamma rays, electron beams, etc.)
- Using infrared rays
- Using chemicals such as alcohols and hydrogen peroxide
- Concomitant use of hydrogen peroxide and ultraviolet rays
- Concomitant use of alcohol and ultraviolet rays
- Etc.
Types of aseptic packaging in food industries
Aseptic packaging has 3 types: rigid, semi-rigid, and flexible.
Rigid packaging includes metal cans and glass containers. Semi-rigid packaging includes multi-layered four-sided packages, hexagonal bricks such as tetrabric, hexagonal triangular packages such as Purepack or Gobel Top, etc. Flexible packaging is also provided in sterile bags such as nylon valves.
Advantages of aseptic systems
- Maintaining the quality and nutrients of food due to the use of high temperatures and short times
- No effect of dimensions and size of the packaging container on the amount and penetration of heat
- Increase of the shelf life of products
- Reduction of cooling energy consumption due to no need for a refrigerator to store food
Disadvantages of aseptic systems
- High cost to run the system
- Limitation in use of aseptic process because this process is only used for liquid foods and fluids such as dairy products, all drinking, and juices because the pump is used for product movement.
- Low packing speed compared to similar packaging methods such as canning
Aseptic in factory
Since all steps should be sterilized in the aseptic process, there should be a specific place called the “Aseptic zone”. It should be designed in a way that the environment, equipment, and space should be sterilized to the maximum capacity and possible power. The aseptic process in the factory is in a way that the product enters the aseptic zone after heating and initial production.
The product is cooled in this range and purred inside the aseptic filling machine. All piping systems and pipes in this aseptic area must be sterilized. Aseptic packaging, which consists of sterilization bags, enters the production process and the product is packaged in them.
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