Made by :
- Almeyda, Jesus
- Palomino, Nicolas
- Peña, Karina
CHEMICAL TREATMENTS
HYDROGEN PEROXIDE
Combination of peroxide and heat to sterilize the surface of
paperboard laminate packaging material.
OBSTACLE : It has been found to induce higher heat resistance in
Bacillus sporothermodurans strains. DESTRUCTIVE EFFECT: • Peroxide solution
Temperature of 70°C, a minimum concentration of 30% and a concentration = 500ppb
minimum time of 6 s are necessary. • Quantity applied to the
packaging material per
*Bacillus sporothermodurans*
unit area
The sterilization conditions have been determined empirically • The intensity of the
irradiant heat
• The temperature
• Quantity of the drying air
• Number of SYSTEMS of this. These processes are briefly described and the time for which it is
in the following : applied.
DIPPING Bath of 30%– 33% H2O2 / Jets of sterile air.
PROCESS
SPRAYING H2O2 is sprayed through nozzles onto prefabricated
packages /Then dried using hot air (130ºC)
PROCESS
RINSING It can be rinsed with peroxide or a mixture of
PROCESS peroxide and PAA / then dried with hot air
COMBINED WITH Optimum effect being at a relatively low
UV IRRADIATION peroxide concentration of between 0.5% and
AND HEAT 5% / Reducing the effectiveness of sterilization
PERACETIC ACID (Peroxyacetic Acid)
• It is produced by the oxidation of acetic acid by H2O2, and the
solution containing PAA and H2O2 is effective against resistant
bacterial spores, even at 20°C .
• Concentrations of PAA greater than 60% / Normally stored at
concentrations of 40%.
• Used for : Sterilizing filling machine surfaces / Packaging
materials PET bottles prior to aseptic filling
VERIFICATION OF STERILIZATION PROCESSES
• By inoculation of the surface of the web, cup or lid stock with the proper
concentration of the test organism and allowing this to dry.
• At least 100 containers should be tested for each time, temperature or sterilizing
agent concentration.
ASEPTIC PACKAGING SYSTEMS
CARTON SYSTEMS
1. The outer polyethylene (12 gsm) protects the ink layer and enables
the package flaps to be sealed.
2. The bleached paperboard (186 gsm) serves as a carrier of the decor
and gives the package the required mechanical rigidity.
3. The lamination layer of polyethylene (20 gsm) binds the aluminum
to the paperboard.
4. The 6.3 μm thick aluminum foil (17 gsm) acts as a gas barrier and
provides protection of the product from light.
5. The adhesive layer of poly(ethylene-co- methacrylic acid) (6 gsm)
ensures good adhesion between the aluminum foil and the
polyethylene.
6. The inner polyethylene layer (29 gsm) provides a heat sealable
liquid barrier
FORM-FILL-SEAL CARTONS :
The LS-strip is composed of a core layer of either PET
or EVOH ; coated with LDPE or LLDPE or a mixture
of the two.
The packaging material is sterilized using one of two
procedures: a wetting system or a deep bath system.
Wetting system, a thin H2O2 film (15%–35% concentration),
containing a wetting agent (Tween-20 or polyoxyethylene sorbitan
monolaurate at 0.2%–0.3%)
Deep bath system, the packaging material is fed through a deep bath
containing H2O2 (35% concentration) at a minimum temperature of
70°C, the residence time being 6 s.
• The sterilized packaging material is fed into a machine where
it is formed into a tube and closed at the longitudinal seal by
induction heating
• The tube is then filled with the product and a transverse
induction seal made below the level of the product, thus
ensuring that the package is completely filled
• The sterilization, filling and sealing processes are all
performed inside a chamber maintained at an over-pressure
of 0.5 atm with sterile air.
Cardboard packaging
• 75-80% of a beverage container is cardboard (by weight).
• Tetrapak uses only the paper from waste bins that have
previously certified their forests by the international ISO
standard.
• Polyethylene represents 15-20% of the weight of the
beverage container.
• Holds the different packaging materials together
• The outer layer is only 12 microns thick.
• The aluminum sheet only represents a maximum of 5% of
the weight
• Acts as an effective barrier against oxygen
• Enables safe storage of packaged products at room
temperature
• Aluminum sheet thickness is 6.5 micron
• TetraPak uses water based inks, with organic pigments and
without heavy metals.
Aseptic Packaging
• The flat, disassembled material passes through a hot
hydrogen peroxide bath
• The 35% peroxide concentration is heated to 70 degrees
Celsius for six seconds, then removed from the packaging
material using hot pressurized air.
• 1. Polyethylene: protects against outside
moisture
• 2. Paper: For stability and strength
• 3. Polyethylene: Adhesion layer
• 4. Aluminium foil: Oxygen, Flavour and light
barrier
• 5. Polyethylene: Adhesion layer
• 6. Polyethylene: seals in the liquid
Filling and sealing
• The filling and sealing machines must be sterile
before packaging and during the production
process
• This is accomplished using hot air or steam
Glass Bottles
• Packaging transparency: The consumer can see the
inside of the packaging to verify the appearance of the
product.
• Barrea against light, especially in amber packaging for
high-fat products.
• They are inert, so they do not produce a chemical
reaction with any element (with the exception of
hydrofluoric acid).
• They are waterproof
• They resist high temperatures
• Reusable and recyclable
• Clean, pure and hygienic. Closed are completely
airtight.
Can system
• The system uses superheated steam at temperatures up
to 225 ° C for up to 40 s to sterilize cans and can ends.
• After the cans are filled with the cold, sterile product,
they are sealed with a conventional can sealer
• Superheated steam is used to maintain asepsis during the
filling operation and results in a high vacuum in the can
(27 cm Hg )
• At the seam temperature of 220 ° C, it is very plastic,
and for this reason, the can with seam must be
transported vertically for at least 15 s to allow the
compound to hermetically seal and seal the can
Sachet and Pouch
system
•To make this container, a vertical machine is used to
form, fill and seal inside a sterile chamber, the
material is passed through 35% H2O2 and then
drained, dried with hot air and irradiated with UV
light.
•The film used is typically a laminate of LLDPE Chalk filled plastic material frame for aseptic bag.
with a central layer of EVOH copolymer and black
carbon to give the bag the required shelf life plus
they have flap seals on all four sides.
•In 1997 a bag was marketed that, unlike cardboard,
was replaced by paper, but recently, a multilayer
plastic bag material was marketed.
Bag-in-Box System
• It is used to pack UHT products. It consists
of a filler that provides a sterile heat-sealed
PP externo
product under completely safe conditions. mPET
• During the filling process it remains sealed PET
until the consumer opens the package, thus EVOH
eliminating any risk of product LLDPE interno
contamination during storage and transport.
The bags range in size from 1.5 to 1400 L
Structure of the bag used for the aseptic bag-in-
and contain EVOH and Metallic PET
box system for the packaging of UHT products.
(mPET).
• Flat tubes This system uses a polymer in the
form of a flat pipe to form a bag with a
transverse seal, the inside of the tube is
sterile due to the temperature reached during
the extrusion process.
• The tube
Is fed from the reel into a chamber in which an
overpressure of air occurs. The sachets are
sealed at the bottom, cut, and moved to a filling
section.
CUP SYSTEMS
Preformed plastic cups
• The cups are generally made of HIPS, PP or
coextruded multilayer polymers.
• The vessels are fed to a conveyor located
inside a sterile tunnel, then emptied inside
with a 35% H2O2 solution and after 3 s, the
solution is removed with hot compressed air
at T max 400 ° C.
• The inner surface reaches a T of 70 °, then
they enter a sterile chamber where
sterilization is completed by spraying with
sterile water and drying with hot air.
• The lid material (usually aluminum foil with a
thin layer of thermoplastic polymer) is
sterilized with 35% H2O2 which is then
removed by heat.
Form, fill and seal cups
• The plastic material is fed from a roll to a
thermoformer, then the co-extruded multilayer
material incorporates a barrier layer of PVdC or
EVOH copolymer.
• The advantages of thermoforming cups is that it
generates lower costs, simplified handling, higher
performance, lower storage requirements and the
maximum sterility of the cups and lids pass
through sterilizing baths.
• An alternative type of form-fill-seal system
sterilizes containers after they have been formed
using saturated steam under pressure at 3–6 atm
(135 ° C - 165 ° C) for 1.5 s. The use of high
temperatures guarantees sterility.
• It is important to maintain a uniform wall
thickness, in addition the cover material also has a
removable outer layer that is a special feature of
the system.
ASEPTIC PACKAGE INTEGRITY TESTS
• The evaluation of the integrity of the container
is one of the most critical problems in aseptic
food packaging since the package must
guarantee the safety and quality of the
product.
• The aseptic package is also important and
must be evaluated before aseptic packaging.
Various performance tests are used to evaluate
its integrity during distribution and handling.
• The integrity of the packaging and seal has
traditionally been verified using destructive
methods such as biotesting, electrolytic tests,
dye penetration or bubble tests.
• There is a growing interest in nondestructive
package integrity testing as it enables online
testing of every package produced, leaving
both the product and the package intact.
(computer aided video inspection) These tests
must meet three criteria: non-specificity, high
sensitivity and speed.
FLEXIBLE PACKAGING : RIGID PACKAGING :
• Packages that are known from roll or coil • They are those containers that have their basic
materials. shape from the moment they are
• Generally the equipment that forms the package is manufactured.
the same that fills and seals it.
• After they have been filled and covered, rigid
EXAMPLE: FORM-FILL-SEAL CARTONS
gaskets are subdivided into the following
• These are formed to appear from laminates made groups.
with different materials such as aluminum ; celofan
paper: Blister and carafes ; etc.
THE MOST USED PLASTICS IN RIGID
PACKAGING ARE :PE;PS:PP; PVC
METALLIC PACKING : SHEETS
WOOD PACKING : FINAL PACKAGING ON
PRODUCTS
GLASS PACKING TRANSPARENCY ; INERTIA AND
RECYCLABILITY
