Aseptic processing

Question 1

Define aseptic processing

Answer 1

The filling of** sterile containers** with commercially sterile product under septic conditions., then the sealing of the containers to prevent contamination.

Includes aseotic packaging

Question 2

What are the applications (describe them)

Answer 2

1 - packaging of pasteruized and sterile products -> extend shelf life / shelf stability (milk, fruit juice, soup, sauce)

2 - Packaging non-sterile product -> prevent contamination (fermented product; ie yogurt)

Question 3

**List differences between product sterilzation, UHT and aseptic process

Sterilization:

Answer 3

• Very low level of MO’s
• Achieved either before or after filling
• After filling: product sterilized
• much longer processing time

Question 4

What is important to remember about the order of operations in aseptic processing?

Answer 4

Aseptic means sterilized BEFORE filling/packaging

Question 5

**List differences between product sterilzation, UHT and aseptic process

UHT:

Answer 5

• Almost fully sterile
• post process contamination is possible
• prolonged shelf life in rerigerated condition

Question 6

**List differences between product sterilzation, UHT and aseptic process

Aseptic process:

Answer 6

• ENSURES shelf stable
• NO post process CONTAMINATION

Question 7

List sterilization methods

Answer 7

• UHT
• Ionizing irradiation (gamma, electron beam)
• Ohmic heating
• Microwave irradiation
• Ultrahigh pressure

Question 8

What all happens withing the asepctic containment

Answer 8

• packaging sterilized
• product sterilized

Question 9

How do you prevent surface contamination? List:

Answer 9

• Mechanical -> brushing, air jet, ultrasound
• Irradiation -> UV, ionizing radiation
• Heat -> steam, hot air, extrusion
• Chemical treatment -> O3, H2O2 (combined with either heat of UV)

Mechanical is cleaning rather than sterilization
H2O2 dip/spray commonly

Question 10

What is the key to aseptic processing?

Answer 10

Everything must be sterile!
- all post-thermal processes must be in sterile environment
- required a CLOSED SYSTEM including several filtration layers
- Air must flow from inside to outside (not reverse)

Question 11

Describe the fill and seal method

Answer 11

1 - preformed containers are sterilized
2 - filled in aseptic environment and sealed
(cup or bottle)

Question 12

Describe form, fill and seal method

Answer 12

1 - packaging material sterilized and formed in sterile environment
2 - filled and sealed
(Tetrapak)

Question 13

Packaging materials

List different packaging materials

Answer 13

• Bottle
• Carton
• Can
• Cup
• Pouch

Question 14

Packaging materials: how they are kept sterile + process

Carton:

Answer 14

1 - ink protected by polyethylene layer
2 - Aliminiunm foil to form barrier from** light** and O2

FORM-FILL-SEAL or FILL-SEAL

Question 15

Packaging materials: how they are kept sterile + process

Can

Answer 15

• Fill seal

Question 16

Packaging materials: how they are kept sterile + process

Bottle (glass vs. plastic)

Answer 16

Glass:
* - fill-seal*
- disadvantage = easy to break
Plastic:
* Fill-seal OR Form-fill-seal
- Advantage = cheaper and safer than glass

Question 17

Packaging materials: how they are kept sterile + process

Pouch:

Answer 17

• Similar to carton system
• Form-fill-seal

Question 18

Packaging materials: how they are kept sterile + process

Cup

Answer 18

Fill-seal OR form-fill-seal