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Aseptic Packaging - Slide 1

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									Aseptic Packaging
         May, 2009

Section – I - Product Packaging - Basics

  • Aseptic Packaging
  • Application of Aseptic Packaging
  • Package Structure and Composition
  • Typical Composition of Tetra Pak Aseptic Cartons
  • Properties of Aseptic Packaging Material
  • Aseptic Processing in TetraPak
  • Aseptic Developments
  • Aseptic Processing – Methodology
  • Aseptic Processing and Packaging

Section – II - Packaging Developments

•   Special Need of Plastics in Aseptic Packaging
•   Sealing of Aseptic Packaging
•   Different types of Closures
•   Types of Aseptic Packages
•   Popular Aseptic Packs
•   Typical packaging applications
•   Advantages of Aseptic Packaging Technology
•   Environmental Impact
•   Extraction of Raw material
•   Alternatives to aseptic packaging:
•   New Product Applications in Aseptic Packaging
         Section I
Aseptic Packaging

   Aseptic packaging can be defined as the filling of a commercially
    sterile product into a sterile container under aseptic conditions and
    hermetically sealing the containers so that re-infection is
    prevented. This results in a product, which is shelf-stable at
    ambient conditions.

   Aseptic Packaging is the important development in the field of

   The first aseptic filling plant for milk was presented in Switzerland
    in 1961.
Application of Aseptic Packaging

There are 2 specific fields

   Packaging of pre-sterilized and sterile products.
          Ex: milk and dairy products, puddings, desserts, fruit and
          vegetable juices, soups, sauces, and products with

   Packaging of non-sterile product to avoid infection by
          Ex: fermented dairy products like yoghurt.
    Package Structure and Composition

    Aseptic package should not only protect the product but also
     maintain the quality of the product. Hence the structure as well as
     composition of aseptic packaging are more complex and vary
     depending on product application, package size and package type.

    Factors such as seal strength and integrity, package shape,
     stiffness and durability, as well as barrier properties determine the
     choice and/or combination of materials required.

    Generally to achieve all required properties, aseptic packages
     incorporate more than one material in the structure that is
     assembled by lamination or co-extrusion process.
Typical Composition of Tetra Pak Aseptic Cartons

   Tetra Pak aseptic cartons are made of three basic materials that
    together result in a very efficient, safe and light-weight package.
    Each material provides a specific function

Properties of Aseptic Packaging Material

• Higher degree of safety, hygiene and nutrient retention in food
• Preserving taste and freshness
• Can be kept for months with no need for refrigeration or
• Efficient (a filled package weight is 97% product and only 3%
   packaging material), using a minimum quantity of materials
   necessary to achieve a given function
• A good example of resource efficiency is its light-weight (among
   the lightest packages available)

    Aseptic Processing in TetraPak

    The Tetra Pak company later became one of the leading suppliers of
     processing and packaging equipment for dairies. Aseptic techniques
     were common in Europe and Asia before they were introduced in the
     United States in the 1980s.

    It is the process by which a sterile (aseptic) product (typically food or
     pharmaceutical) is packaged in a sterile container in a way which
     maintains sterility.

    Sterility is achieved with a flash-heating process (temperature
     between 195° and 295°F (91° to 146°C)), which retains more
     nutrients and uses less energy than conventional sterilization
     techniques such as retort or hot-fill canning.
    Aseptic Developments

    Aseptic containers may range in size from a few fluid ounces to a
     nearly 8-million-gallon aseptic tank on an ocean-going ship. Aseptic
     processing makes worldwide export and import of new, economical
     and safe food products possible. Other common package types are
     drink boxes and pouches.

    In 1991, the Institute of Food Technologists rated the top 10
     innovations in food technology. Aseptic processing and packaging
     ranked No. 1, ahead of juice concentrates, safe canning processes,
     freeze-drying and food fortification.

    In 2007 Dr. Philip E. Nelson received the World Food Prize in
     recognition for his pioneering work in aseptic processing and bulk

    A child is using TetraPak in 1965
    Aseptic Processing – Methodology

    Methodology:
      – Sterilization of the products before filling.
      – Sterilization of packaging materials or containers and closures
        before filling.
      – Sterilization of aseptic installations before operation (UHT unit,
        lines for products, sterile air and gases, filler and relevant
        machine zones).
      – Maintaining sterility in this total system during operation;
        sterilization of all media entering the system, like air, gases,
        sterile water.
      – Production of hermetic packages.

    Sterilization Agents:
      – Heat,
      – chemicals
      – radiation
Aseptic Processing and Packaging
                          Classification of Aseptic filling and Packaging Systems
              CATEGORY                                             EXAMPLES OF SYSTEMS

1.Metal and Rigid Containers Sterilized by Heat
             a. Steam metal containers                  Dole Canning systems
                                                        Drum fillers, e.g. Scholle, PranRica
             b. Hot air Composite Can                   Dole hot air system
2.Webfed paperboard sterilized by H2O2                  Tetra Pak (Brik Pak)
                                                        International Paper
3.Preformed paperboard containers                       Combibloc
4.Preformed Rigid plastic containers                    Metal box AsePack
5.Thermoform-fill-seal                                  Benco Asepack
                                                        Bosch Servac
                                                        Thermoforming USA
6.Flexible Plastic containers                           Scholle Liqui Box
               a. Bag-in-box type                       Asepak
              b. Pouches                                Prepac
                                                        Prado pak
            c. Blow - moulded                           Serac
       Section II
Special Need of Plastics in Aseptic Packaging

   Packaging for aseptic was particularly in demand for Long Shelf-
    Life, High Seal Integrity and Consumer Appeal.

   However, because plastic material is so important to aseptic
    packaging, it is useful to discuss some special properties
    demanded of plastics by aseptic process itself. They are as

    –   Chemical resistance and wet ability
    –   Thermal stability
    –   Low levels of contaminating microorganisms; and
    –   Resistance to ionizing radiations
Sealing of Aseptic Packaging

   Any aseptic system must be capable of closing and/or sealing the
    package hermetically to maintain sterility during handling and

   Longitudinal and Transverse seam are important.

Different types of Closures

   Multiple “Opening” options were also available beyond the punch
    hole and straw option.

      Twist Cap        Stream Cap

                                      Slim Cap opening    Simply Twist
                                                          Screw Cap
    Types of Aseptic Packages
-    Over the past few years aseptic packaging options have multiplied.
-    In 2007, SIG Combibloc alone offered 9 package format series with
     37 packages in various size options.

Popular Aseptic Packs

Aseptically filled Consumer Packages

   –   Bags and Pouches
   –   Bottles and Jars
   –   Carton Boxes:
   –   Composite Cans
   –   Cups and Trays
   –   Metal Cans
   –   Plastic Cans
Typical packaging applications

• Fruit Juices, concentrates, purees
• Tomato Products
• Milk and Cream
• Coconut Products
• Jam

Advantages of Aseptic Packaging Technology

Few advantages in all categories

   -   Process
   -   Protection
   -   Logistics
   -   General advantages
   -   Environmental Impact

Advantages of Bulk Aseptic Packaging

   -   Safety
   -   Reliability
   -   Extended Shelf-life
   -   Product quality
Advantages in Protection

  Food and drinks are optimally protected and keep their high
  quality for extended shelf life.

  - Protection from light
  - Light impairs the taste of milk and reduces the vitamin content
    in many beverages
  - Protection from oxygen
  - Oxygen causes juices to oxidize and spoil quickly
  - Protection from other odors and flavors
  - Other odors and flavors can impact natural product taste
Advantages in Logistics

Lower transport weight
   - A one liter beverage carton weighs only 28 grams verses a
      glass container which weighs up to 380 grams

Lower storage costs
   - Warehousing Efficiency
   - Good stack ability
   - Improved pallet utilization configuration
   – Empty packages are stored flat until ready to be used (unlike
      glass or cans). A standard semi-trailer truck can transport 1.5
      million empty drink boxes versus only 150, 000 glass bottles.
   – Space efficient in transport when filled. Brick shape = more
      product able to be stacked in the truck.
Advantages in general

   Convenience – portable, lightweight, shatterproof.
   Food Safety – cooking and packaging process ensures that the
    liquid is free from harmful bacteria and contaminants.
   No refrigeration required – saves energy both in transportation
    and in storage.
   Requires less energy to heat and sterilize the product than some
    other packaging methods.
   Nutrition benefits – process places less heat stress on foods than
    canning therefore product can contain more nutrients as well as
    taste, color and texture.
   Low packaging to product ratio – typically 96% product and only 4
    % packaging.
Safety and Reliability in Aseptic

Safety due to
   • Steam sterilization of spout, and sterilization effect can be controlled
      and recorded.
   • No chemical sprays used to sterilize the chamber.
   • Spout is tamperproof.
   • Safer sterilization and easier to monitor.
   • No risk of adding chemicals to the product.
   • No risk of laminate material relating with chemicals

Reliability, because:
   • The filling machine is uncomplicated as there is no sterile chamber.
   • Filling is controlled by weight. This ensures accuracy as no adjustments
      for specific gravity need to be made.
   • Customer will have one partner with worldwide service organizations
      and long experience in processing and packaging technology.
Life and Quality with Bulk Aseptic

Extended Shelf-life due to:

   • High oxygen barrier of the laminate. Laminate is less susceptible to flex
   • Secure spout with limited possibility of oxygen permeation. Spout is
      made of HDPE, which has three times less oxygen transmission rate
      compared to LDPE.
   • There is no head space in the bag.

Product quality because:

   • Chemical browning is minimized due to high oxygen barrier properties of
      pouch material.
Environmental Impact
 Renewable Raw Material
   – Aseptic cartons are based on a renewable resource-paperboard from

 Resource Efficiency
   –   Lightweight
   –   Transportation Efficiency
   –   Storage without cooling
   –   Energy efficient production

 Recyclable Material
   – Aseptic cartons are easy to recycle and are being recycled where
     respective collection systems exist

 Small or Zero CO2 Footprint
   – Aseptic cartons have a good performance regarding fossil resource
     consumption and greenhouse gas effect which impacts global warming
Extraction of Raw material

Aseptic Packaging offers Ecological Optimization from Raw
  Material Extraction through Recycling.

                                                       Raw materials extraction

                                                                  Production of
                                                                  packaging material

                                        of packaging

                         * Source: German Federal Environmental Agency, 2000
 Alternatives to aseptic packaging:

 Steel cans – require longer heating times,   heavier to transport, does not
   stack as efficiently, can appear damaged and unusable to the consumer if
   dented in transport, opening not as convenient, can be recycled.
 Retort pouches or tray packaging - Typical processing            conditions
   involve temperatures of 121 degrees for up to 30 minutes. Unlike the metal
   can, retort pouches and trays are susceptible to rupture or seal separation
   during retorting if the internal pressure exceeds the external process
 Glass bottles – may lack the oxygen and light barriers needed to increase
   shelf life, heavier to transport, breaks more easily than aseptic packaging,
   stacking not as efficient, may require refrigeration or preservatives to be
   added to the product, can be recycled.
 Plastic container – can lack the oxygen and light barriers needed to
   increase shelf life, stacking not as efficient, may require refrigeration or
   preservatives to be added to the product, can be recycled if local council
   provides the right facilities.
New Product Applications in Aseptic Packaging

 Traditional Core Segments     New Applications

   -   Juices                     - Wine
   -   Iced Teas                  - Small particle foods
   -   Dairy based beverages         - Soups
   -   Low acid foods                - Salsas
   -   Broths etc                 - Waters
                                     - Natural Spring Water
                                     - Vitamin and Energy Water
                                     - Customized Functional
Innova Database Analysis
Aseptic Packaging
   Introduction
   Quick Stats of Aseptic Packaging Products
   Market Analysis – Top 5 Markets
   Market Analysis – Top 10 Market Categories
   Market Analysis: Top 15 Countries
   Market Analysis: Top 10 Companies
   Aseptic Packaging - Positioning Category Analysis
   Aseptic Packaging - Flavor Analysis: Flavor Group
   Dairy and Soya Drinks
   Juices and Drinks
   Baby Foods and Drinks
   Soups in TetraBrik
   Wines and Alcoholic Soft Drinks
   Vegetables and Fruits in Aseptic Packaging
   Summary

   This section focuses on Aseptic Packaging product launches
    globally from the Innova Database. Search for products where
    Packaging matches one of Tetra Brik, Tetra Fino, Tetra Pak, Tetra
    Pouch, Tetra Prisma, Tetra Rex, Tetra Top across all regions.

   The review contains information regarding new Aseptic Packaging
    product launches from January 2008 to December 2008.

   Market Analysis
   Company Analysis
   Positioning Analysis
   Flavour Analysis
   Aseptic Packaging Product Trends
 Quick Stats of Aseptic Packaging Products

Search for products where Packaging matches one of Tetra
Brik, Tetra Fino, Tetra Pak, Tetra Pouch, Tetra Prisma, Tetra
Rex, Tetra Top across all regions for Date Published between
01/1/2008 and 12/12/2008
Market Analysis – Top 5 Markets
Market Analysis – Top 10 Market Categories
Market Analysis: Top 15 Countries
Market Analysis: Top 10 Companies
Aseptic Packaging - Positioning Category Analysis
Aseptic Packaging - Flavour Analysis: Flavour Group
Dairy and Soya Drinks

                                                                             Dukat Trajno Mlijeko +
                                                                             7 Vitamina - Milk with
                                                                             7 Added Vitamins -
 Alpro Soya Dairy                                    Gogreen Soygurt Jordgubb:
                        Auchan Rik & Rik Batido
                                                     Soy Yogurt Drink in
 Free Shake -           Sabor Vanilla: Skimmed
 Saudi Arabia           Milk with Vanilla Flavor -   Strawberry Flavor -
                        Spain                        Sweden

Lactasoy Soy Milk         Parmalat Vanilla                                  Schardinger Formil Milk-
in Chocolate Flavor -     Flavored Milk -             Indomilk UHT Milk     Austria
Thailand                  Colombia                    Chocolate Drink -
   Juices and Drinks

                          Frugo Pear Flavored
                          Juice Drink - Chile                            Carnini Arance Fior di Frutti
El Corte Ingles Melocoton                     Original Orange Nectar –
 Y uva - Peach & Grape                                                   - Orange Juice - Italy
                                              Saudi Arabia
Juice Drink - Spain

                           Leco Grape
    Berri Dark Grape
    Juice – Singapore      Nectar- Brazil           Dimes Apple Juice-    Scheiber Dynamix
                                                    South Korea           Daries Ltd-India
Baby Foods and Drinks

                                                  Nutriben 8 Cereales Papilla
                                                  Lista Para Tomar - 8 Cereal
                      P'tit Souper Douceur        Baby Food – Spain
Parmalat Len Liquid
                      d'Artichaut – Artichokes                                    Nestle Junior Milk 2+
Formula Milk for 3Yrs
                      Soup for Infants – France
Children - Colombia                                                               Switzerland

                     Semper Smoothie Banan och
Agusha Reconstituted Mango - Banana and Mango
                                                                                Prenagen Chocolate
Apple-Apricot Juice  Flavor Smoothie for Babies - Cow & Gate Ready              Flavored Milk for
with Pulp - Russia   Sweden                       Made Infant Milk for          Pregnant Women -
                                                  Hungrier Babies - UK          Indonesia
  Soups in TetraBrik

  Campbell's V8      Knorr Fish Soup   Auchan Caldo de Pollo       Liebig Pur Soup' Potiron
  Southwestern       with Vegetables   - Chicken Soup - Spain      d'Automne - Pumpkin
  Corn Soup - US     – Belgium                                     Soup - France

Aneto Caldo Natural       Itoen Green Colored
Pollo - Natural Chicken                       Knorr Vellutata
                          Vegetable Soup -
Soup - Saudi Arabia                           Di Spinaci - Ready         Ekstroms Rosehip
                                              Spinach                    Soup - Taiwan
                                              Soup - Belgium
Wines and Alcoholic Soft Drinks

                                                       Sangria Cruzares
                                                       Cocktail - Mexico
                    Pinard Red
                    Wine - Denmark

                                     Don Simon Vino                        Tavernello
Caviro Tavernello                    Rosado Table Rose                     White Wine -
Rose Wine - Italy                    Wine – Saudi Arabia                   Italy
  Vegetables and Fruits in Aseptic Packaging

                                                                              Wal-Mart Great Value
Naplina Sieved             Coop Ceci:           Del Monte Tropical Fruit:     Tomato Pulp - Brazil
Tomato Passata - UK        Chickpeas - Italy    Tropical fruit in sweetened
                                                fruit juices - US

                       Del Monte Sweet
                       Corn Cream Style                                           Knorr Vegetable
SPC Crushed                                                Kelda Kokos: Low       Puree: Vegetable
                       - Indonesia                         Fat Coconut Milk
Tomatoes - Australia                                                              puree made with
                                          Broja Banana     Cooking Sauce -        12 different
                                          Puree - China    Sweden                 vegetables - Spain
Tetra Aseptic Packs

Tetra Aseptic Packs

Source:   Source:
 Tetra Aseptic Packs


Tetra Aseptic Packs

Tetra Aseptic Packs

Tetra Aseptic Packs


                              Aseptic packaging   Source:
                              in aluminum foil
 Tetra Aseptic Packs


                                 Sky long aseptic brick       Source:
   The aseptic packaging is very well accepted in food product applications worldwide as a
    safe and high-quality packaging option.
   Aseptic processing sterilizes food products by destroying the harmful bacteria and
    pathogenic micro-organisms through a tightly controlled thermal process and combines
    the sterile product with the sterile packaging material in a sterile environment, the end
    result is a shelf-stable product requiring no refrigeration.
   Innova Database analysis indicates that Dairy & soft Drinks are the top markets for
    Aseptic packaging. Recently, wines, soups, baby foods and Water are added to aseptic
    packaging line.

Packaging must address the following
• Food Safety
• Convenience
•   Affordability

• Cost-effective transport and storage with minimal environmental impact
•   No need for cold chain
• Makes safe food available the whole year

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