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Aseptic Packaging May, 2009 Contents 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 Contents 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 PRODUCT PACKAGING - BASICS 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 packaging 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 particulates. Packaging of non-sterile product to avoid infection by micro-organisms. 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 Source: www.gpap.ca 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 preservatives • 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) Source: www.envis-icpe.com 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 storage. 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 LuquiPak 4.Preformed Rigid plastic containers Metal box AsePack Gasti Crosscheck 5.Thermoform-fill-seal Benco Asepack Bosch Servac Conoflast Thermoforming USA 6.Flexible Plastic containers Scholle Liqui Box a. Bag-in-box type Asepak b. Pouches Prepac Prado pak Inpaco Bottlepack c. Blow - moulded Serac ALP Section II PACKAGING DEVELOPMENTS 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 follows: – 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 distribution. Longitudinal and Transverse seam are important. Source: www.envis-icpe.com 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. Source: www.tetrapak.com 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 Source: www.tradeget.com 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 cracking. • 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 wood. 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 Recycling/Waste management Production of packaging material Distribution Production 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 pressure. 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 drinks - Customized Functional Waters Innova Database Analysis ASEPTIC PACKAGING 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 Introduction 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 - Croatia 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 - Indonesia 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 Japan 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 Source: www.tetrapak.ca Tetra Aseptic Packs Source: pffc-online.com Source: www.gpap.ca Tetra Aseptic Packs Source: www.sustainableisgood.com Source: www.littleviews.com Tetra Aseptic Packs Source: www.lanpak.ca/packaging.htm Source: www.oakleaf-european.co.uk Tetra Aseptic Packs Source: www.tetrapak.com Tetra Aseptic Packs Source: www.tetrepak.co.jp Source: www.tetrapak.com Aseptic packaging Source: www.asepticbaginbox.com in aluminum foil Tetra Aseptic Packs Source: www.dotfood.eu Source: www.packagingeurope.com Source: savushkinproduct.com Source: www.thehealthywayfoods.com Sky long aseptic brick Source: www.caspllc.com www.21food.com Summary 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 Convenience • 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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