What makes aseptic different from hot-fill processing?
Aseptic is a desirable alternative to hot-fill or retort processing because it doesn't expose products to extended periods of high thermal temperatures , which can lead to vitamin, color, taste, and texture degradation. The aseptic process ultimately ensures a better quality product that can still maintain shelf-stable distribution.
What is aseptic technique and why do we use it?
Aseptic technique is a procedure used by medical staff to prevent the spread of infection. The goal is to reach asepsis, which means an environment that is free of harmful microorganisms.
What is the difference between aseptic and sterile?
- Creating barriers by wearing sterile gloves
- Using environmental control by allowing only a couple of medical professionals in the room with the patient
- Performing equipment preparation by opening sterile packaging that consists of a sterile catheter. ...
What are interventions in aseptic manufacturing?
Interventions & Risk In evaluating aseptic processing we must be fixated on the need to avoid interventions, and where they are unavoidable to minimize their impact as much as possible. Routine interventions are activities that are inherent parts of the aseptic process and integral parts of every batch. Non-routine interventions are activities
What is an example of aseptic processing?
Sterilization of product by heating and immediate cooling. Sterilization of containers and lids using steam. Filling of cooled products aseptically into previously sterilized containers. Sealing of lids at an atmosphere of saturated or super heated steam.
Why aseptic food processing is important?
The safety of food and beverages produced is of paramount importance. Because aseptic packaged products are shelf stable, they are stored at room temperature. If proper processing and packaging is not performed, these products can be compromised, putting the consumer at risk.
What is the meaning of aseptic technique?
Aseptic technique is a collection of medical practices and procedures that helps protect patients from dangerous germs. Bacteria, viruses, and microorganisms are everywhere, so using aseptic technique can help keep important equipment from being contaminated.Apr 25, 2021
What is the difference between aseptic and sterile?
In the context of medicine, aseptic and sterile both mean germ-free. Aseptic is most commonly applied in the context of techniques and procedures, while sterile is most commonly used to describe environments and instruments that have been cleaned (sterilized). Sterile also means “incapable of producing offspring.”Sep 23, 2021
What is the difference between aseptic processing and canning?
Aseptic processing and conventional canning are both thermal processes that include heating, holding, cooling, and packaging steps. In aseptic processing, packaging is done after the heat transfer steps, so product quality as well as packaging size and material options are generally improved.
What are the 5 principles of aseptic technique?
These principles include the following: (1) use only sterile items within a sterile field; (2) sterile (scrubbed) personnel are gowned and gloved; (3) sterile personnel operate within a sterile field (sterile personnel touch only sterile items or areas, unsterile personnel touch only unsterile items or areas); (4) ...Sep 11, 2016
What is aseptic processing?
Aseptic processing allows for the food to be properly sterilized outside the container and then placed into a previously sterilized container, which is then sealed in a sterile environment. Most systems use ultra-high temperature (UHT) sterilization to sterilize the food product before it is packaged.
Why is aseptic processing more expensive than canning?
Aseptic processing costs more than canning because sterilization of the packaging materials requires different machinery and can get complex. In addition, maintaining air sterility in the processing room is difficult.
What factors affect the aseptic container?
The following factors may influence the choice of packaging material for aseptically processed products: functional properties of the plastic polymer (gas and water vapor barrier properties, chemical inertness, and flavor and odor absorption or scalping ), potential interactions between plastic polymer and food product, desired shelf life, economical costs, mechanical characteristics of the packaging material (molding properties, material handling characteristics, and compatibility with packaging and sterilization methods), shipping and handling conditions (toughness, compression), compliance with regulation, and targeted consumer group.
What are the categories of aseptic packaging?
Aseptic packaging are generally placed in the following categories: fill, erect, form, thermoform , blow mold, and bulk packaging and storage systems. Fill and seal. The containers are filled and sealed in a sterile environment to avoid contamination. Erect, fill and seal.
What nutrients are retained in aseptic canning?
Due to the significantly lower processing time and temperature range used in aseptic processing compared to conventional sterilization, such as canning, products that are aseptically processed are able to retain more nutrients. Riboflavin, pantothenic acid, biotin, niacin, and vitamin B6 are unaffected.
Why are aseptic facilities required?
To ensure commercial sterility, aseptic processing facilities are required to maintain proper documentation of production operations, showing that commercially sterile conditions were achieved and maintained in all areas of the facility.
What vitamins are lost in aseptics?
Approximately 10% of thiamine and vitamin B12, approximately 15% of folic acid and pyridoxine, and approximately 25% of vitamin C are lost during aseptic processing.
What is used for aseptic sterilization?
Aseptic processing equipment sterilization procedures often use steam or hot water under pressure. Packaging equipment and packaging materials are sterilized with various medium or combination of mediums (i.e., saturated steam, superheated steam, hydrogen peroxide and heat and other treatments).
What is a start up procedure?
Start-Up- The firm must follow their filed scheduled process for bringing the equipment to a condition of commercial sterility. A lack of proper time/temperature sterilization of the equipment is a process deviation and must be handled in accordance with 21 CFR 113.89. The thermocouple indicating sterilization temperature for the equipment will probably be the same one used to indicate the temperature during operations, and should be located in the most-difficult-to-sterilize area.
How to determine if a sterile filter is used?
If a sterile filter is used, determine the specifications of the filter, filter location and number of filters. Determine if the firm changes the filter at intervals recommended by the manufacturer or process authority for their method of use. Filter changes should be documented on the processing records.
Why is product formulation critical to the process?
The conductivity and electrical resistance of the product influences the heating rate. Because of this, product formulation becomes critical to the process. Food products, which are not good conductors of electrical current, are not good candidates for ohmic heating.
What is a recording device in sterilization?
Recording devices - In order to demonstrate that the required sterilization is accomplished, firms use automatic recording devices. During the inspection it is important to document the number, location, and type of sensors used. In a steam sterilization system, such as the Dole unit, the basic components of the system are:
What is aseptic processing?
Aseptic processing is defined as “handling of sterile product, containers, and/or devices in a controlled environment, in which the air supply, materials, equipment, and personnel are regulated to maintain sterility” (ISO 13408-1, 2008).
How was the aseptic system maintained?
Aseptic conditions were maintained by a number of measures such as disinfectants, a steady stream of superheated steam, UV radiation etc. The aseptic enclosure was kept at slight over-pressure to prevent penetration of air from outside.
What is terminal sterilization?
Terminal sterilization. One of two type of processing methods (also aseptic processing) to help eliminate the risk of infection; associated with sterility assurance level (SAL) and is predictive within a measurable range based on the likelihood that one disease-causing germ remains after sterilization.
What is the process of removing germs from objects?
Decontamination . A process that removes germs from objects, resulting in the ability to safely discard and/or to handle and reuse. Disinfection. A procedure utilized in the elimination of most, if not all, disease-causing (pathogenic) microorganisms on inanimate objects with the exception of bacterial spores.
How were cans sterilized?
The cans and lids were sterilized with steam or a mixture of superheated steam and air. The sterilized food and the sterile cans met in an aseptic enclosure that contained the filling machine and the seamer, closely coupled.
What do you need to know about aseptic processing?
9 things you need to know about food and beverage aseptic processing. 1. Product compatibility. The first step in planning for aseptic processing is to determine whether aseptic processing is compatible with your product.
Why is it important to go aseptic?
One of the biggest benefits of going aseptic is producing high-quality food and beverage packaged goods that are shelf stable for long periods of time under normal storage conditions. Because the products don’t need to be refrigerated in the supply chain or at the retail outlet, you can not only save the cold chain costs ...
Why is food safety important?
The safety of food and beverages produced is of paramount importance. Because aseptic packaged products are shelf stable, they are stored at room temperature. If proper processing and packaging is not performed, these products can be compromised, putting the consumer at risk. Every process step and piece of equipment involved in ...
What is aseptic validation?
Validation of aseptic processes is not a single-time operation but a holistic approach that starts at product and process development and ends when a product or equipment is retired. The approach must include product development, equipment commissioning, plant startup, microbial validation, changes in process or product, ...
What training is required for food production?
All operations personnel, including plant management, quality control, maintenance and engineering, must be properly trained on the production of high-quality and safe foods. This training should not only include Current Good Manufacturing Practices and Better Process Control School but also provide ongoing professional development and refresher courses. Training must be an ongoing process to prevent complacency.
Does aseptic processing eliminate preservatives?
Plus, aseptic processing may even allow you to reduce or eliminate preservatives in your product. This offers marketing opportunities for the growing number of consumers who want clean-label packaged food and beverages that are sustainably produced.
1. Coordinating Processing Operations
Every part of the system, from purchasing, utilities, ingredient dosing, batching, and mixing, to the thermal process, control, and data recorder, must be designed with the purpose of operating as designed—concurrently—at all times.
2. Success Comes from a Good Plan
Aseptic processing design requires planning for several scenarios based on the flexibility needed by the producer as well as the variability in ingredients and supply chain. Aseptic “hidden costs”—such as downtime for maintenance and sanitation, preventive maintenance, calibration, and inspections—should be considered from the start.
3. Validation Is Not a One-Time Activity
Validation is typically associated with commissioning and hazard analysis and critical control points ( HACCP ), but in real life, it’s a continuous activity that is closely tied with operations and quality.
4. People Make the Difference
This is one of the biggest culprits in waning vigilance over time for aseptic processing. Every employee involved in the validation of aseptic processes—operations, quality control, plant management, maintenance, and engineering—should receive training on high-quality and safe foods.
5. Quality Assurance
Testing goes hand in hand with coordinating processes. The failure to maintain accurate records and test products periodically can cause the quality to diminish, risking contamination and serious illness, including contamination with Clostridium botulinum.
What is an aseptic?
Aseptic is a word expressing independent sterilization of food and packaging and integration in a sterile environment to produce packaged products capable of safe distribution at ambient temperatures.
How does an aseptic carton exit?
Exit of the sealed carton is through a narrow slit under positive pressure of sterile air. Aseptic filling of cups, bowls, and tubs (and some laminated paperboard cartons) is analogous to that for cartons but could also be accomplished using a two-phase process—one for liquid and the other for the solid particles.
What is the chemical that destroys microorganisms in a package?
Simultaneously—or perhaps not, in some “re-sterilized” instances—the package is exposed to a system that destroys microorganisms—a chemical such as hydrogen peroxide; acidified water for high acid foods; ionizing radiation such as gamma or beta rays; or even thermal energy.
Overview
Effects on food quality
Aseptic processing preserves food quality through fast heat treatment followed by a short holding time and rapid cooling. Compared to canning where food products are subjected to high temperature processing, the fast heat treatment provided by aseptic processing enables heat-sensitive characteristics of the food to be better retained.
The flavor of aseptically processed food products is minimally changed. Dairy products could ha…
Historical development in foods
Aseptic processing was derived from Olin Ball's heat-cool-fill (HCF) machine that was developed in 1927. While HCF was successful in improving the sensory quality of the processed chocolate milk as compared to canned product, the use of the equipment was hindered by its cost, maintenance, and inflexibility to process various container sizes, rendering the machine a failure.
Processing
Aseptic processing allows for the food to be properly sterilized outside the container and then placed into a previously sterilized container, which is then sealed in a sterile environment. Most systems use ultra-high temperature (UHT) sterilization to sterilize the food product before it is packaged. UHT sterilizes food at high temperatures usually above 135 C for 1–2 seconds. This is advantageous because it allows for faster processing, usually a few seconds at high temperatur…
Packaging material
Aseptic packaging consists of filling and sealing a sterilized packaging material with a sterilized product. Aseptic packaging material not only has to assure sterile conditions within the package and protect the product from physical damage, but also maintain the quality of the product inside the packaging. To achieve this, a laminate material is formed from the following components: se…
Aseptic packaging consists of filling and sealing a sterilized packaging material with a sterilized product. Aseptic packaging material not only has to assure sterile conditions within the package and protect the product from physical damage, but also maintain the quality of the product inside the packaging. To achieve this, a laminate material is formed from the following components: se…
Advantages and limitations
Foods that are processed aseptically have better nutritional, vitamin, and natural pigment retention (chlorophyll, anthocyanins, betalains, carotenoids) compared to canned food products because of the lower temperature the foods are subjected to upon processing. Aseptic processing provides flexibility in using various container sizes as well as possibility of addition of bioactive and heat-sensitive components after processing (probiotics, omega-3 fatty acids, conj…
FDA inspection and regulation for aseptic processing
Inspections of aseptic processing is one of the most complex inspection of food manufacturing operations. Process authorities are required to establish a process that ensures commercial sterility for the following:
1. The product
2. All equipment including the hold tube and any equipment downstream from the holding tube such as the filler
See also
• Blow fill seal
• Cosmetics
• Dietary supplement
• Food and Bioprocess Technology
• Food chemistry