Compared with hot filling technology, heated fillingt cold aseptic filling provides longer shelf life without adversely affecting the quality of the product. product
Aseptic filling technology has created a major transformation for beverage manufacturers in recent years. Previously, shelf life was determined through hot filling technology. In fact, the bottle is sterilized with hot liquid as part of the filling process. It can be effective, however, there are limitations in product quality and the design of the plastic bottle that will affect its ability to withstand the heat applied during the filling process.
In comparison, cold aseptic filling provides a certain shelf life without adversely affecting the quality of the product, providing much more flexibility in bottle design.
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Aseptic filling line
Aseptic filling is a method of quantitative filling is applied in many manufacturing industries, and an aseptic bottling line is more than simply a series of connected machines. It is an integrated system.
Disinfect bottles
Disinfection aims to destroy all forms of microorganisms, rendering them unable to grow. Absolute sterility cannot be achieved. There is hardly any technology that can achieve 100% absolute sterility. For this reason, industrial food manufacturers often refer to it as ‘commercially sterile’.
The effectiveness of the sterilization process is affected by three basic factors: temperature, chemical concentration and contact time. Temperature affects disinfection the most, followed by concentration and contact time.
Disinfection Techniques
There are four sterilization techniques widely applied in the market for high-speed aseptic filling lines that can be applied to both PET and HDPE bottles as well as plastic caps, each technique has its own characteristics. different characteristics:
Wet PAA-based technology sprays liquid Peroxyacetic Acid at high pressure and relatively low temperature. Lightweight PET bottles can withstand wet PAA treatment without significant shrinkage. The simple system can be applied in the same way with flat lids. Immersed in a liquid PAA sterilization tank to distribute the sterilizer on the lid surface and achieve the desired kill rate. Rinse with sterile water to remove the last remaining residue of the PAA solution.
PAA steam treatment uses small amounts of PAA in food-grade steam. This uses a very small amount of chemical but is more complicated because the temperature of the bottle must be closely monitored to ascertain the activation of the disinfectant. Furthermore, it may not be effective enough when required. requires a high level of disinfection.
Sterilize the container with H2O2 CHP using condensed Hydrogen Peroxide vapor when it is injected into the vessel, causing droplets to form on the inner wall. They are removed with hot air. H2O2 CHP treatment is also used to sterilize foil.
H2O2 VHP (Vapourised Hydrogen Peroxide) is a dry sterilization technique that uses H2O2 Bottles are heated before processing to prevent condensation on the inner surface, minimizing residue values.
Aseptic Filling
Aseptic filling technology aims to achieve the best filling speed, accuracy and flexibility while maintaining product and container sterility throughout the filling process . The filling environment must be sterile: the entire area must be thoroughly cleaned and disinfected before production begins. Remove any residual material to avoid the risk of microbial growth.
Bottles can be filled by volume or by weight. Both filling principles each has its own advantages. Volumetric filling uses a magnetic flow meter installed in each filling head to precisely control the level of the liquid.
The flow meter can directly control the valves to start and stop the filling cycle. Most sterile products are liquid so they can be filled without the filling tip touching the bottle. Some products may foam, so careful control of the flow rate is required. Please vary the speed during filling of each bottle to achieve the required accuracy.
Capping and sealing machine
In the aseptic bottling line, capping is integrated into the filling process. When designing capping and sealing machines, opportunities for cross-contamination must be eliminated. This is very important because during this process the risk of the product no longer being sterile is very high.
How to choose the appropriate aseptic filling machine for your product
Aseptic technology is the best production system for the beverage industry, but the investment capital to install an aseptic technology system is very high. The cost/benefit analysis for aseptic bottling is based on three factors: Production volume, required product quality, and bottle design.
In terms of production volume the aseptic filling line is designed to run 24 hours a day and ensures a high level of efficiency. High output allows higher amortization of costs during production operations.
Product quality: At a basic level, aseptic filling technology provides aQuality output with minimal chemicals or additives. Therefore, the advantage of aseptic filling is that it retains the unique characteristics of the raw materials, maintaining their flavor, color and nutritional content.
Bottle design: Filling at room temperature allows for more flexibility in bottle design. If manufacturers want complex designs or frequent design changes, aseptic technology is a distinct advantage.
Address providing reputable aseptic filling machines in Vietnam
Tin Dan is a supplier of machinery and equipment imported 100% from Korea and Europe. Is the exclusive distributor of aseptic filling products from Korea. With many preferential policies, support and consultation are completely free. Contact hotline +84 90 383 5500 or Faceebook Page: https:// www.facebook.com/daychuyenchietrot for detailed information.