As food and beverage trends continue to lean toward natural products, aseptic processing is becoming increasingly popular and chosen by manufacturers. You can read our article here to find out all the advantages of aseptic processing for your beverage brand.
What is aseptic processing?
Aseptic processing is a manufacturing technique that involves filling a pasteurized product into a pre-sterilized container. The filling process happens in a sterile (or aseptic) ambient environment.
Through this process, beverages can be stored without refrigeration, giving manufacturers endless opportunities to develop innovative and convenient product solutions. Thanks to its many advantages, aseptic processing is quickly replacing in-container sterilization of many liquid foods.
Aseptic processing is now used for many products with short shelf life. This includes milk, fruit juices and concentrates, yogurt and ice cream, salad dressing, liquid eggs and cream mixes, among many others. Manufacturers now have a promising answer to their production needs by improving manufacturing operations’ efficiency and improving the safety and quality of these products.
How does aseptic processing work?
The aseptic process allows food and beverages to be properly sterilized on the outside of the container, placed in a previously sterilized container, and sealed in a sterilized environment.
Diagram of an aseptic beverage production line – Tan Do Beverage
Here, we’ll take a look at the 3 stages of aseptic processing for a beverage product
Stage 1: Aseptic sterilization of the product and packaging
The product and packaging will be sterilized separately.
Aseptic sterilization of the product
Most systems use ultra-high temperature (UHT) sterilization to sterilize food before packaging. UHT sterilizes food at high temperatures, typically above 135 °C, for 1-2 seconds. The goal is to eliminate harmful microorganisms (bacteria, yeast, and mold) that can damage or endanger health.
There are two primary methods of UHT sterilization: direct heat transfer and indirect heat transfer.
- Direct Heat Transfer (Injection Method) involves directly injecting steam into the liquid food. The steam rapidly raises the product temperature to the desired level (usually above 140°C). This method is commonly used for UHT milk and other liquid products. It guarantees quick heating without lengthy exposure to high temperatures, which minimizes the destruction of flavour and nutrients.
- Indirect Heat Transfer (Plate Heat Exchanger Method) utilizes a plate heat exchanger to transfer heat indirectly. The liquid food and the heating medium (usually steam) flow through separate channels in the heat exchanger. The product receives heat from the steam as it passes through the plates. Soups, sauces, fruit juices, and other liquid foods work well with this technique.
Aseptic sterilization of the packaging
Sterilising packaging materials is one of the most important steps in aseptic food processing. These containers are sterilised to ensure that no bacteria survive the formation, transportation, and filling processes. Heat, boiling water, chemical sterilants (such as hydrogen peroxide or peracetic acid), radiation, or a mix of these are just a few of the many ways that containers can be sterilized.
A few methods used to sterilize the packaging are:
Steam or hot water under pressure: Packaging material is exposed to steam or hot water under pressure, effectively killing any microorganisms present. They are often used with cartons, flexible pouches, and other specialized containers.
Hydrogen peroxide and Heat: The package surface is treated with hydroperoxide and heat. This method effectively removes any potential contaminants. They are often used to sterilize the surfaces of filling machines, sealing equipment, and other packaging machines.
Other methods, such as irradiation, infrared light, and combinations of techniques, will depend on the manufacturer’s requirements to choose the appropriate method. The sterile product is then filled into the aseptic packaging in a sterilized environment. This is called the Aseptic Filling Zone, where aseptic processing occurs.
Stage 2: Transferring to Aseptic Filling Zone
In the next stage, the product must be fed into the aseptic filler in the aseptic filling zone. The aseptic filler is designed to sterilize the packaging material, fill the sterile product into the package in a sterile environment, and then hermetically seal the package.
To ensure complete sterilization, the sterilized product must be safely transferred to the aseptic filling zone via a system of pumps, holding tubes and tanks.
The Aseptic Filling Zone usually includes:
Grade A area:
- Local zone for high-risk operations, such as filling and making aseptic connections.
- Achieved using a unidirectional airflow workstation (also known as a laminar flow hood).
- Provides uniform air speed of approximately 0.36-0.54 m/s to prevent contamination.
Isolators and Barrier Systems:
- Dedicated area to create a carefully controlled sterile environment.
- Isolators allow operators to handle products without direct contact with the outside environment.
- Barrier systems provide physical separation between operators and products, helping to minimize contamination risks.
Laminar Airflow Hoods:
- These hoods work by providing a continuous stream of filtered air.
- Provide a clean and sterile workspace for component preparation, product filling, and aseptic connections.
Sterilization Systems:
- Equipment used to sterilize components (such as containers and lids) before packaging.
- Methods include heat, hydrogen peroxide vapour, etc.
Environmental Monitoring Systems:
- Continuous monitoring of air quality, temperature and humidity to ensure the sterile environment remains within regulatory limits.
- Alerts the operator if conditions deviate from acceptable levels.
Personal Training and Gowning Area:
- Proper training and gowning procedures are essential to prevent contamination.
- Operators wear gowns, gloves, and protective clothing before entering the sterile area.
Quality Control Stations:
- Sample area to check sterility and quality.
- Ensure finished products meet sterile requirements.
Stage 3: Aseptic filling of final products
In the filling process, depending on the technique used by the aseptic filling machine, the machine must maintain both the product and the container in a sterile state.
This means that whether the material is flowing in the holding tubes or moving through different tubes or the tank, the state must not change. The same applies to raw material containers.
Again, the aseptic machine must have a deaerator to remove air during the aseptic filling process. This will prevent possible oxidation reactions in the products after filling.
Aseptic packages are hermetically sealed, preventing possible contamination after packaging. It helps maintain product integrity.
The final step in the aseptic packaging process is to check whether the products have been properly sealed and whether the batch number is printed.
What are the advantages and disadvantages of aseptic processing?
Advantages of aseptic processing
Aseptic processing is the best production system for the beverage industry, with outstanding advantages such as:
- Product shelf life is extended without the need for refrigeration or preservatives thanks to UHT (ultra-high temperature) sterilization packaging, which allows for faster processing (usually a few seconds at a high temperature of 130–150 °C) and better preservation of sensory and nutritional qualities.
- Beverages using aseptic processing can retain nutrients, vitamins and natural pigments better than canned or bottled products, which usually use hot filling or retort processing.
- Aseptic processing offers the possibility of incorporating bioactive and heat-sensitive components into food. This method uses UHT pasteurization, which minimizes the beverage’s exposure to high heat; therefore, it helps to prevent over-processing and minimize the degradation of heat-sensitive components like vitamins and polyphenols.
- Aseptic processing enables flexibility in bottle design. Unlike traditional hot-fill or pasteurization methods, which may limit design options, aseptic filling accommodates various bottle geometries. Manufacturers can explore multiple options, from grip, pouring spouts to easy-to-hold shapes, and tailor them for user convenience.
- The aseptic beverage filling line contributes to production and cost efficiency. It is designed to run 24 hours daily, allowing continuous production without frequent shutdowns or cleaning. This streamlined process reduces downtime and increases overall production efficiency.
Disadvantages of aseptic processing
However, manufacturers also need to pay attention to the following limits of aseptic processes:
- Operating costs are high, and production standards must always be strictly guaranteed. Aseptic processing requires a microorganism-free, closed, and fully automated environment. Such a facility would need regulated equipment to control microbial contamination. Equipment must also be continuously sterilized with heat and chemicals to remove bacteria.
- Aseptically packaged products are shelf-stable, so they are stored at room temperature. Therefore, if proper handling and packaging are not carried out, these products can be contaminated, putting consumers at risk.
- Building an aseptic technology facility requires a lot of expertise. The manufacturer must be ready to assist the quality assurance department in training, validation, and documentation during installation and manufacture.
- In addition, the up-front investment costs for aseptic filling machines are astronomical. Only a few companies in the world (like TetraPak) have the expertise to make aseptic production lines. And the highly advanced and automated equipment in these production lines is a massive expenditure.
What are the most suitable aseptic packaging for beverage?
Aseptic packaging materials must ensure aseptic conditions inside the packaging, protect the product from physical impact, and maintain product quality inside. A suitable packaging must meet the following criteria:
- Functional properties of the plastic polymer (gas and water vapour barrier properties, chemical inertness, and flavour and odour absorption or scalping).
- Potential interactions between the plastic polymer and food products.
- Desired shelf life.
- Economic costs.
- Mechanical characteristics of the packaging material (moulding properties, material handling characteristics, and compatibility with packaging and sterilization methods).
- Shipping and handling conditions (toughness, compression).
- Compliance with regulations and targeted consumer groups.
Here are some common materials used for beverages to ensure safety, sterility, and product quality:
| Material type | Characteristics |
| Polyethylene (PE) |
|
| Film foil |
|
| Paperboard |
|
| Aluminum |
|
Which beverage products need aseptic processing?
Products with the following characteristics are most suitable for aseptic processes:
- Natural ingredients, high nutritional value: Aseptic processing can preserve the natural flavours and nutrients in fresh, all-natural products like fresh-squeezed fruit juices. It also eliminates using preservatives, artificial flavourings, or expensive refrigeration.
- High enzyme activity: The aseptic method ensures that heat or other treatments do not deactivate the naturally present enzymes in the product. By preserving their activity, aseptic processing helps maintain the authentic flavour and quality of enzyme-rich products.
- Low acidity: Low acidity food has a shorter shelf life than high acidity ones (acidic substances are natural preservatives). Aseptic processing can fully eliminate contaminants, which can help with these beverages’ shelf life.
Some examples of beverage products most suitable for aseptic processing:
Milk
To be considered sterile, milk must undergo UHT pasteurization, which requires the product to be heated to 138–150 degrees Celsius (280–302 degrees F) for one or two seconds. This kills harmful bacteria before the product is poured into the bottle. The stability of the product, combined with the resealability of the packaging, provides a perfect fit for the consumer and excellent marketing possibilities for the manufacturer.
Examples of aseptic products:
Milk products in aseptic carton bricks
Dairy-based beverages
The aseptic process maintains the natural flavour of dairy beverages. Consumers can enjoy the authentic taste without compromising quality, whether it’s a creamy latte or yogurt. The aseptic process also helps minimize nutrient loss. Vitamins and minerals are retained better, providing a nutritious product.
Examples of aseptic products:
Dairy-based products in aseptic carton packaging
Tea
Different from traditional canning, aseptic processing helps maintain tea’s natural flavour and aroma. Lower temperatures during processing help retain essential oils, antioxidants and other beneficial compounds. Consumers prefer products that do not use additives, so aseptically processed tea will become an attractive choice for health-conscious customers.
Examples of aseptic products:
Tea products in aseptic carton packaging
Fruit Juices
Fruit juice contains many valuable compounds, such as vitamins and minerals, so aseptic processing is a method that helps preserve natural flavours without having to use additives.
Examples of aseptic products:
Fruit juice in aseptic pouch
Coconut water
Coconut water has a high concentration of natural enzymes and minerals. The aseptic process ensures that coconut water remains healthy and fresh for a long time without refrigeration. This is especially valuable for distributing coconut water globally while reducing cold chain costs.
Examples of aseptic products:
Coconut water in aseptic packaging
Fermented beverages
The aseptic process maintains the viability of beneficial probiotic cultures in fermented beverages. These living microorganisms contribute to intestinal and digestive health.
Examples of aseptic products:
Bag-in-Box for cider packaging
So, why should you sell aseptic beverages?
In short, customers perceive aseptic beverages (in cartons) as of superior quality. Aseptic beverages have longer shelf life, more natural ingredients and better flavor profiles compared to traditional hot-filled beverages.
But, an aseptic production factory can cost millions of dollars to set up. The profit margin is way too thin for most Small & Medium Companies. So, how can you create aseptic-level quality products at reasonable costs?
At Tan Do Beverage, we produce premium quality beverage via Retort Processing Methods. They allow us to package the freshest organic tropical juices in sleek and modern aluminum cans. And using our own advantage, the manufacturing costs for Retort Processing is much more favorable for customers.
If you are interested in producing high-quality beverages, feel free to leave us a message below.
