Aseptic Packaging

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

PRODUCT PACKAGING - BASICS

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 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 bymicro-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

1.Metal and Rigid Containers Sterilized by Heat

a. Steam metal containers

b. Hot air Composite Can

Dole Canning systemsDrum fillers, e.g. Scholle, PranRicaDole hot air system

2.Webfed paperboard sterilized by H2O2 Tetra Pak (Brik Pak)International Paper

3.Preformed paperboard containers CombiblocLuquiPak

4.Preformed Rigid plastic containers Metal box AsePackGastiCrosscheck

5.Thermoform-fill-seal Benco AsepackBosch ServacConoflastThermoforming USA

6.Flexible Plastic containersa. Bag-in-box type

b. Pouches

c. Blow - moulded

Scholle Liqui BoxAsepakPrepacPrado pakInpacoBottlepackSeracALP

Classification of Aseptic filling and Packaging Systems

CATEGORY EXAMPLES OF SYSTEMS

PACKAGING DEVELOPMENTS

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 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.

Slim Cap opening Simply Twist Screw Cap

Twist Cap Stream 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.

* Source: German Federal Environmental Agency, 2000

Recycling/Waste management

Raw materials extraction

Production of packaging material

Production of packaging

Distribution

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

- Juices- Iced Teas- Dairy based beverages- Low acid foods- Broths etc

New Applications

- Wine- Small particle foods

- Soups- Salsas

- Waters- Natural Spring Water- Vitamin and Energy Water

drinks- Customized Functional

Waters

ASEPTIC PACKAGING

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

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

Alpro Soya DairyFree Shake -Saudi Arabia

Auchan Rik & Rik Batido Sabor Vanilla: Skimmed Milk with Vanilla Flavor - Spain

Gogreen Soygurt Jordgubb: Soy Yogurt Drink in

Strawberry Flavor - Sweden

Dukat Trajno Mlijeko + 7 Vitamina - Milk with

7 Added Vitamins - Croatia

Lactasoy Soy Milk

in Chocolate Flavor - Thailand

Parmalat Vanilla Flavored Milk -Colombia

Indomilk UHT MilkChocolate Drink -

Indonesia

Schardinger Formil Milk-

Austria

Juices and Drinks

El Corte Ingles Melocoton Y uva - Peach & Grape Juice Drink - Spain

Frugo Pear Flavored Juice

Drink - Chile Original Orange Nectar –Saudi Arabia

Carnini Arance Fior di Frutti

- Orange Juice - Italy

Scheiber Dynamix Daries Ltd-India

Berri Dark Grape Juice – Singapore Dimes Apple Juice-

South Korea

Leco GrapeNectar-

Brazil

Baby Foods and Drinks

Parmalat Len Liquid Formula Milk for 3YrsChildren - Colombia

P'tit Souper Douceur d'Artichaut – ArtichokesSoup for Infants – France

Nutriben 8 Cereales Papilla Lista Para Tomar - 8 Cereal Baby Food – Spain Nestle Junior Milk

2+

Switzerland

Agusha Reconstituted Apple-Apricot Juice with Pulp - Russia

Semper Smoothie Banan och Mango - Banana and Mango Flavor Smoothie for Babies - Sweden

Cow & Gate Ready Made Infant Milk for Hungrier Babies - UK

Prenagen Chocolate Flavored Milk for Pregnant Women - Indonesia

Soups in TetraBrik

Campbell's V8 Southwestern Corn Soup - US

Knorr Fish Soup with Vegetables – Belgium

Auchan Caldo de Pollo - Chicken Soup - Spain

Liebig Pur Soup' Potiron d'Automne - Pumpkin Soup - France

Aneto Caldo Natural Pollo - Natural Chicken Soup - Saudi

Arabia

Itoen Green Colored Vegetable Soup - Japan

Knorr Vellutata Di Spinaci - Ready Spinach Soup - Belgium

Ekstroms Rosehip

Soup - Taiwan

Wines and Alcoholic Soft Drinks

Sangria Cruzares Cocktail - Mexico

Caviro Tavernello Rose Wine - Italy

Pinard RedWine - Denmark

Don Simon Vino Rosado Table Rose Wine – Saudi Arabia

Tavernello White Wine - Italy

Vegetables and Fruits in Aseptic Packaging

Coop Ceci: Chickpeas - Italy

Naplina Sieved Tomato Passata - UK

Del Monte Tropical Fruit: Tropical fruit in sweetened fruit juices - US

Wal-Mart Great Value Tomato Pulp - Brazil

SPC Crushed Tomatoes - Australia

Knorr Vegetable Puree: Vegetable puree made with 12 different vegetables - Spain

Broja Banana Puree - China

Del Monte Sweet Corn Cream Style - Indonesia

Kelda Kokos: Low Fat Coconut Milk Cooking Sauce - Sweden

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.htmSource: www.oakleaf-european.co.uk

Tetra Aseptic Packs

Source: www.tetrapak.com

Tetra Aseptic Packs

Source: www.tetrapak.com

Aseptic packagingin aluminum foil

Source: www.asepticbaginbox.com

Source: www.tetrepak.co.jp

Tetra Aseptic Packs

Source: www.thehealthywayfoods.com

Source: www.packagingeurope.com

Sky long aseptic brickwww.21food.com

Source: www.dotfood.euSource: savushkinproduct.com

Source: www.caspllc.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