WO2008149377A1 - Procédé de conditionnement aseptique - Google Patents
Procédé de conditionnement aseptique Download PDFInfo
- Publication number
- WO2008149377A1 WO2008149377A1 PCT/IN2008/000146 IN2008000146W WO2008149377A1 WO 2008149377 A1 WO2008149377 A1 WO 2008149377A1 IN 2008000146 W IN2008000146 W IN 2008000146W WO 2008149377 A1 WO2008149377 A1 WO 2008149377A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- film
- packaging
- sterilizing agent
- filling
- conditioned
- Prior art date
Links
- 238000000034 method Methods 0.000 title claims abstract description 73
- 230000008569 process Effects 0.000 title claims abstract description 35
- 238000009455 aseptic packaging Methods 0.000 title claims abstract description 25
- 238000011049 filling Methods 0.000 claims abstract description 34
- 239000003206 sterilizing agent Substances 0.000 claims abstract description 31
- 238000004806 packaging method and process Methods 0.000 claims abstract description 28
- 238000007789 sealing Methods 0.000 claims abstract description 22
- 230000001143 conditioned effect Effects 0.000 claims abstract description 15
- 238000009740 moulding (composite fabrication) Methods 0.000 claims abstract description 12
- 230000003750 conditioning effect Effects 0.000 claims abstract description 11
- 239000012785 packaging film Substances 0.000 claims abstract description 8
- 229920006280 packaging film Polymers 0.000 claims abstract description 8
- 238000002791 soaking Methods 0.000 claims abstract description 4
- 238000003892 spreading Methods 0.000 claims abstract description 3
- 230000007480 spreading Effects 0.000 claims abstract description 3
- MHAJPDPJQMAIIY-UHFFFAOYSA-N Hydrogen peroxide Chemical compound OO MHAJPDPJQMAIIY-UHFFFAOYSA-N 0.000 claims description 61
- 230000001954 sterilising effect Effects 0.000 claims description 32
- 238000004659 sterilization and disinfection Methods 0.000 claims description 25
- 239000007788 liquid Substances 0.000 claims description 8
- 230000000694 effects Effects 0.000 claims description 7
- 238000005201 scrubbing Methods 0.000 claims description 7
- 230000008016 vaporization Effects 0.000 claims description 7
- KFSLWBXXFJQRDL-UHFFFAOYSA-N Peracetic acid Chemical compound CC(=O)OO KFSLWBXXFJQRDL-UHFFFAOYSA-N 0.000 claims description 4
- 238000007598 dipping method Methods 0.000 claims description 2
- KEUKAQNPUBYCIC-UHFFFAOYSA-N ethaneperoxoic acid;hydrogen peroxide Chemical compound OO.CC(=O)OO KEUKAQNPUBYCIC-UHFFFAOYSA-N 0.000 claims description 2
- 238000005507 spraying Methods 0.000 claims description 2
- 238000007740 vapor deposition Methods 0.000 claims description 2
- 230000009467 reduction Effects 0.000 description 19
- 239000005022 packaging material Substances 0.000 description 13
- 238000002474 experimental method Methods 0.000 description 12
- 239000010410 layer Substances 0.000 description 12
- 235000013305 food Nutrition 0.000 description 10
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 9
- 230000000813 microbial effect Effects 0.000 description 7
- 238000010998 test method Methods 0.000 description 7
- 238000012360 testing method Methods 0.000 description 7
- 229910052782 aluminium Inorganic materials 0.000 description 6
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 6
- 235000013361 beverage Nutrition 0.000 description 6
- 238000004140 cleaning Methods 0.000 description 6
- 238000000576 coating method Methods 0.000 description 6
- 238000003851 corona treatment Methods 0.000 description 5
- 238000010030 laminating Methods 0.000 description 5
- 239000000463 material Substances 0.000 description 5
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 4
- 239000011248 coating agent Substances 0.000 description 4
- 239000011888 foil Substances 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
- 244000005700 microbiome Species 0.000 description 4
- 229910052760 oxygen Inorganic materials 0.000 description 4
- 239000001301 oxygen Substances 0.000 description 4
- 239000000243 solution Substances 0.000 description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 3
- 239000000853 adhesive Substances 0.000 description 3
- 230000001070 adhesive effect Effects 0.000 description 3
- 230000004888 barrier function Effects 0.000 description 3
- 238000009924 canning Methods 0.000 description 3
- 238000005530 etching Methods 0.000 description 3
- 239000000976 ink Substances 0.000 description 3
- 238000003475 lamination Methods 0.000 description 3
- 235000021056 liquid food Nutrition 0.000 description 3
- 230000002906 microbiologic effect Effects 0.000 description 3
- 230000037452 priming Effects 0.000 description 3
- 238000007639 printing Methods 0.000 description 3
- 238000012545 processing Methods 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- GVJHHUAWPYXKBD-UHFFFAOYSA-N (±)-α-Tocopherol Chemical compound OC1=C(C)C(C)=C2OC(CCCC(C)CCCC(C)CCCC(C)C)(C)CCC2=C1C GVJHHUAWPYXKBD-UHFFFAOYSA-N 0.000 description 2
- CIWBSHSKHKDKBQ-JLAZNSOCSA-N Ascorbic acid Chemical compound OC[C@H](O)[C@H]1OC(=O)C(O)=C1O CIWBSHSKHKDKBQ-JLAZNSOCSA-N 0.000 description 2
- 244000063299 Bacillus subtilis Species 0.000 description 2
- 235000014469 Bacillus subtilis Nutrition 0.000 description 2
- 241000894006 Bacteria Species 0.000 description 2
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 2
- GRYLNZFGIOXLOG-UHFFFAOYSA-N Nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 description 2
- -1 Polyethylene Polymers 0.000 description 2
- 239000012790 adhesive layer Substances 0.000 description 2
- 239000000356 contaminant Substances 0.000 description 2
- 238000011109 contamination Methods 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 229910052739 hydrogen Inorganic materials 0.000 description 2
- 239000001257 hydrogen Substances 0.000 description 2
- 239000012535 impurity Substances 0.000 description 2
- 230000036512 infertility Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 229910017604 nitric acid Inorganic materials 0.000 description 2
- 235000015097 nutrients Nutrition 0.000 description 2
- 235000016709 nutrition Nutrition 0.000 description 2
- 239000004033 plastic Substances 0.000 description 2
- 229920003023 plastic Polymers 0.000 description 2
- 229920006267 polyester film Polymers 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
- 229920005672 polyolefin resin Polymers 0.000 description 2
- 239000002987 primer (paints) Substances 0.000 description 2
- 230000005855 radiation Effects 0.000 description 2
- 238000005057 refrigeration Methods 0.000 description 2
- 239000000758 substrate Substances 0.000 description 2
- 238000004381 surface treatment Methods 0.000 description 2
- 238000010200 validation analysis Methods 0.000 description 2
- 238000009736 wetting Methods 0.000 description 2
- QLOKJRIVRGCVIM-UHFFFAOYSA-N 1-[(4-methylsulfanylphenyl)methyl]piperazine Chemical compound C1=CC(SC)=CC=C1CN1CCNCC1 QLOKJRIVRGCVIM-UHFFFAOYSA-N 0.000 description 1
- BZSXEZOLBIJVQK-UHFFFAOYSA-N 2-methylsulfonylbenzoic acid Chemical compound CS(=O)(=O)C1=CC=CC=C1C(O)=O BZSXEZOLBIJVQK-UHFFFAOYSA-N 0.000 description 1
- 238000012371 Aseptic Filling Methods 0.000 description 1
- 229920000219 Ethylene vinyl alcohol Polymers 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 229930003427 Vitamin E Natural products 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 239000004411 aluminium Substances 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 229960005070 ascorbic acid Drugs 0.000 description 1
- 235000010323 ascorbic acid Nutrition 0.000 description 1
- 239000011668 ascorbic acid Substances 0.000 description 1
- 238000012865 aseptic processing Methods 0.000 description 1
- 239000012298 atmosphere Substances 0.000 description 1
- 230000001580 bacterial effect Effects 0.000 description 1
- 239000002585 base Substances 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 239000011449 brick Substances 0.000 description 1
- 239000012267 brine Substances 0.000 description 1
- 238000003490 calendering Methods 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 238000003486 chemical etching Methods 0.000 description 1
- 230000001427 coherent effect Effects 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 239000002537 cosmetic Substances 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 239000000645 desinfectant Substances 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 238000005429 filling process Methods 0.000 description 1
- 239000005003 food packaging material Substances 0.000 description 1
- 235000015203 fruit juice Nutrition 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- WIGCFUFOHFEKBI-UHFFFAOYSA-N gamma-tocopherol Natural products CC(C)CCCC(C)CCCC(C)CCCC1CCC2C(C)C(O)C(C)C(C)C2O1 WIGCFUFOHFEKBI-UHFFFAOYSA-N 0.000 description 1
- 239000001963 growth medium Substances 0.000 description 1
- 239000000383 hazardous chemical Substances 0.000 description 1
- 230000036541 health Effects 0.000 description 1
- 231100000206 health hazard Toxicity 0.000 description 1
- 230000008642 heat stress Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000012376 hot air sterilization Methods 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 238000011534 incubation Methods 0.000 description 1
- 230000001678 irradiating effect Effects 0.000 description 1
- 230000005923 long-lasting effect Effects 0.000 description 1
- 239000002609 medium Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 235000013336 milk Nutrition 0.000 description 1
- 239000008267 milk Substances 0.000 description 1
- 210000004080 milk Anatomy 0.000 description 1
- 230000035764 nutrition Effects 0.000 description 1
- 239000007800 oxidant agent Substances 0.000 description 1
- 238000006385 ozonation reaction Methods 0.000 description 1
- 238000012856 packing Methods 0.000 description 1
- 239000012071 phase Substances 0.000 description 1
- 239000001967 plate count agar Substances 0.000 description 1
- 238000007747 plating Methods 0.000 description 1
- 229920006122 polyamide resin Polymers 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- KMUONIBRACKNSN-UHFFFAOYSA-N potassium dichromate Chemical compound [K+].[K+].[O-][Cr](=O)(=O)O[Cr]([O-])(=O)=O KMUONIBRACKNSN-UHFFFAOYSA-N 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000010926 purge Methods 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 235000011121 sodium hydroxide Nutrition 0.000 description 1
- HPALAKNZSZLMCH-UHFFFAOYSA-M sodium;chloride;hydrate Chemical compound O.[Na+].[Cl-] HPALAKNZSZLMCH-UHFFFAOYSA-M 0.000 description 1
- 230000008646 thermal stress Effects 0.000 description 1
- 239000012808 vapor phase Substances 0.000 description 1
- 235000013311 vegetables Nutrition 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
- 229940046009 vitamin E Drugs 0.000 description 1
- 235000019165 vitamin E Nutrition 0.000 description 1
- 239000011709 vitamin E Substances 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- 239000000080 wetting agent Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B55/00—Preserving, protecting or purifying packages or package contents in association with packaging
- B65B55/02—Sterilising, e.g. of complete packages
- B65B55/04—Sterilising wrappers or receptacles prior to, or during, packaging
- B65B55/10—Sterilising wrappers or receptacles prior to, or during, packaging by liquids or gases
- B65B55/103—Sterilising flat or tubular webs
Definitions
- the present invention relates to food packaging, more particularly to the process of aseptic packaging.
- Aseptic packaging involves filling a sterilized package with a sterile food in a confined hygienic environment.
- Aseptic packaging methods such as flash heating and cooling substantially reduce the energy use and nutrient loss associated with conventional sterilization.
- aseptically packaged products can retain more nutritional value and exhibit more natural texture, colour and taste, all the while using less energy.
- the aseptic package of the prior art is typically a, multi-layer lamination that combines the best attributes of paper, plastic and aluminum to form a singular, high-performance beverage container. The combination of quality aseptic processing, shelf stability and source reduction also makes the aseptic package ideal for a variety of food products.
- the liquid food or beverage is sterilized outside the package using an Ultra- High Temperature (UHT) process that rapidly heats, and then cools the product before filling.
- UHT Ultra- High Temperature
- the processing equipment allows the time (generally 3 to 15 seconds) and temperature (195° to 285°F) to be tailored to place the least amount of thermal stress on the product while ensuring safety.
- Flexible packages for aseptic packaging are made from three materials:
- Paper - provides stiffness, strength and the brick shape.
- Polyethylene plastic (polymeric materials in aseptic packaging) — provides leak proofing and keeps the exterior dry.
- Aluminium - provides light and oxygen barrier thereby eliminating the need for refrigeration.
- the sterilization of packaging material in the prior art is carried out by the following methods: 1. Subjecting the packaging material to ultrasonic vibrations through a liquid medium and then subjecting the packaging material to ultraviolet radiation like gamma rays.
- the aseptic packaging material is immersed in a bath Of H 2 O 2, which is generally heated between 60 0 C and 80 0 C.
- the coat of H 2 O 2 maintains the sterilized condition.
- Sodium chlorate can also be used.
- the surface energy of a packaging film often referred to as the "dyne" level (dynes/cm) is a critical film property when printing, coating or laminating packaging films.
- the main objective of any surface treatment method is to increase the surface energy of the film surface to improve wet-out and adhesion of coatings, inks and adhesives used in converting the film into packaging.
- Typical polymers used for packaging films without surface treatment will naturally have a surface energy of 29 to 45 dynes/cm.
- a typical rule of thumb to ensure good wet-out and adhesion to a substrate is that the surface energy of the substrate should be 7-10 dynes/cm higher than the surface tension of the coating being applied.
- water has a surface tension of 72 dynes/cm compared to the surface tension of methanol which is 22.6 dynes/cm.
- the surface energy of a polyester film is approximately 42 dynes/cm thus allowing the methanol to easily wet-out the surface of the polyester, however the water (-72 dynes/cm) which is 50 dynes higher than the methanol, will form droplets without wetting the polyester film.
- Priming of a film is done in conjunction with corona treatment to increase the surface energy and improve adhesion of a coating, ink or adhesive.
- the film is corona treated to increase the surface . energy, enough to provide good adhesion for the primer coating to the film.
- a primer is selected that will provide a high surface energy for good adhesion and possibly improve the surface texture of the film. This method however, greatly increases the cost of the film.
- Chemical treatment of a film typically involves cleaning, etching and rinsing the film. Cleaning removes surface contaminants. Etching involves the use of an acid, base or oxidizing agents such as nitric acid (NHO 3 ) or potassium chromate (K 2 Cr 2 O 7 ) in order to chemically alter the polymer surface. Finally, the film is rinsed and cleaned of the etching chemicals and dried. This process is usually done following film manufacturing, which significantly adds to the final cost of the film. This treatment method is often slow and creates waste disposal issues.
- Flame treatment involves the use of a burner unit that generates a flame with a specific plasma value (PV) ratio or fuel to oxygen ratio.
- PV plasma value
- the film is made to pass directly through flame tips, which have formed oxygen rich plasma there by treating the surface of the film with the flame.
- This treatment method is known to produce high surface energy levels and long lasting treatment levels. In the past this method was considered dangerous due to the presence of long open flame. However, improvements in equipment design and controls have greatly reduced the hazards.
- Corona discharge equipment consists of a high-frequency power generator, a high-voltage transformer, a stationary electrode, and a treater ground roll. Standard utility electrical power is converted into higher frequency power which is then supplied to the treater station. The treater station applies this power through ceramic or metal electrodes over an air gap onto the material's surface. The effects of corona treatment diminish over time. Therefore, many surfaces will require a second "bump" treatment at the time they are converted to ensure bonding with printing inks, coatings, and adhesives. This treatment method is user friendly and can be run at high line speeds (in excess of 1000 feet per minute). The line speed controls the final treatment level. Corona Treating Equipment is widely used throughout a diverse range of industries including medical, electronics, automotive component, cable, ophthalmic, pipe, printing, packaging, domestic appliance, cosmetics packaging, food and beverage packaging.
- United States Patent no. 4888223 discloses a method for preparation of food packaging material.
- the film laminate in the form of seamless tube is made up of a base layer formed from polyamide resin, an intermediate adhesive layer and a layer formed from ethylene-vinyl alcohol copolymer and an innermost, food-contacting layer formed from polyolefin resin.
- the innermost, food-containing surfacing of polyolefin resin layer is subjected to corona discharge applied from one pair of positions outside the seamless tube.
- United States Patent no. 6858106 discloses a method of manufacturing of a laminating packaging material which does not have the delaminating between the layers.
- the deoxidant of vitamin E, ascorbic acid or its derivative is adhered/attached, to the inside of a barrier layer web, the barrier layer is temporarily rolled round by the reel shape, kept, and laminated by the extrusion lamination by the molten polyolefin.
- a corona treatment is also suggested to the surface of laminating material, such as the aluminum foil, and additional processing such as ozonization can be carried out if needed.
- European Patent no. 1177891 discloses a method for manufacturing a laminate for packaging containing an aluminum foil. This method involves a step of covering the surface of the laminate with an adhesive layer, rolling round the web shape laminate obtained by the lamination of aluminum foil to a reel shape and a step of processing the aluminum foil surface by corona discharge after unwinding the laminate from the reel and laminating the fibrous carrier layer. This disclosure provides a sterilizing process for multilayer laminate and only the inner most layers is subjected to corona treatment, which does not sterilize the entire packaging laminate.
- United States Patent no. 6183691 discloses a method and apparatus for sterilizing packages.
- the method provide packaging to be sterilized at the sterilization station, the packaging is a partially formed carton having an interior, an exposed exterior and a fitment.
- the method includes subjecting the packaging to a predetermined quantity of vapor phase hydrogen peroxide thereby creating a packaging coated with a thin layer of hydrogen peroxide.
- the next step is irradiating the coated packaging with ultraviolet radiation and last step is drying the irradiated packaging with heated air.
- European Patent no. 0484730 discloses a method of sterilizing a packaging material by means of a sterilizing agent in liquid form.
- the packaging material is first discharged in order to eliminate electrostatic surface charges occurring on the strip.
- the sterilizing agent is then applied to the packaging material in a finely distributed, electro statically charged form to create a coherent, homogeneous film.
- the packaging material is finally heated to drive away the sterilizing agent from the ready sterilized packaging material.
- the object of the present invention is to obviate said drawbacks by providing a triple stage sterilizing process.
- An object of the present invention is to provide a method for aseptic packaging of a sterile product.
- Another object of the present invention is to provide a method for aseptic packaging film. Yet another object of the present invention is to provide a method which cleans the film thoroughly to remove the impurities.
- One more object of the present invention is to provide a method which reduces the microbiological load.
- Still another object of the present invention is to provide a method wherein the sterilizing agent is uniformly spread.
- Yet another object of the present invention is to provide a method to double sterilize the film to completely remove the undesirable sterilizing agent.
- Yet another object of the present invention is to provide a method which sterilizes the packaging without causing any health hazards.
- the conditioning is performed by at least one process selected from a group of processes consisting of corona discharge, plasma arc and flame treatment.
- the conditioning is performed to provide a surface energy between 30 to 45 dynes/cm.
- the sterilizing agent used is from a group consisting of Hydrogen Peroxide, Oxonia and peracetic acid.
- the sterilizing agent is applied by one of the methods of spraying, dipping in a bath squeezing rollers and vapor deposition.
- the step of treating during forming, filling and sealing is performed by introducing hot air and a sterile product to be filled via a coaxial tube, the product being discharged through the inner annulus and the hot air being discharged through the outer annulus and providing a laminar flow of hot sterile air on the inside of the film in the opposite direction of film pulling thereby creating the scrubbing arid vaporizing effect to ensure evacuation of sterilization liquid adhered to the inner surface of said film before introducing of the sterile product inside formed package, wherein the flow rate of the hot air is from 500 to 2000 lit/min.
- FIG 1 shows the representative flowchart to demonstrate the process in accordance with the present invention
- FIG 2 is the side view of the schematic diagram of the method in accordance with this invention.
- FIG 3 is the front view of the schematic diagram of the method in accordance with this invention.
- the present invention provides a method for sterilizing a composite packaging laminate or a film.
- the first stage of this method is to increase the surface energy of the film by conditioning the film .
- Second stage is impinging the said film with high speed jets of hydrogen peroxide and then applying the hydrogen peroxide on the inside surface of the film.
- the third stage is sterilizing of the film which includes forming, filling and sealing of the packaging laminate.
- the laminate first undergoes conditioning to increasing the surface energy of the operative inner surface of the film to 30 to 45 dynes/cm.
- the method of conditioning may include corona discharge, plasma arc and flame treatment. Condition permits receiving of the sterilizing agent uniformly on the film surface and improves the wetting and adhesion of the sterilizing agent on the film surface. It has been found that if the conditioning provides a surface energy below 30 dynes/cm, then the application of sterilizing agent will be sporadic and not uniform, which leads to insufficient scrubbing and vaporizing.
- the entire sterile product filling path surfaces are cleaned to remove impurities and to reduce microbiological load and sterilize the filling path.
- CIP cleaning-in-place
- SIP sterilization-in-place
- An in built CIP and SIP unit is provided with this method, in accordance with this invention which is 1 designed to control the process parameters. Both the CIP and SIP are monitored through a PLC.
- the cleaning in place involves circulation of different cleaning solutions like hot water, caustic soda brine, nitric acid, in the product filling path for specific parameters like concentration of the cleaning solution and residence time of the solution.
- the complete sterile product filling path is steam sterilized to make the system free of any microorganisms.
- the steam at a temperature of 115 to 140 degree C is contacted with the inner surfaces of the product tank for 20 to 60 min.
- the conditioned film roll is pulled over the filling Pipe for the film sterilizing process.
- Cleaning-in-place is carried out after every machine stoppage or once in a day.
- the machine is sterilized using culinary steam before next production. If there is any interruption during CIP and SIP, the cycle is made to restart from the beginning and any drop in temperature during the cycle is interrupted by a audio - visual alarm.
- the conditioned film is rolled on to a film roller (10).
- the film is then moved to a film unwinding machine (12) to unwind the film roll and further rolled to a hydrogen peroxide bath (16) for sterilization.
- the film is sterilized in two stages by a sterilizing agent.
- hydrogen peroxide is used as a sterilizing agent.
- the inner surface of the film which has been conditioned having a surface energy between 35 to 40 dynes/cm is subjected to a high speed jets (14), where 35 % to 50 % concentration of hydrogen peroxide is impinged tangentially on the film at a pressure of around 2 - 5 bar.
- the film is passed vertically over two guide rollers (18) while it is impinged.
- the high speed jets cause mechanical dislodgement of bacteria from the inner surface of the film and also remove dust.
- the film from the first stage sterilization is then soaked in the hydrogen peroxide bath (16) by passing in the soaking tank containing hydrogen peroxide (16) of 35% to 50 % concentration at a temperature of 30 to 35 degree C.
- the minimum residual time of the film in the bath is around 5 - 10 sec. The time varies as per the speed of the roller and the film length.
- the film leaving the hydrogen peroxide tank (16) is then wiped off using a wiper (15) to remove excess hydrogen peroxide adhering to the film surface.
- the sterilized film is further passed over metallic rollers (18) for uniform dispersion of hydrogen peroxide on the inner surface of the film by a calendaring effect of the rollers.
- the microbiological load on the film is further reduced with the exposure to UV light for 1 to 3 sec.
- the third and final stage sterilization is done by hot sterile air, synchronizing with forming and filling of the packaging, wherein train of sterilized pouches is formed.
- the forming and filling equipment (8) for hot air sterilization consists of a folding roller (22) with a coaxial filling tube fitted at the center (24), wherein the sterile air is introduced through the outer tube of the coaxial tube and the product through the inner tube, a horizontal seal (28) for horizontal sealing and a vertical seal (26) for vertical sealing.
- the sealing is achieved with an impulse or constant sealing element or jaw.
- the current range during a typical impulsive sealing is maintained between 30 - 60 amps and heat expose time between 300 to 600 milliseconds depending upon film thickness and film properties.
- Curing/cooling of the typical impulse sealers is achieved by circulating chilled water through the sealing jaws when they are in closed condition.
- the curing time varies from 100 to 300 milliseconds.
- the air for sterilization is supplied from the air blower, which is heated by an air heater, to a temperature of 100 - 150 degree C and at a pressure of 0.5 to 2 bar.
- the hot sterile air from the air heater also provides purging on top of the product in the product tank (36), wherein air is introduced to the tank.
- the hot sterile air also maintains the modified atmosphere during filling process thus avoiding contamination from outside air.
- the film from the second stage sterilization is rolled on to the folding collar (22) where the film is folded to form a tube.
- One of the edges of the film is vertically sealed by the vertical sealer (26). Further the tube is sealed horizontally by a horizontal seal (28) at the operative bottom end with the other end open.
- the hot sterile air is introduced into the coaxial tube (24) at a flow rate of 500 lit/min - 2000 lit/min.
- the inner surface of the film tube is scrubbed by hot air to remove/scrub off hydrogen peroxide from the sterilized film. This vapor simultaneously liberates nascent oxygen which further reduces the microbial load and also acts as a disinfectant.
- the scrubbed film on the folding collar (22) is pulled continuously by pulling rollers (34) at a speed ranging from 1000 - 2500 rpm.
- a typical sterile product like sterile liquid at a flow rate of 6 lit/min to 60 lit/min is introduced from a product tank (36) in to the film tube.
- the operative upper end of the film tube is sealed by the horizontal seal (28) to form a pouch.
- the flow of the product is controlled by a constant flow valve (40) fitted to the product tank (36).
- the sealed pouches are discharged from the pouch discharge unit (38).
- in situ sterilization of packaging material is carried out where the film tubes are hot air sterilized and parallely filled with the product; this method minimizes the contamination of the sterilized pouches and helps in achieving a cent percent sterilization. Hot air removes excess hydrogen peroxide as well and the quantity of hydrogen peroxide is about 0.1 - 5 ppm in the final packaging.
- the filling system undergoes a CIP and SIP process. The method of forming, filling and sealing process is carried as described in the above method after the CIP process.
- These aseptic pouches can be used for packaging of milk, vegetable purees, fruit juices and the like. Test procedure and Results for aseptic packaging in accordance with this invention are as shown in Table 1, 2 and 3.
- Validation of the pre-sterilization of an aseptic packaging machine and validation of the machine's sterilization of the packages require many evaluations, including a microbial count reduction.
- the uniformity of the log count reduction (LCR) must be demonstrated for the standard sterilization technique to be applied to the machine and to the packages.
- test Procedures are designed by the working group formed for standardizing the test procedures and worked out originally at Fraunhofer Institute of Food Technology & Packaging, Kunststoff
- the packaging materials were infected with the test microorganism and passed through the aseptic plant, in doing so the number of viable spores was determined before and after passage of the sterilization device and from the difference in microorganism counts, the killing rate was determined.
- MLCR log (initial count) - log (final count)
- the packaging was artificially inoculated with test micro organisms as in the count reduction test.
- the infected packaging was filled with a sterile culture medium and after incubation phases the number of unsterile packaging units was determined.
- the end point provides the effectiveness of the package and as well as information about the entire process from supplying the product and filling through the recontamination free closure of the packs.
- MLCR log (initial count per pack) - (log ln(number of packs tested/number of sterile packs))
- the required minimum Mean Logarithmic Count Reduction (MLCR) is 4.
- the results in table 1 show a MLCR greater than 4, which has superior aseptic properties than the packages in the prior art.
- MLCR Minimum MLCR required is 4. MLCR achieved is greater than 4.
- a corona treated laminate of 38 dynes/cm surface energy and thickness of 90 micron was sterilized by impinging the laminate surface with high speed jets of hydrogen peroxide of 40 % concentration at temperature of 30 degree C.
- the sterilized film was passed into a hydrogen peroxide bath for second sterilization, wherein the film was contacted with the bath for 6 sec.
- the hydrogen peroxide sterilized film was wiped by passing through a wiping/squeezing roller. Then the wet film was passed over the folding collar with coaxial filling tube at the center.
- a tube was formed by the vertical sealing of the film and then into a pouch by a horizontal sealing of the tube on the folding collar.
- the film was then air sterilized by passing hot air through the outer tube of the coaxial filling tube, at a temperature 85 degree C and a pressure of 1.5 bar.
- the flow rate of the hot air was maintained at 1500 lit/min.
- a sterile Product from the product tank at a flow rate of 45 lit/min was introduced through the inner tube and was sealed at the lower end.
- a corona treated laminate of 38 dynes/cm surface energy and thickness of 90 microns was sterilized by impinging the laminate surface with high speed jets of hydrogen peroxide of 40 % concentration at temperature of 30 degree C.
- the sterilized film was passed into a hydrogen peroxide bath for second sterilization, wherein the film was contacted with the bath for 6 sec.
- the hydrogen peroxide sterilized film was wiped by passing through a wiping/squeezing roller. Then the wet film was passed over the folding collar with coaxial filling tube at the center.
- a tube was formed by the vertical sealing of the film and then into a pouch by a horizontal sealing of the tube on the folding collar.
- the film was then air sterilized by passing hot air through the outer tube of the coaxial filling tube, at a temperature 90 degree C and a pressure of 1.5 bar.
- the flow rate of the hot air was maintained at 1500 lit/min.
- Product from the product tank at a flow rate of 45 lit/min was introduced through the inner tube and was sealed at the lower end.
- a corona treated laminate of 38 dynes/cm surface energy and thickness of 90 micron was sterilized by impinging the laminate surface with high speed jets of hydrogen peroxide of 40 % concentration at temperature of 30 degree C.
- the sterilized film was passed into a hydrogen peroxide bath for second sterilization, wherein the film was contacted with the bath for 6 sec.
- the hydrogen peroxide sterilized film was wiped by passing through a wiping/squeezing roller. Then the wet film was passed over the folding collar with coaxial filling tube at the center.
- a tube was formed by the vertical sealing of the film and then into a pouch by a horizontal sealing of the tube on the folding collar.
- the film was then air sterilized by passing hot air through the outer tube of the coaxial filling tube, at a temperature 95 degree C and a pressure of 1.5 bar.
- the flow rate of the hot air was maintained at 1500 lit/min.
- Product from the product tank at a flow rate of 45 lit/min was introduced through the inner tube and was sealed at the lower end.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Apparatus For Disinfection Or Sterilisation (AREA)
Abstract
La présente invention concerne un procédé de conditionnement aseptique comprenant les étapes suivantes : (a) conditionnement de la surface d'utilisation interne du film d'emballage qui reçoit l'agent stérilisant de manière homogène ; (b) application de l'agent stérilisant sur ladite surface conditionnée et trempage dans ledit bain d'agent stérilisant ; et (c) étalement homogène dudit agent stérilisant sur ladite surface conditionnée et ensuite formation, remplissage et scellage dudit film portant ladite surface interne conditionnée par traitement pendant la formation, le remplissage et le scellage d'une poche formée dudit film avec de l'air chaud à une température de 100 à 150° C et une pression de 0,5 bar à 2,0 bars pour stériliser le film et vaporiser ledit agent stérilisant hors de la surface interne conditionnée tout en remplissant simultanément la poche formée avec un produit à emballer à l'intérieur du conditionnement.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
IN1053/MUM/2007 | 2007-06-04 | ||
IN1053MU2007 | 2007-06-04 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2008149377A1 true WO2008149377A1 (fr) | 2008-12-11 |
Family
ID=40093237
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/IN2008/000146 WO2008149377A1 (fr) | 2007-06-04 | 2008-03-14 | Procédé de conditionnement aseptique |
Country Status (1)
Country | Link |
---|---|
WO (1) | WO2008149377A1 (fr) |
Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP2641834A1 (fr) * | 2012-03-23 | 2013-09-25 | Solvay Sa | Procédé de remplissage de dentifrice |
JP2017128395A (ja) * | 2017-04-20 | 2017-07-27 | 大日本印刷株式会社 | 無菌充填装置及びその浄化方法 |
JP2017165488A (ja) * | 2017-04-20 | 2017-09-21 | 大日本印刷株式会社 | 無菌充填装置及びその浄化方法 |
EP3199462A4 (fr) * | 2014-09-25 | 2018-05-23 | Dai Nippon Printing Co., Ltd. | Procédé de stérilisation de préforme et de récipient en résine |
WO2019152453A1 (fr) * | 2018-01-30 | 2019-08-08 | Saslekov Todor | Film multicouche stérilisé, et procédé et appareil de fabrication dudit film multicouche stérilisé |
US20230303283A1 (en) * | 2020-07-28 | 2023-09-28 | Universal Pack S.R.L. | Delivery Unit for an Aseptic Packaging Machine, Aseptic Packaging Machine and Sterilization Method |
Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPS6437326A (en) * | 1987-07-24 | 1989-02-08 | Ckd Corp | Process and device for aseptic packaging |
JPH11105832A (ja) * | 1997-10-01 | 1999-04-20 | Toppan Printing Co Ltd | 液体包装用充填機チャンバーの無菌陽圧保持方法及び装置 |
CN2327614Y (zh) * | 1998-03-04 | 1999-07-07 | 陶维忠 | 液封式无菌包装装置 |
CN2419167Y (zh) * | 2000-03-30 | 2001-02-14 | 徐冬顺 | 液态食品的无菌包装机 |
CN1356938A (zh) * | 1999-03-19 | 2002-07-03 | 日本利乐株式会社 | 包装用层压材料的制造方法 |
US6442915B1 (en) * | 1998-11-27 | 2002-09-03 | Hassia Verpackungsmaschinen Gmbh | Process and plant for endless-cycle sterilization of sheet material utilized in aseptic packaging |
-
2008
- 2008-03-14 WO PCT/IN2008/000146 patent/WO2008149377A1/fr active Application Filing
Patent Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPS6437326A (en) * | 1987-07-24 | 1989-02-08 | Ckd Corp | Process and device for aseptic packaging |
JPH11105832A (ja) * | 1997-10-01 | 1999-04-20 | Toppan Printing Co Ltd | 液体包装用充填機チャンバーの無菌陽圧保持方法及び装置 |
CN2327614Y (zh) * | 1998-03-04 | 1999-07-07 | 陶维忠 | 液封式无菌包装装置 |
US6442915B1 (en) * | 1998-11-27 | 2002-09-03 | Hassia Verpackungsmaschinen Gmbh | Process and plant for endless-cycle sterilization of sheet material utilized in aseptic packaging |
CN1356938A (zh) * | 1999-03-19 | 2002-07-03 | 日本利乐株式会社 | 包装用层压材料的制造方法 |
CN2419167Y (zh) * | 2000-03-30 | 2001-02-14 | 徐冬顺 | 液态食品的无菌包装机 |
Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP2641834A1 (fr) * | 2012-03-23 | 2013-09-25 | Solvay Sa | Procédé de remplissage de dentifrice |
EP3199462A4 (fr) * | 2014-09-25 | 2018-05-23 | Dai Nippon Printing Co., Ltd. | Procédé de stérilisation de préforme et de récipient en résine |
JP2017128395A (ja) * | 2017-04-20 | 2017-07-27 | 大日本印刷株式会社 | 無菌充填装置及びその浄化方法 |
JP2017165488A (ja) * | 2017-04-20 | 2017-09-21 | 大日本印刷株式会社 | 無菌充填装置及びその浄化方法 |
WO2019152453A1 (fr) * | 2018-01-30 | 2019-08-08 | Saslekov Todor | Film multicouche stérilisé, et procédé et appareil de fabrication dudit film multicouche stérilisé |
US20230303283A1 (en) * | 2020-07-28 | 2023-09-28 | Universal Pack S.R.L. | Delivery Unit for an Aseptic Packaging Machine, Aseptic Packaging Machine and Sterilization Method |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
Ansari et al. | An overview of sterilization methods for packaging materials used in aseptic packaging systems | |
US9290286B2 (en) | Method and apparatus for preparing and filling packages including pouches and containers, such as pouches and containers for food products | |
WO2008149377A1 (fr) | Procédé de conditionnement aseptique | |
US4396582A (en) | Method and apparatus for sterilizing food packages or the like | |
WO2011089765A1 (fr) | Procédé de stérilisation de la surface d'un espace et système de stérilisation | |
EP0083448A2 (fr) | Stérilisation de matériaux d'emballage | |
EP4091964B1 (fr) | Procédé pour la stérilisation de manchon | |
US10596283B2 (en) | Sterilization apparatus | |
US4494357A (en) | Sterilization of packaging material | |
Peng et al. | Packed food and packaging materials disinfected by cold plasma | |
US20100221146A1 (en) | Method of aseptically treating, forming, filling, and sealing flexible bag packages in a bag packaging machine | |
Von Bockelmann et al. | Aseptic packaging of liquid food products: a literature review | |
US8834790B2 (en) | Apparatus and method for sterilizing container closures | |
EP1020363A2 (fr) | Procédé et dispositif de stérilisation de matériau d'emballage pour produits alimentaires | |
JP2004535338A (ja) | 形成−充填−密封機械におけるウェブ材料の滅菌用装置 | |
US20240124175A1 (en) | Filling Aluminum Cans Aseptically | |
JP5573020B2 (ja) | カップ状容器の殺菌方法 | |
NO331757B1 (no) | System for automatisk/kontinuerlig sterilisering av en formings-, fyllings- og forseglings-emballeringsmaskin og fremgangsmate for a sterilisere en dor i en slik maskin | |
US20050276723A1 (en) | Aseptic sterilant using ozone in liquid carbon dioxide | |
JP2020172297A (ja) | 無菌充填機及び無菌充填方法 | |
JP2012056607A (ja) | 飲料水用包装材料及びその製造方法 | |
JP2003146313A (ja) | 殺菌方法 | |
JPH09240629A (ja) | 無菌充填装置における紙容器の殺菌方法及び殺菌装置 | |
JPH10157713A (ja) | 過酸化水素及びマイクロ波を利用した容器殺菌方法及び容器殺菌装置 | |
JP6843578B2 (ja) | チャンバー殺菌装置 |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
121 | Ep: the epo has been informed by wipo that ep was designated in this application |
Ref document number: 08720165 Country of ref document: EP Kind code of ref document: A1 |
|
NENP | Non-entry into the national phase |
Ref country code: DE |
|
122 | Ep: pct application non-entry in european phase |
Ref document number: 08720165 Country of ref document: EP Kind code of ref document: A1 |