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Aseptic Filler & Sealer

The choice of the aseptic filler and Sealer is dependent upon the food or the product to be packed, type of packaging, shelf life requirements, available technology, resources, costs involved and so many other variables. Below are different Aseptic filling and sealing options for different products.

Fill and seal: preformed containers made of thermoformed plastic, glass or metal are sterilized, filled in aseptic environment, and sealed

Form, fill and seal: roll of material is sterilized, formed in sterile environment, filled, sealed e.g. tetrapak

Erect, fill and seal: using knocked-down blanks, erected, sterilized, filled, sealed. e.g. gable-top cartons, cambri-bloc

Thermoform, fill, sealed roll stock sterilized, thermoformed, filled, sealed aseptically. e.g. creamers, plastic soup cans

Blow mold, fill, seal

Major types of Aseptic Packs

A great variety of packages may be aseptically filled now as listed.

  Carton Boxes:-Some of the existing aseptic carton boxes may now be filled with particulates,also aseptically.

•  Bags and Pouches:-Pillow pouches are usually used for packaging of milk; three-sided sealed pouch.

•  Cups and Trays:-These are either used pre-made or formed, filled and sealed in thermoform/fill/seal machines. Both types of machines exist for filling particulates and also in packs suitable for microwave heating. Usually polypropylene-based multilayer materials withEVOH barrier are applied for this purpose.

  Bottles and Jars:-Glass bottles may be aseptically filled with food containing small particles. Closing is usually done by heat-sealing aluminium lids.

•  Metal Cans:-Steel and aluminium cans can also be filled aseptically.

•Plastic Cans:-Cans and lids with easy opening feature consist of PP/EVOH/PP. They are sterilized with hydrogen peroxide, UV radiation and heat-sealed inductively.

Few of the prevalent Sterilization / Aseptic techniques are

  •Sterilisation Agents:-Heat, chemicals and radiation have been used, alone or in combination, for sterilization of aseptic equipment and packaging materials.

 • Heat:-Initially, heat was used as the sterilant for aseptic systems as a natural extension of thermal processing. Product supply lines and fillers are commonly sterilized by ‘moist’ heat in theform of hot water or saturated steam under pressure. ‘Dry’ heat, in the form of super-heated steam or hot air, may also be used to sterilize equipment.

 • Chemicals:- Hydrogen peroxide is the overwhelming choice for use as a chemical sterilant. Other chemicals which have been used as sterilants, primarily for use in systems for acidfood, include various acids, ethanol, ethylene oxide and per-acetic acid.

  • Radiation:-Gamma-radiation has been used for decades to decontaminate packaging materials foruse in aseptic systems for packing acid and acidified food. Due to the penetrating powers of gamma-radiation, packages are treated in bulk at commercial irradiators. Adose of approximately 1.5 Megaradians (Mrad) is commonly used to decontaminate containers for acid and acidified food. Recently, processes for low acid food aseptic filling and packaging systems are also being accepted. Doses required to sterilize containers for use with low acid food are considerably higher than those required for acid and acidified food.

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