Aseptic processing

Aseptic processing is the process by which a sterile (aseptic) product (typically food or pharmaceutical) is packaged in a sterile container in a way that 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. Pharmaceutical Sterile processing includes use of clean rooms, bacteria retaining filters, dry or steam heat. Aseptic food preservation methods allow processed food to keep for long periods of time without preservatives, as long as they are not opened. The aseptic packages are typically a mix of paper (70%), polyethylene (LDPE) (24%), and aluminum (6%), with a tight polyethylene inside layer. Sterile pharmaceuticals are usually packaged in plastic or glass. Together these materials form a tight seal against microbiological organisms, contaminants, and degradation, eliminating the need for refrigeration.

The first aseptic filling plant for milk was presented in Switzerland in 1961. 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.

Aseptic containers may range in size from a few fluid ounces to a nearly 8-million-US-gallon (30,000 m³) aseptic tank on an ocean-going ship. Aseptic processing makes worldwide export and import of new, economical and safe food products possible. Bag-In-Box technology is commonly used because it provides strong containers that are lightweight and easy to handle prior to being filled. 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.

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