2.aseptic system.6
TRANSCRIPT
7/28/2019 2.Aseptic System.6
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Panich Choenthanomwong
Training and Quality Department
6 June, 2013 Page 1SIG Combibloc
Aseptic Filling Machine
Sleeve
feed
Sleeve
forming
Base
activation
Base
folding
Base
pressing
Peroxide
sterilizationDrying Filling
Top
sealing
Top
formingConveying
Aseptic Zone
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Panich Choenthanomwong
Training and Quality Department
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Aseptic system
What is the meaning of “Aseptic
”
Aseptic means “working under germ-free condition.
Or the summary of all measures guaranteeing the
absence of any reproductive micro-organism.
Or free from or keeping away.
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Panich Choenthanomwong
Training and Quality Department
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Preservation of foodstuffs by heat treatment
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Training and Quality Department
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Preservation of foodstuffs by heat treatment
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Training and Quality Department
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Aseptic system
comparison of processing method
Packaging Product
Sterilisation
of sealed packs
Packaging Sterilisation
Aseptic Zone
Aseptically
packed product
Sterilisation
Packed,
sterilised product
Filling and
sealing
Microorganisms
(bacteria)
Microorganisms
(Bacteria)
Filling and
sealing
Product
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Training and Quality Department
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Factors of influenceon the asepticprocess:
Aseptic filling
of beverages,dairy and foodproducts intocarton packs
Aseptically packaged
product
ASEPTIC
Sterilisation liquid/
Package sterilisation
Filling machine
sterilisation
Human
factor
Quality of the non-sterile product
Product
heating
Aseptic
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Training and Quality Department
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Factors affecting the sterility rate of an aseptic production
1. The Microbiological load of the raw material
2. Sterilization effect of UHT process3. Cleanliness and sanitary conditions of plant
4. Maintenance of aseptic conditions during production
5. Microbiological contamination of carton’s surface (inner)
6. Efficiency of sterilization of carton’s surface
7. Packages integrity8. Cleaning and sterilization of filling machine (Aseptic zone)
9. Care and diligence of operating staffs
10. The service and preventive maintenance of the aseptic processing and
packaging system
11. Plant hygiene.
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Training and Quality Department
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Aseptic Filling Machine
Three main processes are used for the decontaminationprocesses:
Steam sterilisation
H202 vapour sterilisation Filtration of air
Filtration of Nitrogen and pressurised air for tank overpressure
(Options)
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Training and Quality Department
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Aseptic Filling Machine
1.Steam sterilisation
Product pipe system,
Product tank,
Product valves,
Filling valves
Air (Pall) filters for product tank pressure
Nitrogen filters for Nitrogen injection
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Training and Quality Department
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Aseptic Filling Machine
2. H2O2 vapour sterilization.
- Pocket chain
- Drying zone
- Filling zone
- Steam injection
- etc
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Training and Quality Department
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Aseptic Filling Machine
3. Filtration of air
HEPA (high efficiency particulate air filter) filtration of the air for the
aseptic zone
Filtration of pressurised air for product tank pressure
Filtration of Nitrogen for Nitrogen injection
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Training and Quality Department
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Combibloc filling machine operation.
Conclus ion.Condition for aseptic operation of the combiblocfilling machine
1. Operator 2. Filling machine
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Training and Quality Department
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1.Operator (5 important rule of Hygiene)
1.Personal cleanliness (wash hands )
2.Clean working clothes and hat
3.Clean environment (walls, floors,ceilings)
4.Do not work at machine with open wounds(even small wounds must be taken care of)
5.Any consumption of food at the filling machineis prohibited
Combibloc filling machine operation.
C bibl filli hi ti
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Training and Quality Department
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Combibloc filling machine operation.
2. The f il l ing m ach ine
1.The parts of filling machine must be cleaned ,sterilized for each start of production:
- Product-holding lines(pipelines, filling station etc)- Aseptic zone
2. Spray sterilization of hands and possibly of partsinstalled into the aseptic zone.
(All parts must be cleaned and dried)
C bibl filli hi ti
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Training and Quality Department
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Combibloc filling machine operation.
3. The filling machine must be cleaned immediately after the end of production (manual cleaning, pocket chaincleaning and CIP cleaning)
4. No leakage at aseptic zone , product pipe.
5. Keep sterile air pressure condition
6. The carton must be sterilized during production and
check cartons for leaks.
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A ti Filli M hi
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Training and Quality Department
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Aseptic Filling Machine
Decontamination processes used within a combibloc system:
Steam sterilisation for product pipe system, product tank, product valves,
filling valves and air (Pall) filters for product tank pressure and Nitrogen filters
for Nitrogen injection
H2O2 sterilisation for aseptic zone surfaces and HEPA air filter system
H2O2 sterilisation of the package during production
HEPA (high efficiency particulate air filter) filtration of the air for the asepticzone
Filtration of pressurised air for product tank pressure
Filtration of Nitrogen for Nitrogen injection
Additional options not available for all formats:
Dedusting unit (to remove dust particles out of the package before it entersthe aseptic zone)
Pocket chain desinfection unit (normally potable water is used for chain
cooling)
A ti Filli M hi
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Panich Choenthanomwong
Training and Quality Department
6 June, 2013 Page 18SIG Combibloc
Aseptic Filling Machine
Decontamination processes used within a combibloc system:
Steam sterilisation for product pipe system, product tank, product valves,
filling valves and air (Pall) filters for product tank pressure and Nitrogen filters
for Nitrogen injection
H2O2 sterilisation for aseptic zone surfaces and HEPA air filter system
H2O2 sterilisation of the package during production
HEPA (high efficiency particulate air filter) filtration of the air for the asepticzone
Filtration of pressurised air for product tank pressure
Filtration of Nitrogen for Nitrogen injection
Additional options not available for all formats:
Dedusting unit (to remove dust particles out of the package before it entersthe aseptic zone)
Pocket chain desinfection unit (normally potable water is used for chain
cooling)
A ti Filli M hi
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Panich Choenthanomwong
Training and Quality Department
6 June, 2013 Page 19SIG Combibloc
Aseptic Filling Machine
Decontamination processes used within a combibloc system:
Steam sterilisation for product pipe system, product tank, product valves,
filling valves and air (Pall) filters for product tank pressure and Nitrogen filters
for Nitrogen injection
H2O2 sterilisation for aseptic zone surfaces and HEPA air filter system
H2O2 sterilisation of the package during production
HEPA (high efficiency particulate air filter) filtration of the air for the asepticzone
Filtration of pressurised air for product tank pressure
Filtration of Nitrogen for Nitrogen injection
Additional options not available for all formats:
Dedusting unit (to remove dust particles out of the package before it entersthe aseptic zone)
Pocket chain desinfection unit (normally potable water is used for chain
cooling)
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Training and Quality Department
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Sterilisation
Product
The liquid food is commercially sterilised.
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Training and Quality Department
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SterilisationSterilisation
Product Packaging
The sleeves are sterilised.
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Training and Quality Department
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SterilisationSterilisation
Product Packaging
Aseptic ZoneFilling and sealing
The sterile product is
filled into sterile
sleeves under sterile
conditions in
aseptically.
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Training and Quality Department
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SterilisationSterilisation
Product Packaging
Aseptic ZoneFilling and sealing
Aseptically filled product
The product is "commercially
sterilised" using a conceptcalled "aseptic processing"
Aseptic Filling Machine
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Aseptic Filling Machine
Aseptic and aseptic filling system
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Aseptic and aseptic filling system
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UHT and “Commercial sterility”
Making Milk Last Longer
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Making Milk Last Longer
We have 2 containers of milk.
• Bottle of milk - fresh or pasteurised
• Pack of UHT milk - closed
• Which one will last longest ?
• Why ?
• What is the difference between the two ?
Question : Which will remain fresher longer ?
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Training and Quality Department
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Question : Which will remain fresher longer ?
Question : Which will remain fresher longer ?
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Question : Which will remain fresher longer ?
The UHT milk can remain fresh
for up to 6 months, or even longer, :-
• without refrigeration and
• without using preservatives.
(The fresh milk will deteriorate in hours at ambient
temperatures, or days if refrigerated.)
Why does the UHT milk last so very long ??
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y does t e U ast so e y o g
• The bacteria in the milk are either killed, or prevented from growing,
by high temperature treatment.
• This is called “commercially sterilising ” the milk.
• The treatment is called “Ultra High Temperature” - UHT.
• It is then aseptically filled into a sterile pack - ie no bacteria.
Definition - Commercial Sterility
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y
“ A commercially sterile product is free from micro organisms which grow under
normal conditions of storage.”
UHT milk does not contain any bacteria capable of multiplication under
normal conditions of storage and distribution.
Same meaning - different words.
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No bacterial
growth
=long shelf life
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Aseptic system
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p y
What is commercial sterility ?
Commercial sterility means:
* The product is free from micro-organism which grow
under normal conditions of distribution and storage
OR
UHT milk does not contain any bacteria capable of multiplicationunder normal conditions of storage and distribution.
Aseptic system
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Commercial Sterility
-Purpose or target of commercial sterility -No Poisons or Toxins-No Pathogens-No Enzyme-No growth of bacteria under room temperature(transportation and shelf stable)
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Aseptic system
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Why UHT product can keep long time in room
temperature ?
1.UHT equipment ,product line and CFA are cleanedand sterilization before production.
2.Product sterilized by UHT system.
3.Package sterilized by H2O2
Aseptic system
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4. Product filled into package under aseptic condition
5. Integrity of the package to prevent post
contamination.
Aseptic system