Explore the Tetra pak Aseptic filling technology in FGC

Have you ever wondered what the functions of Tetra Pak boxes are? What is Aseptic filling technology and how does it work? Continue reading this article to find out the answer.

Contents

Introduction

Consumers are moving towards natural and organic drinks without preservatives. As a result, interest in products packaged in Tetra Pak boxes and produced using Aseptic Technology has also increased. Some typical product lines commonly packaged using Aseptic technology are dairy products, juices, soups, sauces, plant-based and protein drinks, prepared foods, and medical products. In this article, FGC will provide detailed information about this packaging and technology.

Concept of Aseptic Filling technology

First known in the medical field, Aseptic technology has gradually demonstrated its strengths when applied to the food and beverage industry. Derived from the Greek word “septicos”, “aseptic” refers to the exclusion of putrefactive microorganisms. Aseptic packaging technology is the process in which product content and packaging are sterilized separately, then filled and sealed in a sterile atmosphere. During aseptic filling, products are sterilized by UHT technology and packaged at room temperature.

In general, Aseptic technology includes a series of sophisticatedly designed, closed, and automatically linked machine systems. The purpose is to prevent bacteria from entering during production, from raw material processing to final products, ensuring minimal loss of product quality and nutritional value. Thanks to sterilized technology, the products can remain fresh at room temperature without preservatives, creating a clean and food-safe packaged food and beverage market.

concept of aseptic filling technology — “aseptic” refers to the exclusion of putrefactive microorganisms

Function of each layer of the Tetra pak Boxes

One of the most popular types of packaging using Aseptic technology is Tetra pak cartons. It is easy to come across milk, juice, or some liquid foods and drinks in Tetra Pak packages. Tetra Pak material is a light laminated film packaging for sterile purposes. People have developed Tetra Pak cartons to preserve the nutritional value and quality of the product inside. Normally, this packaging is used to liquid, concentrate, or sauce products with small particle sizes and low viscosity. They contain six layers made from three materials, including paperboard (75%), polyethylene (20%), and aluminum (5%).

The outer layer is from polyethylene (PE) to shield the products from external moisture and bacteria. The second layer is paperboard, also called cellulose, which provides strength and dimensional stability and increases durability. The next layer, made from PE, works as a binding layer. The fourth layer is made of aluminum, building a barrier to prevent oxygen, flavor, and light from leaking. Following is another layer of polyethylene, which is needed for the lamination process. Finally, the inner layer, also made of polyethylene, seals off the liquid inside.

Six layers are connected using heat and pressure to protect the products from environmental impacts, such as light, oxygen, air, dirt, moisture, and bacteria. Besides, Tetra Pak boxes are recyclable, lightweight, and portable, which is easy for transportation. They also need easier storage conditions, in which products do not need to be kept in the fridge until opened. After being used, Tetra Pak packages can be recycled into other paper products, panel boards, roof sheets, etc.

6 layer tetrapak boxes — Each layer has its own function

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Aseptic filling process

In general, aseptic processing includes sterilization of the product content, packaging materials or containers, and the aseptic installations, then filling and sealing.

Sterilizing raw materials

The first step in an aseptic filling process is to sterilize raw materials. Manufacturers will heat the unprocessed ingredients and sterilize them at a high temperature, about 110°C to 120°C, for a short time (from 10 to 15 seconds). Then, let them cool to room temperature or higher to get the desired viscosity for filling and sent to the packing facilities. Depending on the nature of the product, heating and cooling processes should be done as quickly as possible to get the highest quality and save operating costs. There are currently several methods to sterilize raw materials, including using microwaves, electrical resistance heating, high voltage discharge, and ultra-high pressure.

Sterilizing packaging materials

Meanwhile, Tetra Pak packaging materials are also sterilized. In Aseptic packaging, sterilization of packaging is often carried out by chemical methods. The most commonly used chemical for sterilization is hydrogen peroxide (H2O2). Depending on the aseptic packaging equipment, there are different methods of using the sterilant, including spraying, using vapor, roll system, or immersion.

sterilie aseptic filling environment — Aseptic technology requires sterile environment

Filling process in sterilized environment

After the sterilization of products and packaging, recontamination must be avoided. Therefore, the containers must be formed, filled, and sealed in a sterile environment. Manufacturers must keep the manufacturing areas sterilized and maintain the level of sterility throughout the production process. The sterilization of the filling machine can be conducted by temperature or the combination of temperature and chemicals. Besides, in most Aseptic packaging systems, positive pressure of sterile air is applied to enclose the forming, filling, and sealing areas.

After the sterilization process, product content flows into a holding tube. A deaerator removes the remaining air to avoid unexpected reactions. The product is then quantitatively poured into individual packaging. Tetra Pak boxes are closed and sealed to maintain sterility during handling and distribution. They are sprayed with water to clean the sticky liquid at the top and bottom welds and dried completely to end the process.

Aseptic regulations

The process of producing sterile products involves many different stages and standards. Aseptic facilities are required to apply the aseptic technology to production. In the aseptic manufacturing plants, products are processed and packaged in a completely automated, closed, and microbiological-free environment. There is some equipment to manage microbial contamination during production.

The environment in the UHT filling areas must be completely sterile, with all the packaging and filling areas thoroughly cleaned and disinfected before production. Positive air pressure is kept throughout the production to prevent re-contamination from the outside environments. Besides, the air is continuously filtered to ensure the required quality related to moisture, temperature, and pressure. To preserve sterility throughout the process, every aseptic system must be able to close or seal the package hermetically. At the end of the production, any product residue remaining in the sterile filling area must be cleaned and removed to avoid creating conditions for bacterial growth.

In addition, workers in these regions are required to adhere to strict regulations to prevent microbiological or particle pollution of the environment. They need to wear sterile clothing with full body coverage and special footwear or shoe covers. Moreover, before entering the UHT filling areas, employees need to wash and sanitize their hands. Protective clothing should be sterilized after each use and replaced periodically.

aseptic regulations — Aseptic technology has strict regulations

Conclusion

The most outstanding feature of Aseptic technology is its absolute sterilization from raw materials and packaging to the production environment. This technology combines with Tetra Pak cartons with 6 layers to help protect products inside and ensure their quality without any preservatives.

About Future Generation Co.,Ltd

We are FGC, the leading tea and beverage exporter in Vietnam and one of the biggest tea suppliers in the world. Our tea products are diverse in types, grades, and production methods. We provide customers with Loose tea (such as Black tea, Green tea, and Oolong tea), Herbal tea (such as Rose tea, Chamomile tea, and Lotus tea), and Specialty tea (such as Matcha), RTD Tea, and Tea Bags. Our mission is to become Vietnam’s leading healthy beverage company.

We ensure stable tea sources for domestic markets and exports with vast high-grown tea farms and available herb gardens. Our tea gardens and factories also meet international standards such as ISO, HACCP, KOSHER, HALAL, etc. In addition, we constantly innovate our machinery system, strengthen production capacity, and increase productivity. We also provide private label and customized packaging services for small and medium enterprises.

If you are a tea distributor, tea importer, teashop manager, or even tea lover, we are committed to being your prestigious tea source supplier in Vietnam!