Aseptic processing and filling.

Different kinds of packaging of foods and beverages.

Aseptic packaging has been developed by the market’s demand of packaging natural products. Thus, the evolution of packaging technology is:

Cans

This way of packaging is used by roughly 90% of the market. Even though this kind of packaging is using more and more aseptic packaging techniques.

It has the following disadvantages:

  • Expensive.
  • Empty cans occupy large storing rooms.
  • High manipulation costs.
  • Foods must be filled in hot so there is big loss of quality.

Asepton

It meant a revolution as substitute of 5 kg cans that are used in the industrial sector. It can be used several times once it has been emptied.

Disadvantages:

  • Expensive.
  • Foods must be filled in hot so there is big loss of quality.
  • Empty cans occupy large storing rooms.
  • Very difficult to be cooled once filled due to its dimension.
  • High manipulation costs.

Tetra Pak's range

This kind of packaging is known by most of the people. It is very well introduced in the milk, dairy and beverage industries.

Disadvantages:

  • It is not an industrial type of packaging.
  • Products with fibers and particulates can't be filled.

Competitors:

  • PKL
  • International Paper

Glass bottles, jars and PET

Glass is loosing momentum in the market. And PET is developing fast for the aseptic filling of juices and beverages.

Frozen foods

Freezing of foods enables the best quality products. But it is not a well established technology.

Disadvantages:

  • Logistics.
  • Storing.

Advantages of HRS' aseptic technology

The perfect team formed by the piston pump, Unicus® or corrugated tube heat exchangers and aseptic filler is key to lead the market of aseptic processing of fruits and vegetables.

Reasons:

  1. HRS Piston Pump is unique in the world when pumping particulate products in a very soft and delicate way for not destroying any piece or deteriorating its shape. Furthermore it is a very strong and reliable pump that can allow high pressure drops. Competition's pumps are usually more expensive (Marlen) or inadequate for achieving the best treatment (Waukesha lobular, Bredel peristaltic, etc).
  2. Unicus® Dynamic Heat Exchangers are the perfect exchangers whenever the going gets rough and either high viscosity or high fouling tendency come on stand. Unicus® guarantees unlimited running times because there is no need to stop for cleaning. It is therefore key for enlarging production cycles and not loosing productivity. On the other hand, SPIRATUBE® Corrugated Tube Heat Exchangers are very appropriate whenever products do not have fouling tendency nor their viscosity is high. Corrugated tubes enable high levels of turbulence that make the heat exchange process fast and effective, thus products can maintain most of their vitamins and natural characteristics.
  3. Once products have been sterilized they can be filled in an HRS aseptic filler, which in different formats can adapt to what the customer needs. Big capacity or average ones for catering, small bags for domestic consumption...

HRS aseptic fillers' applications

Aseptic filling can be used for any type of fluid or doughy product processed by the food industry. In order to satisfy all requirements, producers of aseptic bags use various kinds of materials: high-barrier, multi-layer, flexible laminates, transparent or dull, coextruded, metalized of provided aluminum foils.

Bag-in-box & Bag-in-drum

Types of bags, sizes and applications:

  1. 55 gallon bags. These bags, available in metalized material (simple or high barrier) or coextruded material, are produced both for the European market associated with conical drums and for the Extraeuropean market associated with cylindrical drums.
    Applications:
    • Traditional products such as tomato concentrate, paste and pulp, citrus fruits juice and fruit puree, they are produced with 1 inch spout.
    • For delicate products such as diced tomato and diced fruit 2 inches closures are used.
  2. Gusseted bags up to 220 liters. The typical gusseted bag is adaptable to any kind of external box, steel drum, cardboard box, plywood box, and jute bag. Modern bags guarantee an excellent barrier to oxygen. Such bag offers a capacity of 5, 10, and 20 liters also.
    Applications:
    • Traditional fruit juice concentrate (pear, apricot, peach, strawberry).
    • Tropical fruit (peach, papaya, guava, acidified and natural banana).
  3. Big size bags. Big size bags up to 1000 liters have been developed with particular care towards practical handling, transport and storage.

Form-fill-and-seal

Bags are available in formats up to 0.5, 1, 5, 10, 15 and 20 liters, and are manufactured with metalized or coextruded material.

These bags are suitable for filling:

  • Acid products, such as tomato and by-products (ketchup, pizza sauce).
  • Fruit juices and citrus fruit juices.
  • Low acidity products like milk and cream, liquid egg, mayonnaise.
  • Precooked foods: beans, vegetable stuffing, etc.
  • Large scale productions such as wine and vegetable oil.

Schematic of HRS' aseptic processing and filling

HRS Aseptic Processing and Filling

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