Aseptic packaging technology emerged in the late 1940s and gained significant traction in the 1960s with the development of plastic packaging materials. This innovation provided a vast platform for its application, especially in food preservation. Aseptic packaging is favored for its minimal impact on food nutrients and flavors, lower costs, ease of storage and transportation, and attractive appearance. As technology advances, the equipment and materials used in aseptic packaging have become more sophisticated, leading to an expanding market. In developed countries, over 65% of liquid food is packaged using aseptic methods, highlighting its promising future.
What is aseptic food packaging? It refers to the process of sterilizing both the food (such as beverages, dairy products, or seasonings) and the packaging environment before sealing them in sterilized containers. This method allows for extended shelf life without the need for preservatives or refrigeration. Essentially, aseptic packaging involves sterilizing the packaging materials, containers, and contents, then sealing them in a sterile environment. The term "aseptic" in the food industry means that the number of non-pathogenic bacteria per gram of food is less than 10. If these bacteria are not able to multiply, the food remains safe even when stored at normal temperatures or under cold or frozen conditions.
Sterilization of packaging materials is a crucial step in aseptic packaging. Common methods include chemical sterilization using hydrogen peroxide and ultraviolet (UV) light. Hydrogen peroxide, typically used at concentrations between 25% and 30%, works best when heated to around 60-65°C. It is often applied by immersion or spraying, followed by heat treatment to ensure complete evaporation. UV sterilization, on the other hand, is most effective at wavelengths between 250-360 nm. While it is safe, non-residual, and cost-effective, it is less efficient than chemical methods and is often used in combination with other techniques.
Common forms of aseptic packaging include cardboard, cup, bag, aluminum/plastic, and plastic bottle packaging. Aseptic cardboard is made from a composite of paperboard, aluminum foil, and polyethylene, offering excellent barrier properties. Sterile cup packaging uses multi-layer co-extruded sheets, such as NAS sheets, which provide a high level of oxygen resistance. Aseptic bag packaging is ideal for large volumes, ranging from 5 to 1000 liters, and is often used in industrial settings. Aluminum/plastic and plastic bottle packaging also utilize similar principles, with materials that can be sterilized during production.
For liquid foods, aseptic packaging has become increasingly popular globally. Aluminum foil composite paper is widely used due to its ability to maintain product quality for over 12 months at room temperature. Key technical considerations include surface treatments for base paper, controlling PE layer thickness, and ensuring the innermost layer meets specific standards. These factors contribute to the effectiveness and reliability of aseptic packaging solutions.
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