The Principle and Application of Aseptic Filling Technology

Aseptic filling is defined as the technology, which fills sterile products into sterile packages through an aseptic operating environment. Its main application is in the filling of liquids with high microbial control standards such as food products, drugs and more. The essence of the technology is to maintain sterility condition of the finished product as well as that of the package material for the entire duration of filling thereby eliminating chances of related contamination and thus enhancing maintained product freshness even in compromised packaging.

The basic process of aseptic filling technology is straightforward and can be summarised in a several steps as follows:

Product Sterilisation

The first step in aseptic filling is concerned with the treatment of the product to be filled into the package to render it free from microbiological organisms. Some of the techniques applied here include high – temperature short time (HTST) and ultra – high – temperature (UHT) sterilization which are instantaneous science high temperatures. Product heating and cooling mechanisms can eliminate all microbes, bacteria molds and yeast including those present in the product and thus ignore bringing the product into the aseptic area because all microbiological organisms have been eliminated from the product that goes into the aseptic area.

Sterilizing Unit’s Packaging

It is not only the product which is required to be sterilized, the organ or the material which contains the product also should be treated in a sterile way. There are different options for sterilizing the packages, including heat, chemicals, and ultraviolet radiation. Hydrogen peroxide is a common chemical that is used in sterilization and is effective in destroying any microorganisms that might be found on the enclosed surface of the package. Aseptic makeup of the packages ensures that when packing and fixing the covers to the filled containers, the covers do not act as a source of contamination.

Aseptic Filling Environment

The aseptic portion of the process takes place within the aseptic filling system. This usually relies on normal and controlled aseptic air with positive pressure or a closed chamber system to avoid the microorganism from external air from getting into the filling system. As far as the placement of apparatus is concerned, machines used for aseptic pouring of liquids and other materials have inherent characteristics positioned to eliminate microorganisms from penetrating the devices & human contact is avoided during operation of filling machines.

Aseptic Sealing of the Package

The second the product is filled up, the next step is to aseptically seal the package. The process of sealing, like filling, must be conducted in an aseptic environment so that the product is able to remain free from microbial and all sources of contaminants once it has been properly sealed. The air tightness of the packaging determines the shelf life of the product and it has to be exacting and dependable.

Aseptic filling technology is, without doubt, better than the traditional filling methods. To begin with, since all the operations are done in aseptic conditions, the product is not subjected to microbial attack which enhances the shelf life of the product especially for perishable foods and drugs. Also, since there is no need for adding preservatives, the product can be more natural in its original taste, hence satisfying the demand of healthy and safe products.

Aseptic filling technology has extensive application in the field of food, beverages, drugs and medical products. Typical ones are such products as milk, juice, functional drinks, liquid forms of drug, non-parenteral and parenteral dosage forms, vaccines, etc. These products are of very high hygiene standard and any form of microbial contamination will jeopardize their quality and safety. As far as the food and beverage industry is concerned, there is an introduction of aseptic filling technology to help enterprises to satisfy consumer’s requirements towards high-quality long-shelf-distance products; such as in the case for the pharmaceutical industry particularly during the manufacturing processes of vaccines & sterile injections, aseptic filling technology acts as a great support for the effectiveness and security if the medications.