Comparison between the most popular traditional pe

2022-08-16
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Comparison between traditional pet filling and aseptic cold filling technology

although aseptic cold filling of pet has not developed for a long time, several famous beverage and brewing equipment manufacturers in the world have developed relatively mature aseptic cold filling technology. Filling process comparison. Traditional hot filling can be divided into two types: one is high-temperature hot filling, and the other is pasteurization by heating the product to 65 ℃ ~ 75 ℃ after medium temperature filling. These two methods do not need to sterilize the product, bottle and cover separately, but only keep the product at high temperature for a long enough time to sterilize the bottle and cover. Aseptic cold filling first needs to sterilize the product, bottle and cover respectively, and then fill in the aseptic environment until it is completely sealed before leaving the aseptic environment

from the comparison of the two process flow diagrams, the biggest difference is that the heating time of the beverage is different. As we all know, the longer the heat treatment time, the greater the impact on the quality and taste of beverages. UHT ultra-high temperature instantaneous sterilization is adopted for aseptic cold filling, and the heat treatment time of materials is not more than 30 seconds, and the sterilization effect can be fully guaranteed under high temperature conditions. However, the sterilization method adopted for hot filling makes materials stay at high temperature for a long time, which seriously affects the taste, color and content of heat sensitive nutrients (such as vitamins) of products

in addition, from the perspective of production line configuration, when the filling machine breaks down and stops, some of the materials processed by hot filling will prolong the heating time, which will seriously affect the quality of the whole batch of products, while this phenomenon will not occur in sterile cold filling. The materials have been reduced to room temperature after instantaneous sterilization, and their quality will not be affected if they are placed in sterile cans

comparison of PET bottles used. It can be seen from the above filling process that the requirements of the two filling methods for PET bottles are different. The hot filling process requires that PET bottles can withstand a high temperature of 85 ℃ ~ 92 ℃ without change, which requires increasing the crystallinity of PET materials and limiting the generation of induced stress during bottle blowing. The PET bottle it uses has the following characteristics: the bottle wall is thick, and there are clear bottle wall ribs to prevent thermal shrinkage; Crystal bottle mouth is required, which greatly limits the freedom of bottle shape design. Aseptic cold filling can use light bottles (with a maximum heat-resistant temperature of 60 ℃) and standard caps, which greatly reduces the cost of bottles and caps, and allows you to choose and design bottle types freely

technical characteristics of aseptic cold filling process

in the hot filling process, the beverage will be kept at high temperature for a long time, so the bacteria and microorganisms will be killed, and preservatives will be added, so the beverage is relatively safe. So, how does aseptic cold filling ensure the safety of beverages? The most important thing is the establishment and guarantee of sterile environment. Compared with hot filling new reinforcement materials such as inorganic whisker reinforcement and carbon fiber reinforced PA, sterile cold filling adopts UHT ultra-high temperature instantaneous sterilization for material sterilization, which has short heating time, little loss of nutrients, and no significant change in quality and taste. The latest aseptic cold filling process can cooperate with pasteurization for cold chain production, so that the loss of nutritional components of materials is lower, and under the condition of cold chain, the safety of products can be fully guaranteed

sterilization of packaging materials is the most critical step in the production process of sterile cold filling. Due to the heat resistance of PET materials, only chemical reagents can be used for sterilization. To ensure that the bottles and covers are effectively sterilized and that the chemical reagents cannot affect the materials, the following measures are taken for aseptic filling: the original colony count of the initially blown bottles is required not to exceed 5cf/bottle; Sterile air is used for conveying bottles, and there should be an air conveyor belt; Peracetic acid disinfectant (PAA) is used inside the bottle for sterilization, which can achieve high sterilization effect (up to 7log); At the same time, disinfect the outside of the bottle with disinfectant; Disinfectant has automatic recovery and concentration measurement system to ensure the stability of disinfectant concentration; Rinse the residual disinfectant in the bottle with sterile water, and then dry it with sterile air to ensure that the residual disinfectant will not affect the materials; The bottle cap is generally sterilized with disinfectant immersion, and the sterilization effect can be well guaranteed by controlling the immersion time

the main equipment of aseptic cold filling is required to comply with the sanitary design, which has advantages in pipeline and valve technology, planing of material surface, surface design of important areas, selection of corrosion-resistant materials in China is no exception, and it also has a complete automatic cleaning (CIP) system, sterilization (SIP) system and external foam cleaning system (COP). In addition, aseptic cold filling machines are designed with their own unique aseptic filling valves, All these measures ensure that the equipment will not cause secondary pollution to materials

because the PET bottle will not shrink after cold filling, there will be some air between the material and the bottle cap, and the oxygen in it will slowly oxidize the material during storage, resulting in the deterioration of the beverage. Therefore, a set of nitrogen (or other inert gases) will be added to the sterile cold filling equipment. Please pay attention to the regular inspection and maintenance of the replacement system of the experimental machine, and blow away the air on the top to ensure that the materials are not oxidized

isolation measures in the purification room are generally adopted to maintain the sterile space environment. The main filling machine is designed as a D100 level air purification room, and there is a 10000 level purification room outside (some aseptic filling equipment are not required). The air cleanliness in the filling environment is guaranteed through the filtration system in the purification room, so that the materials will not be secondary polluted by suspended microorganisms in the air

neutral drinks cannot be produced by the hot filling process. Due to the sterilization of the bottle cap by pouring bottles, high acid drinks can also inhibit the growth of microorganisms, while neutral drinks cannot guarantee the product safety, and the product defect rate is very high. If neutral tea drinks are produced by hot filling process, preservatives must be added. For aseptic cold filling, because the filling is carried out under aseptic conditions, its process is suitable for strong growth, and it can produce a wide range of products, including neutral tea drinks, milk drinks and other beverages. Only adjusting the pretreatment equipment can change the product type

operator factor: in the whole environmental system, the operator is the largest source of pollution. The design of air purification room not only purifies the air, but also reduces the pollution caused by personnel; When entering the 10000 level purification room, the operators should go through spray sterilization; The 100 grade purification room is designed to be small and practical, so that operators can operate without destroying their sterile environment; The inner surface of the purification equipment can be automatically cleaned and disinfected

management factors. The aseptic cold canning technology of beverages is very high, which requires high-level technicians and high-quality managers to carry out unified management. Generally, HACCP management system is applied. All management shall be documented and implemented by special personnel. Only standardized management can be achieved; In order to truly ensure the safety of aseptic cold filled beverages

cost comparison between raw materials and production line

there is a great difference in the input cost of the production line between the two filling methods. The bottle blowing machine used for aseptic cold filling has fast bottle blowing speed and low power consumption, while the bottle blowing machine used for hot filling has slow bottle blowing speed and high power consumption. Under the same production capacity, the investment is much higher than the bottle blowing sail used for cold filling (excluding bottle blank equipment). Aseptic cold filling process is complex, and there are many filling auxiliary equipment. Overall, the initial investment of a sterile filling production line is higher than that of a hot filling production line

in terms of raw material cost, the main reason is that the quality of the two kinds of bottles is very different, so raw materials are saved to reduce the cost. Due to the special requirements of hot filling PET bottle mouth, the weight of the two kinds of bottle caps is also different

in terms of operating cost, the consumption of sterile cold filling multi item bactericide is still much lower, and the faster the production line is, the higher the output is, the lower the production cost is

through comparison, it can be seen that the initial investment of aseptic cold filling is relatively large. 2. The experimental requirements of impact testing machine, but because the raw material cost and operation cost of aseptic cold filling are relatively low, the higher part of the investment will be recovered soon. With the extension of the use time of the equipment, the low-cost advantage of aseptic cold filling can be clearly demonstrated

conclusion

both the traditional hot filling technology and the sterile cold filling technology have been widely used. The technology has its own advantages. The traditional hot filling technology is mature, the product risk is small, the operation is relatively simple, and the skill requirements for employees are not very high, but its shortcomings in beverage preservation cannot be completely solved. Aseptic cold filling technology has complex process requirements and certain risks, but its products have incomparable advantages in beverage nutrition and fresh-keeping, and have a very broad prospect in the future market development. It should be noted that with the improvement of modern filling technology, aseptic cold filling will gradually replace hot filling as the main way of beverage packaging

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