Difference of aseptic filling and hot filling

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Difference of aseptic filling and hot filling

Aseptic packaging technology was born in the 1930s. The PET aseptic cold filling production line uses aseptic space for sterilization to ensure that the entire filling process meets aseptic requirements.
Different filling process

1. Hot-filling: product \ bottle \ lid sterilization, after filling the product into the PET bottle, the center temperature of the product is measured to be 88 degrees, the high temperature product is sterilized by pouring the bottle, and then enters the cooling machine and cooled to room temperature;
Cold filling: Sterilize the products, bottles, and caps separately, fill them in an aseptic environment, and completely seal the products and bottles before leaving the aseptic environment.

2. Process difference
The biggest difference is the heating time of the product.
Aseptic cold filling: The product adopts UHT ultra-high temperature instantaneous sterilization, then quickly cools to room temperature, and stores it in an aseptic tank for filling at any time;
Hot-filling: The product is sterilized by UHT high temperature instantaneously, and then cooled to above 90 degrees; the product temperature after filling is 88 degrees. Because the product has been heated for a long time, it will have a certain impact on the color, flavor and nutrition.


3. Different production line configuration
Hot filling: 1) When the filling machine fails and shuts down, the product will flow back in the sterilizer. Repeated sterilization will damage the flavor and nutrition of the product to a certain extent; 2) The filling will be completed with a large cooling device The product is cooled to normal temperature.
Aseptic cold filling: 1) The product is temporarily stored in the aseptic tank after the sterilization is completed, and repeated sterilization will not occur; 2) The product is filled at room temperature without cooling equipment.


4. The difference between PET bottles
Hot filling: The process requires that the PET bottle can withstand a high temperature above 92 degrees, so the PET bottle used should have the following characteristics:
The bottle wall is thick and there are clear ribs on the bottle wall to prevent heat shrinking and crystallization of the bottle mouth. The bottle mouth does not deform during the filling and cooling process. Aseptic cold filling: the maximum heat-resistant temperature is 60 degrees, so you can use PET light bottles And standard caps, greatly reducing the cost of bottles and caps. Note: PET bottle production process Blanking---disposing of embryos---loading (into the embryo---heating---pre-blowing---high-pressure blowing---exhausting---unloading---sterile air duct

5. Different production line costs
Hot-filling: The blow molding machine is slow and consumes a lot of power. Under the same production capacity, the investment is much higher than that of the cold-filling blow molding machine (excluding preform equipment);
Aseptic cold filling: The blow molding machine used for aseptic cold filling has fast blowing speed and low power consumption, and the blow molding machine is fast and consumes less power. However, the aseptic cold filling process is complicated and there are more filling auxiliary equipments. . Overall, the initial investment of an aseptic filling production line is higher than that of a hot filling production line.


6. Different raw material costs
Hot-filling: The bottle body and mouth are required to be able to withstand high temperatures (low heat shrinkage), so the quality of the bottle and lid is very high;
Aseptic cold filling: There is no requirement for high temperature resistance of bottles and caps, so lightweight bottles and individual caps can be used. In comparison, aseptic cold filling packaging materials cost lower than hot filling.

7. Different operating costs
Hot-filling: In the production process, the consumption of sterilizing liquid is relatively small, but the production line speed is slow and the production capacity is relatively low
Aseptic cold filling: In the production, the consumption of sterilizing liquid is relatively high, but the production speed is fast and the production capacity is high. In comparison, the operating cost of aseptic cold filling is lower than that of hot filling.


8. The outstanding hot spots of PET aseptic cold filling compared with hot filling
Using ultra-high temperature instantaneous sterilization technology (UHT), the heat treatment time of the materials does not exceed 30 seconds, which guarantees the taste and color of the product to the greatest extent, and preserves the vitamin (heat-sensitive nutrients) content in the material to the greatest extent.
The filling operation is carried out in an aseptic, normal temperature environment, and no preservative is added to the product, thus ensuring the safety of the product.
Improve production capacity, save raw materials, reduce energy consumption, and reduce product manufacturing costs. The advanced technology can be widely applied to filling various products.


9. Aseptic filling technology environment
Definition At room temperature (≤30℃), the sterile product is filled into a sterile packaging container in a sterile environment, and then sealed.
Aseptic environment: The filling and sealing of the entire product is completed in an aseptic environment, so the hygiene requirements for the filling environment are very high. The filling is generally completed in a closed filling equipment, and it is required to enter All media and packaging in the filling equipment must undergo aseptic treatment, and the surface of the filling equipment must also undergo aseptic treatment to ensure the sterility of the entire filling environment. The medium entering the filling equipment includes air, water, and liquid; packaging materials include bottles and caps.
Air treatment: It is completed by air filtration system, which is generally composed of primary filter, medium efficiency filter, and high efficiency filter. Primary-efficiency filters mainly filter dust particles in the air; medium-efficiency filters mainly filter larger bacteria and some dust particles in the air, with a filtration efficiency of more than 85%; high-efficiency filters can filter almost all the bacteria in the air Including the smallest bacteria, the filtration efficiency is over 99.97%. The treated air is called aseptic air, and the sterility of the aseptic air needs to be verified regularly during the production process to ensure product quality.

Water treatment: There are currently two methods: the first method is to use UHT equipment to sterilize the water entering the filling environment; the second method is to use a pure water aseptic filtration system to complete, and the treated water is called It is sterile water. The water mentioned here is not the water we use when we prepare beverages. Sterile water is mainly used for rinsing the sterilized caps and bottles in the filling environment and after the surface of the filling environment is disinfected.
Processing of packaging materials: Packaging materials refer to bottle caps, bottles, bottle caps and bottles are sterilized by disinfectant. Due to different sterilization methods of production equipment, Tetra Pak and Tetra Pillow are different in the dairy industry. Packaging methods such as black and white film generally use immersion sterilization, and PET bottled beverages generally use perfusion or spray sterilization. The main disinfectants used to disinfect packaging materials are peracetic acid and hydrogen peroxide.

Material liquid treatment: UHT equipment is used to sterilize the material liquid, and the water entering the filling environment is sterilized.