The composition of milk is very complex. The vitamin component is very sensitive to light. UV and visible light can be absorbed by vitamins up to 500 nm, resulting in loss of vitamins. Experts have discovered through experiments (taste and gas) that when the milk is exposed to light for hours, the taste will change. Therefore, barrier packaging containers and suitable sterilization techniques are necessary.
By increasing the shelf life of products, it is possible to expand sales channels and market share. Therefore, advances in liquid dairy product packaging technology are of great significance to large dairy product groups. However, improving shelf life, maintaining the taste of liquid dairy products, and maintaining proper costs are a contradiction. The emergence of sterile blow-molded bottles and aseptic filling technology has found a balance.
Sterilization and Aseptic Filling
The length of storage life of dairy products depends on the influence of bacteria, yeast and granular objects on it. There are several ways to extend the shelf life of a product. The traditional method is to first fill the product into a packaging container, and then use a high temperature of 118° C. to 129° C. to heat sterilize the product together with the packaging container. This method of heat sterilization applies to containers such as metal cans, glass cans, glass bottles, and plastic HDPE bottles. In Europe, this method is widely used in the field of milk packaging. To achieve this process, hydraulic disinfection tower is a commonly used technology. In the hydraulic disinfection tower, the pressure outside the bottle body can offset the internal pressure of the bottle body due to the high temperature of 118°C to 129°C, thereby avoiding the deformation of the bottle body. Although these methods are safe and effective, they are limited by application conditions, such as restrictions on the shape of the container. In addition, glass containers need to be slowly warmed and cooled to prevent them from breaking; products also tend to cause changes in taste at high temperatures. The problem that arises is that the final product packaging of each manufacturer is similar in shape and lack of creativity. So sterile packaging method was born. The aseptic packaging process is to sterilize the product and the packaging container separately, and then aseptic packaging using an aseptic filling machine. Its advantages are: instant high-temperature sterilization, reducing the risk of product changes in taste; adapt to a variety of packaging methods and shapes, can be sterilized according to user requirements of the packaging, such as Tetra Pak, sterile plastic bag packaging.
Blow molding sterile plastic bottle
In a variety of aseptic packaging, plastic bottles are the most economical ones. In particular, the blow-molded sterile plastic bottles not only have the advantages of ordinary plastic bottle packaging, but also can be used for multi-layer co-extrusion and in-mold labeling, so that the packaging effect is colorful and the handle can be made Easy to use, but also reduce costs.
The blow-molded sterile plastic bottle is a plastic bottle that is completely sterile inside, free of yeast and other loose particles. Due to the sealing of the bottle mouth, this bottle remains sterilized during storage and during transportation to the aseptic filling machine. Just prior to filling, the outside of the bottle is subjected to sterile liquid disinfection to ensure that the entire process of reopening, filling, and secondary sealing of the bottle is carried out under aseptic conditions.
Aseptically blown bottles are more reliable and cost-effective than pre-filled plastic bottles. The principle is simple: instead of cleaning and disinfecting the soiled objects, it is better to leave them free from pollution. After the bottle body is molded, it is sterilized and sterilized. Not only is the cost high, the equipment is complicated, and the technical requirements for the workers are also high.
Aseptic blow bottle manufacturing
Sterile blow-molding During the blow molding process, the temperature of the plastic is maintained at about 200°C. This temperature is considered by the FDA (United States Food and Drug Administration) as a condition for forming a sterile surface. At this temperature, air and metal contacting the container will not contaminate the container. Blow-molded sterile plastic bottles use this principle. In general blow molding, melted plastic is extruded from an extruder to form a tubular or spherical parison and blow-molded in a mold. During mold closing, the preform is usually filled with low-pressure gas to ensure that the preform will not stick before blow molding.
The aseptic blow-molding technology developed by TECHNE of Italy uses blow air from aseptic compressed air to eliminate any danger of contaminating the interior of the bottle. The hollow blow needle is inserted into the upper dome of the bottle structure in the mold, and then sterile air is blown to form the designed bottle shape. In the blow molding process, after the plastic is cooled by the mold, the gas is released, and then the bottle body is sealed between the insertion point of the blowing pin and the dome by two independently operated mechanisms. This sealing area is isolated from the metal part with the cooling channel, so that after the gas channel is closed by the sealing mechanism, the plastic in this area remains high temperature and the plastic self-adhesion. Due to the close relationship between sterilization and sealing process, two sealing processes are generally used to improve the reliability of sterilization. The reason for using two sealing processes is not because of the imperfection of a sealing device, but to reduce any risk of contamination. The sealing process is completed before the bottle body is removed from the mold, avoiding the possibility of contamination. Afterwards, the mold is opened and the bottle body is removed for scrapping. The sterile bottles now produced can be packaged, stored, shipped or sent directly to the filling process. When sealing the bottle body, it is sometimes necessary to reduce the pressure to slightly lower than normal pressure to ensure that when the bottle body is sealed and the gas is reheated, the latent heat of the plastic does not cause deformation of the bottle body. It should be emphasized that during the entire blow molding process, the inside and the outside of the bottle are completely isolated from the contaminated air, and only the compressed compressed air is in contact with the inside of the bottle.
In order to ensure the barrier properties of the bottle, a multi-layer co-extrusion process is also required. Sterile bottle bodies for liquid dairy products are typically made from 3 or 6 layers of HDPE. TECHNE's multi-layer co-extrusion technology was originally used to solve waste edge materials, mainly to reduce the amount of raw materials used and to recover 10% to 30% of the material in each container, but gained important applications in the manufacture of dairy blow molding bottles. The inner and outer layers of the 3-layer bottle are white and the middle layer is black, which acts as an anti-ultraviolet light. The product has a shelf life of 3 months without refrigeration. The 6-layer bottle adds EVOH barrier layer and the product shelf life can reach 6-9 months.
How to ensure the sterility of compressed air guarantees the sterility of compressed air is a key link. With precision filters, compressed air can be sterilized. When compressed air passes through the microfilter, bacteria and yeast can be filtered out. However, when sterilizing with a filter, the air channel downstream of the filter must also be sterilized. At the same time, in order to meet the hygienic standards for milk production, all the air that comes in contact with the product requires smooth passageways and meets other special requirements for product production. That is, all compressed air passages must be sterilized and maintained sterile throughout the blow molding process. Many sterilization methods currently used are complicated and costly. A simple method is to use the company's OXONIAP3 active sterilizer for sterilization. The sterile bottles and aseptic filling lines produced by this process have been produced and run for years in some European milk production plants. Practice has proved that they are safe and reliable.
By increasing the shelf life of products, it is possible to expand sales channels and market share. Therefore, advances in liquid dairy product packaging technology are of great significance to large dairy product groups. However, improving shelf life, maintaining the taste of liquid dairy products, and maintaining proper costs are a contradiction. The emergence of sterile blow-molded bottles and aseptic filling technology has found a balance.
Sterilization and Aseptic Filling
The length of storage life of dairy products depends on the influence of bacteria, yeast and granular objects on it. There are several ways to extend the shelf life of a product. The traditional method is to first fill the product into a packaging container, and then use a high temperature of 118° C. to 129° C. to heat sterilize the product together with the packaging container. This method of heat sterilization applies to containers such as metal cans, glass cans, glass bottles, and plastic HDPE bottles. In Europe, this method is widely used in the field of milk packaging. To achieve this process, hydraulic disinfection tower is a commonly used technology. In the hydraulic disinfection tower, the pressure outside the bottle body can offset the internal pressure of the bottle body due to the high temperature of 118°C to 129°C, thereby avoiding the deformation of the bottle body. Although these methods are safe and effective, they are limited by application conditions, such as restrictions on the shape of the container. In addition, glass containers need to be slowly warmed and cooled to prevent them from breaking; products also tend to cause changes in taste at high temperatures. The problem that arises is that the final product packaging of each manufacturer is similar in shape and lack of creativity. So sterile packaging method was born. The aseptic packaging process is to sterilize the product and the packaging container separately, and then aseptic packaging using an aseptic filling machine. Its advantages are: instant high-temperature sterilization, reducing the risk of product changes in taste; adapt to a variety of packaging methods and shapes, can be sterilized according to user requirements of the packaging, such as Tetra Pak, sterile plastic bag packaging.
Blow molding sterile plastic bottle
In a variety of aseptic packaging, plastic bottles are the most economical ones. In particular, the blow-molded sterile plastic bottles not only have the advantages of ordinary plastic bottle packaging, but also can be used for multi-layer co-extrusion and in-mold labeling, so that the packaging effect is colorful and the handle can be made Easy to use, but also reduce costs.
The blow-molded sterile plastic bottle is a plastic bottle that is completely sterile inside, free of yeast and other loose particles. Due to the sealing of the bottle mouth, this bottle remains sterilized during storage and during transportation to the aseptic filling machine. Just prior to filling, the outside of the bottle is subjected to sterile liquid disinfection to ensure that the entire process of reopening, filling, and secondary sealing of the bottle is carried out under aseptic conditions.
Aseptically blown bottles are more reliable and cost-effective than pre-filled plastic bottles. The principle is simple: instead of cleaning and disinfecting the soiled objects, it is better to leave them free from pollution. After the bottle body is molded, it is sterilized and sterilized. Not only is the cost high, the equipment is complicated, and the technical requirements for the workers are also high.
Aseptic blow bottle manufacturing
Sterile blow-molding During the blow molding process, the temperature of the plastic is maintained at about 200°C. This temperature is considered by the FDA (United States Food and Drug Administration) as a condition for forming a sterile surface. At this temperature, air and metal contacting the container will not contaminate the container. Blow-molded sterile plastic bottles use this principle. In general blow molding, melted plastic is extruded from an extruder to form a tubular or spherical parison and blow-molded in a mold. During mold closing, the preform is usually filled with low-pressure gas to ensure that the preform will not stick before blow molding.
The aseptic blow-molding technology developed by TECHNE of Italy uses blow air from aseptic compressed air to eliminate any danger of contaminating the interior of the bottle. The hollow blow needle is inserted into the upper dome of the bottle structure in the mold, and then sterile air is blown to form the designed bottle shape. In the blow molding process, after the plastic is cooled by the mold, the gas is released, and then the bottle body is sealed between the insertion point of the blowing pin and the dome by two independently operated mechanisms. This sealing area is isolated from the metal part with the cooling channel, so that after the gas channel is closed by the sealing mechanism, the plastic in this area remains high temperature and the plastic self-adhesion. Due to the close relationship between sterilization and sealing process, two sealing processes are generally used to improve the reliability of sterilization. The reason for using two sealing processes is not because of the imperfection of a sealing device, but to reduce any risk of contamination. The sealing process is completed before the bottle body is removed from the mold, avoiding the possibility of contamination. Afterwards, the mold is opened and the bottle body is removed for scrapping. The sterile bottles now produced can be packaged, stored, shipped or sent directly to the filling process. When sealing the bottle body, it is sometimes necessary to reduce the pressure to slightly lower than normal pressure to ensure that when the bottle body is sealed and the gas is reheated, the latent heat of the plastic does not cause deformation of the bottle body. It should be emphasized that during the entire blow molding process, the inside and the outside of the bottle are completely isolated from the contaminated air, and only the compressed compressed air is in contact with the inside of the bottle.
In order to ensure the barrier properties of the bottle, a multi-layer co-extrusion process is also required. Sterile bottle bodies for liquid dairy products are typically made from 3 or 6 layers of HDPE. TECHNE's multi-layer co-extrusion technology was originally used to solve waste edge materials, mainly to reduce the amount of raw materials used and to recover 10% to 30% of the material in each container, but gained important applications in the manufacture of dairy blow molding bottles. The inner and outer layers of the 3-layer bottle are white and the middle layer is black, which acts as an anti-ultraviolet light. The product has a shelf life of 3 months without refrigeration. The 6-layer bottle adds EVOH barrier layer and the product shelf life can reach 6-9 months.
How to ensure the sterility of compressed air guarantees the sterility of compressed air is a key link. With precision filters, compressed air can be sterilized. When compressed air passes through the microfilter, bacteria and yeast can be filtered out. However, when sterilizing with a filter, the air channel downstream of the filter must also be sterilized. At the same time, in order to meet the hygienic standards for milk production, all the air that comes in contact with the product requires smooth passageways and meets other special requirements for product production. That is, all compressed air passages must be sterilized and maintained sterile throughout the blow molding process. Many sterilization methods currently used are complicated and costly. A simple method is to use the company's OXONIAP3 active sterilizer for sterilization. The sterile bottles and aseptic filling lines produced by this process have been produced and run for years in some European milk production plants. Practice has proved that they are safe and reliable.
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