“Food safety is not only a national concern”
DNP – Aseptic Systems Hall B4 – Booth 533
Interview with Atsushi Hayakawa, General Manager, Technical Development Department, Aseptic Systems – DNP Dai Nippon Printing Co., Ltd.
PETplanet: DNP Group has three main business areas: aseptic PET bottle filling, liquid filling systems for paper containers, and bag-in-box filling systems. You started with aseptic PET bottle filling in the 1990s. What were the main challenges at that time, and what technological developments made it possible?
Mr Hayakawa: Our first hydrogen peroxide-based aseptic filling system for PET bottles was developed in 1994. At the time, the main challenges were the stable conveyance of bottles and caps and maintaining aseptic quality throughout the process. This was particularly important because the system was dedicated to milk tea, which requires a high level of sterility. We overcame these challenges by switching from traditional conveyor transport to neck-handling of bottles, and by developing an ultra-short hydrogen peroxide sterilisation process. The aseptic filling system we developed for milk tea became the foundation of our current aseptic technology.
PETplanet: How has the beverage market in Japan evolved since then, and which product types are currently the most popular among your customers?
Mr Hayakawa: Between 1994 and 2000, an aseptic PET filling system was still not widely recognised in the Japanese market, and hot filling remained the dominant method. However, in 2000, we launched our third-generation hydrogen peroxide bottle sterilisation system, capable of 72,000 bph. Once its high sterility and stable operation, regardless of bottle type, were demonstrated through neck-handling technology, the market gradually began shifting towards aseptic filling.
Today, the most popular products among our customers are tea-based beverages. A wide variety of teas are produced, often blended with different flavours or milk.
PETplanet: In Japan, you hold a market share of around 60% in aseptic PET bottle filling. Which markets outside Japan are of particular interest, and where do you see the most potential, especially in terms of applications?
Mr Hayakawa: We are particularly focused on the Asian market outside Japan, where tea-based beverages are widely consumed, much like in Japan. These drinks are naturally low in acidity, which increases the risk of spoilage – especially in warmer climates. This makes aseptic PET technology an ideal choice for ensuring product stability and safety over time, without the need for refrigeration.
PETplanet: In Europe, drinktec is considered the leading trade fair for the beverage industry. Do you attend regularly, and what are your expectations for this year’s event?
Mr Hayakawa: Until now, we have attended drinktec primarily as visitors. However, this year marks our first time exhibiting. We are excited to present our proprietary aseptic PET bottle filling system, which has been refined over more than 50 years in Japan’s highly demanding market.
We hope to introduce this technology to beverage professionals from around the world and explore new opportunities for collaboration.
This is because we believe that “food safety” is not only a national concern, but a shared global goal. In pursuit of this goal, we aim to deliver safe and reliable aseptic products while minimising the use of the Earth’s energy and reducing CO2 emissions as much as possible.
PETplanet: What technological highlights can visitors expect to see at your booth?
Mr Hayakawa: Although our booth will be modest in size, we will be showcasing two key technological highlights: our latest innovations: the Two-Step Sterilisation and Green Aseptic. The Two-Step Sterilisation System consists of preform sterilisation followed by compact bottle sterilisation. By sterilising in two steps, we have achieved a 40% reduction in chemical usage and energy consumption, along with a 30% reduction in installation footprint compared to conventional systems.
Green Aseptic is a next-generation aseptic PET filling system that utilises non-thermal water sterilisation. This system has been practically applied to tea-based beverages for the first time globally (according to our internal research). It successfully reduces CO2 emissions and energy consumption during liquid processing by up to 80%.
We warmly invite all visitors interested in sustainable beverage production to stop by our booth to learn more.
PETplanet: Thank you so much Mr Hayakawa.