PETpla.net Insider 03 / 2020

BOTTLING / FILLING PET planet Insider Vol. 21 No. 03/20 www.petpla.net 20 Flexible, sustainable and digital: filling technology’s future is now Sterilisation of containers for aseptic beverages is an important part of the filling process and there are several techniques available to manufacturers, each with their own benefits and drawbacks. Whether they use chemical or energy-based container decontamination, bottling manufacturers will be embracing greater digitisation and (best of all) can look for- ward to more sustainable methods of filling. Barbara Bricoli, Ph.D., Innovation Manager for GEA, and Paolo Abelli, Head of Product Development of Blow Moulding and Filling at GEA, look at the options available and speculate on what the future may hold for the technology. We live in a world in which ‘natural’ is perceived as good. Consumers want fresh tasting products, full of nat- ural ingredients, with high nutritional value and a long shelf life. In devel- oped countries, refrigeration and cold chain distribution networks provide the fresh products consumers crave. But where this is not available it seems that freshness and long shelf life are in conflict. With aseptic technology now available for aesthetically and ergonomically appealing plastic con- tainers, it’s possible to achieve both, bringing fresh-tasting products to a wider audience and avoiding environ- mental disadvantages of maintaining the cold chain. Wanted: aseptic filling that minimises water and chemical waste Aseptic bottling technology ensures that sterile bottles are filled with sterile products and sealed with sterile caps, all within a sterile environment. Elimi- nating bacteria from the process in this way makes it possible to produce beverages and liquid foods with a fresh taste, which will remain safe to use for over six months, even at ambient temperatures. Although the principle of aseptic bottling is widely practiced, the way that bottles (and caps) should be sterilised in the first place is intriguing. Achieving the required level of steril- ity is usually not a problem; doing so while minimising water and chemical usage is more difficult. Chemicals used for sterilisation are expensive; bottles need to be purged of any residue prior to filling; and the chemical itself must be recovered safely and efficiently. Furthermore, sterile water is expensive to produce. PAA sterilisation: required for some applications PAA sterilisation, which is well- known and effective, sterilises bottles and closures using a warm solu- tion of peracetic acid. This provides both a chemical and a very important mechanical element to the sterilisa- tion process; the chemical neutralises any biological contamination, while the action of filling and removing the solution purges bottles of physical debris, such as dust or plastic frag- ments, which may be found inside the container. The bottles then need to be rinsed with sterile water to remove any chemical residue. While this process is still the most effective, it requires a lot of water. Many applications still require PAA sterilisation and research into more sustainable methods is ongoing. H 2 O 2 sterilisation – an option, just not for everyone Other applications, such as hydrogen peroxide (H 2 O 2 ) require no water at all. Containers sterilised by FILLING Natural, fresh, safe, long- life food: sterilisation processes and aseptic filling and packaging play a major role. (Images: GEA)