BOTTLING / FILLING PETplanet Insider Vol. 26 No. 06/25 www.petpla.net 22 DNP launches environmentally friendly aseptic fi lling system for PET bottles Reducing CO2 emissions with latest aseptic filling innovation Aseptic Systems Co., Ltd. (APS), a subsidiary of Dai Nippon Printing (DNP), has recently introduced a new aseptic filling system to help beverage manufacturers cut CO2 emissions, reduce chemical usage and still provide a trustworthy solution for beverage producers. APS has released its latest aseptic filling technology: GREEN ASEPTIC. A new system that reduces CO2 emissions from the liquid processing equipment used in PET bottle aseptic filling systems to fill beverages in a sterile environment. The technology is claimed to reduce energy consumption by approximately 80% (based on a dilution ratio of 5) by replacing a portion of the ultra-high temperature (UHT) sterilisation of beverages with a nonthermal sterilisation system that combines a sterilising filter and a medium pressure ultraviolet (UV) lamp. Additionally, the adoption of a two-step sterilisation system – which sterilises the preform before it is moulded, followed by forming the bottle shape with sterile air – results in a significant reduction in the amount of chemicals used for bottle sterilisation. By combining these two systems, CO2 emissions can be reduced by approximately 40%. With a growing demand for soft drinks globally, the use of PET bottles is expected to increase. With this expected market expansion, beverage manufacturers are also accelerating their efforts to be environmentally conscious and are facing the challenge of decarbonising the PET bottled beverage manufacturing processes and the filling of soft drinks. In response to such challenges, APS has developed a proprietary non-thermal sterilisation system that focuses on the proportion of water included in soft drinks. To date, the risk that filterable bacteria may pass through the filters has limited the use of sterilising filters for sterilising beverages. In many cases, large amounts of energy have been required to heat water to approximately 140 °C to achieve sterilisation. APS’s solution is to combine UV lamps that eliminate the smallest microbes with a sterilising filtration filter. This method makes it possible to produce beverages of the same quality as those produced by conventional thermal sterilisation, without the need to heat the main component of the beverage - water. Key facts: Non-thermal sterilisation system: In conventional PET bottle aseptic filling systems, large volumes of beverages are produced by diluting the product solution, or syrup, with water sterilised using UHT treatment. UHTsterilised water is also used to wash the containers. APS reduces energy consumption in liquid treatment by approximately 80% by sterilising the water for both diluting and cleaning, with UV lamps and sterilising filters; a method that uses less energy than conventional thermal sterilisation. Two-step sterilisation system: The new aseptic filling system for PET bottles sterilises in two steps: before blow moulding, at the preform stage, and then during blow moulding into the final bottle shape. Because the surface area of a preform is much smaller than that of a fully blown bottle, this two-step approach reduces the amount of chemicals used by The two-step sterilisation system takes place before and during the blow moulding process. (Up to 60,000bph) The non-heat sterilised water is diluted with green tea and filled into PET bottles under aseptic conditions.
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