The Aseptic Packaging Machine Streamlines the Process of Transferring Liquid Products to Their Final Containers

The aseptic packaging machine streamlines the entire process of transferring liquid products to their final containers. The machines are designed to handle a wide range of liquid products, from juices to dairy products.

The machine’s advanced technology ensures precise dosing and accurate volume control, minimizing product waste. It also allows for a faster production process, resulting in lower operating costs for manufacturers.

Sterilization

Sterilization is used to kill microorganisms that could affect the quality of the product. The product and packaging are sterilized separately before being combined under sterile conditions to form a shelf-stable package. The process is often used for products such as milk and juices that require extended storage without refrigeration.

Most aseptic systems rely on steam or hot water under pressure as the sterilizing medium. The resulting heat or chemical treatment sterilizes the processing equipment and the container materials. The process may be validated using resistant microbial spores placed on adhesive strips in equipment or on the container materials. Results of these microbial validation studies should be filed with CFSAN in support of the firm’s scheduled processes.

Some form-fill-seal systems (including the bag-in-box system) sterilize through heat co-extrusion. This heating method uses temperatures reached by thermoplastic resin during the co-extrusion process to sanitize the package contact surface. However, this sterilization technique has only been demonstrated to be effective for acidic products with a pH below 4.6.

Other aseptic systems sterilize through a series of heating and cooling chambers. These processes are typically validated by challenging the system with a high number of challenge organisms that are highly resistant to the applied sterilization agent. The resulting log cycle reduction (LCR) is used to verify that the system consistently achieves the desired level of sterilization.

Filling

Using an aseptic filling machine, liquid products are packaged in a sterile environment. This prevents the growth of bacteria and other microorganisms that can damage the product or aseptic packaging machine change its taste. This also allows the product to retain its quality and extend its shelf life. In addition, an aseptic packaging system is easy to clean and sanitize, allowing producers to maintain high levels of sanitation and hygiene.

A reliable aseptic filling machine can be used to package a wide range of low- and high-acid liquids in a variety of formats. These include bags-in-box and bulk 210-1500L (55-395G) bags for drums, bins, and intermediate bulk containers (IBC). These machines offer heat-sealed closure both before and after filling. They can be configured with multiple product dispense systems and electronic batch record reporting.

Aseptic filling machines can use various types of vials, including glass, plastic, and aluminum. When choosing a container, it is important to consider the composition of the drug, its reactivity, and pH level. Amber vials are often preferred for photosensitive compositions.

TECH-LONG aseptic filling machines use sealed containers that guarantee a long shelf life for products. The machine’s sterile process eliminates the need for cooling, which reduces production costs and increases efficiency. Its versatile operation ensures a continuous flow of packaging, preventing downtime caused by changes in roll size.

Sealing

Aseptic machines ensure the sterility of a drug or vaccine through and after its vial filling step, which reduces the risk of pathogen exposure to a minimum. This level of security helps pharmaceutical manufacturers meet demand while keeping their products safe for consumers.

The aseptic machine’s sterilization system uses hydrogen peroxide vapor or steam to eliminate microorganisms from both the product and its packaging materials. This process removes a significant amount of bacteria, viruses, and other potentially harmful microorganisms from the container and its contents before filling and sealing.

After a product is filled, the capping system seals the vials using a variety of methods. The machine may use a gravity or pressure filling technique, or it might apply a liquid-tight cap to the container. This last step prevents any contamination from occurring before or after the container leaves the facility, protecting the integrity of a drug during its journey to its final destination.

Regular cleaning and sanitization procedures are essential for aseptic machine operation. TECH-LONG’s advanced aseptic filling machines are designed to be easily disassembled for efficient cleaning and sanitation, mitigating the possibility of contamination during subsequent production runs. This is especially important for high-risk industries, such as food and pharmaceutical production, where a single incident of contamination can be devastating. Regularly cleaning and sanitizing the machine also helps reduce the risk of cross-contamination between different batches of product.

Packaging

Aseptic processing allows manufacturers to produce high-quality products that retain their natural freshness and avoid preservatives. This process focuses on sterilizing the contents and container separately before inserting them into the final package, resulting in a safe product with extended shelf life. TECH-LONG offers state-of-the-art aseptic filling machines that ensure sterility and extend the shelf life of pharmaceutical products, food, beverages, cosmetics, chemicals, and more.

The aseptic filling machine’s pre-treatment system is responsible for ensuring the containers are free from any pathogens prior to the filling process. It uses hydrogen peroxide vapor or hot water rinsing to eliminate any contaminants that may be present in the container or its environment.

After the sterilization, cooling, and washing processes, the containers are ready for the aseptic filling process. aseptic packaging machine manufacturers The aseptic packaging machine inserts the cold liquid into the container using a specialized pump that operates in a commercially sterile atmosphere. This is accomplished by using a high-speed, rotary vacuum piston that is controlled by a computerized system to prevent overfilling.

The ESSI A4 aseptic packaging machine has 4 production heads that operate independently from each other and pack presentations in capacities of 200 ml to 1,000 ml. It also features a hygienic stainless steel design that meets EHEDG guidelines. It also has automatic CIP and a remote connection via Ethernet.