Aseptic filling in dust-free workshop refers to a filling method in which semi-finished products with commercial aseptic status obtained after sterilization are sealed in sterilized containers and poured in a clean environment. After filling, the filling containers are kept sealed to prevent re-infection, so as to achieve a longer quality guarantee period under the condition of no preservatives and no refrigeration. Due to the short sterilization time of aseptic filling, the nutritional components of the filling are less destroyed, and the color and taste are better maintained. In recent years, aseptic filling has been widely used in the filling of milk, yogurt, juice, etc.

Car free and dust-free filling workshop

Aseptic filling includes four elements: asepsis of filling materials, asepsis of filling products, asepsis of filling environment and complete sealing after filling. "Sterility" means that the product does not contain any microorganisms that may affect the quality of the product, and "complete sealing" means that the product is sealed into a filling volume by proper mechanical means to prevent microorganisms and gases or water vapour from entering the filling. Aseptic filling materials generally include metal cans, glass bottles, plastic containers, composite cans, paper based composite materials, multi-layer composite soft filling and so on. The sterilization of food material is divided into thermal sterilization and cold sterilization. At present, thermal sterilization is mainly divided into two kinds: ultra-high temperature sterilization and high-temperature short-time sterilization. Cold sterilization method of engineering materials in aseptic dust-free room mainly refers to ultraviolet and microwave sterilization.

The specific requirements of filling sterilization in dust-free workshop are as follows:

1, ultra-high temperature sterilization refers to the temperature and time of 135-150℃ and 2-8 seconds respectively under the conditions of milk or other beverages for processing a process.

2. High temperature sterilization can be used for materials with cooking taste, and sterilization can be carried out under the conditions of 70-75℃ temperature and 15-20s time.

3, cold sterilization method refers to the use of ultraviolet sterilization, radiation sterilization, microwave irradiation sterilization in order to achieve the purpose of sterilization.

4, the asepsis of the filling environment, aseptic filling system is mainly divided into two categories of systems, open aseptic filling system and closed aseptic filling system. The biggest difference between them is that the closed aseptic filling system has more asepsis rooms than the open aseptic filling system; The filling materials should be sterilized, formed and filled in a sterile room. Because the asepsis room has a straight through the asepsis gas to maintain its positive pressure, so the asepsis room can effectively prevent microbial pollution, so it is widely used in beverage production.

5. The first thing to ensure the aseptic filling environment is that the equipment is aseptic. The main sterilization methods include heating method and chemical method. For open aseptic fillers, the surfaces in contact with the product must be sterilized prior to aseptic filling. Its sterilization is through the filling machine itself produced sterile hot air (or sterile hot steam) to achieve. In the sterilization process, sterile hot air directly contact the surface of the filling machine and the product contact for sterilization.

6. It is not enough to sterilize the closed aseptic filling machine only by sterile hot air, but also to ensure the asepsis of the closed space, that is, the sterilization of the asepsis room. Before production, the asepsis room is generally dried with hydrogen peroxide spray and sterile air. The sterile air is heated to a certain temperature by the sterile air heater in the filling machine. When sterilization, liquid hydrogen peroxide is sprayed into the sterile hot air and instantaneous evaporation, so the mixture of sterile air and hydrogen peroxide gas enters the asepsis room for sterilization, and the condensed hydrogen peroxide on the inner surface is dried through the sterile hot air, so as to complete the sterilization of the asepsis room.

7, as sterilization environment generally adopts measures such as washing, heating, drugs and ultraviolet radiation, in contact with beverage sterilization device and the entire surface of the container handling, space environment, use drug more sterilization, the aseptic filling system of the state of the maintain, which is then entered the sterile air and maintain positive pressure, the whole system to prevent external microbial invasion in the air.

8. It is recommended that the peripheral environment of open aseptic filling system and closed aseptic filling system is also the best "positive pressure aseptic dust-free room". How does this clean, sterile air come into being? Its "dust-free" mainly depends on high efficiency filter filter cycle filtration; "Asepsis" is in the purification unit supporting the installation of "Nicoler dynamic sterilization components", air every cycle is a sterilization, so that the controlled environment is always controlled in the online sterilization status, without any harm to the human body.

9. Microorganisms will multiply when the equipment is shut down, which may lead to a large number of microorganisms that cannot be fully killed. Therefore, the equipment should be drained as far as possible after cleaning, so that there is no water or solution residue.

10, filling sealing, filling sealing for aseptic filling is the last link, is also a key link, which directly affects the filling quality and storage life of the product. Its requirement is on the one hand can prevent microorganism and gas or water vapor invasion, on the other hand can not let the product's own smell and original solution overflow.

11, most aseptic filling sealing using heat sealing, ultrasonic or film, gas sealing, some with folding, item sealing, sealing attention should be evenly distributed on the sealing surface; Sealing process conditions such as sealing temperature, time, pressure must have safety limits, and can be controlled; The sealing surface should avoid contamination by products or other dirt. The sealing position must be accurate, especially in the case of hot forming/filling/sealing in the same machine, to prevent the deviation of the sealing position.

In addition, due to the beverage viscosity, pH value, heat sensitivity, easy oxidation and other particularities, so that the sterilization methods and equipment are also different. The pH value often determines the temperature and time of the material sterilization, and the pH value depends on the number of acidic substances in the drink, and the degree of separation. The pH value of low-acid beverage is greater than 4.6, which can provide ideal growth conditions for pathogenic microorganisms, and spoilage microorganisms can also grow well. Generally, ultra-high temperature instantaneous sterilization is adopted. Beverage acidic PH value between 3.7 to 4.6, it is one of the pathogenic bacteria is not easy to grow, but corruption bacteria can grow, generally USES the instantaneous ultra high temperature sterilization or high temperature short time sterilization, of low acid beverage by adding acid or the method of fermentation to make it into acidic beverages, thereby reducing the sterilization requirements, improve the shelf life, this method is used to handle your tomato beverages khan, cheese, etc.

The pH value of highly acidic drinks is less than 3.7, and in this acidity, pathogenic bacteria cannot grow, nor can spoilage bacteria. Therefore, sterilization is not a problem that needs special attention, and maintaining quality becomes the primary purpose. The general use of pasteurization can meet the requirements, that is, treatment at 62℃ for 30 minutes, can also be used ultra high temperature instantaneous sterilization or high temperature short time sterilization, depending on the specific circumstances. Therefore, the clean workshop purification program must be implemented in accordance with the designed technical requirements.