Aseptic processing is a manufacturing method that can produce a product absent of bacteria without subjecting the product to terminal sterilization processes. However, many products subjected to harsh conditions of terminal sterilization degrade and become ineffective. Therefore aseptic processing equipment allows these products to be produced in a sterile environment, allowing them to maintain their effectiveness while being safe to inject into patients.
There's a drastic shift for beverage producers as a result of aseptic filling technology development. Back then, shelf life was achieved through hot fill technology such that, in effect, the sterilized bottle with hot liquid was part of the filling process. Despite the effectiveness of the technology, it still had some product limitations in quality. plastic design bottles were limited with the inability to withstand heat applied during filling without distortion. In comparison, cold aseptic processing equipment provides the required shelf life without adversely affecting product quality. The technology uses fewer plastic bottles. it gives greater flexibility in designing the bottles.
Aseptic Processing Equipment
With globalization, aseptic technology aims to achieve accuracy, best-filling speed, and flexibility while maintaining the sterility of product and container during the whole process. It also aims to avoid recontamination.
The filing environment must be aseptic, which means the whole area must be thoroughly sterilized and cleaned using decisive mechanical actions and proper chemicals. Immediately after filling, any residue must be removed to avoid the risk of microorganisms' growth.
The containers can be filled by weight or volume. The volumetric filling uses a magnetic flow meter fitted to each filling head to control liquid flow accurately. Since most aseptic products are liquids, they can still be bottled without the filling head touching the bottle. However, products that are subject to foaming make it necessary to ensure a careful control flow rate. it varies during each filling bottle in order to achieve the required accuracy.
Filling by weight in turn is reserved by liquid products whose quantity packaging are declared in grams. It's also used as a second check to take account of variation caused by product viscosity or temperatures. Filing by weight might become testing to control in rapid tasks, for example, impact and vibration inside the framework, which influences the estimations.
Why Should Manufacturers Establish Environmental Control For Aseptic Processes?
Typically, all drug manufacturing, including solid oral dosage form and terminal sterilization manufacturing, must have established environmental controls. It is a requirement addressed in global current good manufacturing practices. It's enforced this way to prevent contamination as a result of insanitary conditions. The environment control measures to be monitored include temperature, humidity, ventilation, air pressure, air quality including particulate matter, and microbial contamination. however, the environment control limits are stricter for aseptic manufacturers due to the nature of the business.
Conclusion
With aseptic development, you can benefit from the ease of maintenance and optimized operational performance. The use of an aseptic processing machine also provides sustainable methods, which contribute to the go green initiative since the packaging comprises renewable resources and uses approximately 60% less plastic than other options.