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The Basics: Aseptic Processing and Packaging

Updated: Apr 30

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Aseptic processing is gaining even more popularity these days for a few different formats and is predominantly, but certainly not exclusively, used in the beverage industry. But what is it essentially? Check out the basics:


Aseptic processing is a method used in the food, pharmaceutical, and biotech industries to produce products that are free from contamination by microorganisms such as bacteria, viruses, and fungi. It involves sterilizing both the product and the packaging separately and then combining them in a sterile environment to prevent any contamination from occurring during the packaging process.


Here's how it typically works:

1. Sterilization of Equipment: All equipment involved in the processing, including containers, pipes, and machinery, must be thoroughly cleaned and sterilized using methods such as steam sterilization, chemical sterilization, or radiation.

2. Sterilization of Product: The product itself (such as food, beverage, or pharmaceuticals) is sterilized using heat, filtration, irradiation, or chemical methods to kill any microorganisms present.

3. Packaging: The sterile product is then filled into sterile containers (such as bottles, pouches, or vials) using aseptic techniques to prevent contamination. These containers are typically made from materials like glass or plastic that have been sterilized beforehand.

4. Combining Product and Packaging: The filled containers are then sealed in a sterile environment to maintain their sterility until they reach the end-user.


Aseptic processing allows for the production of shelf-stable products that do not require refrigeration and have a longer shelf life. It is widely used in the production of products such as dairy products, juices, sauces, soups, pharmaceuticals, and medical devices.


So what kind of packaging is used for aseptically processed products? There are several types of aseptic packaging available, each suited to different products and industries. Here are some common ones:

1. Aseptic Cartons: These are paper-based cartons with multiple layers of materials including paperboard, polyethylene, and aluminum foil. They are commonly used for packaging products like milk, juices, and soups.

2. Aseptic Pouches: Flexible pouches made from materials like plastic or laminate films. They are used for packaging a wide range of liquid and semi-liquid products, including beverages, sauces, and dairy products.

3. Aseptic Trays and Containers: These are rigid containers made from materials like plastic or glass. They are used for packaging products such as ready-to-eat meals, baby food, and pharmaceuticals.

4. Aseptic Bottles: Plastic or glass bottles designed for aseptic packaging. They are commonly used for packaging beverages like juice, sports drinks, and dairy-based drinks.

5. Aseptic Bags-in-Boxes: These consist of a flexible bag contained within a cardboard box. They are commonly used for packaging products like wine, dairy products, and liquid egg products.

6. Aseptic Vials and Ampoules: Small glass containers used for packaging pharmaceutical products like vaccines, injectable drugs, and ophthalmic solutions.


Each type of aseptic packaging has its advantages and is chosen based on factors such as the type of product being packaged, shelf life requirements, transportation considerations, and consumer preferences.


Aseptic processing may be the best fit for your product. Here are some of the issues you may face and should be aware of as you start your search for an aseptic copacker:

When looking for an aseptic copacker (a company that provides aseptic packaging services), you may encounter several issues or challenges:

1. Capacity Constraints: Aseptic processing requires specialized equipment and facilities, and not all copackers may have the capacity to handle large volumes or specific types of products.

2. Quality Standards: Ensuring that the copacker meets stringent quality standards is crucial to prevent contamination and maintain product integrity. You need to verify that the copacker has the necessary certifications and adheres to industry regulations.

3. Cost: Aseptic packaging can be more expensive compared to conventional packaging methods due to the specialized equipment and processes involved. Finding a copacker that offers competitive pricing while maintaining quality standards is essential.

4. Technical Expertise: Aseptic processing requires technical expertise and experience to ensure proper sterilization, packaging, and sealing of products. You'll want to work with a copacker that has a skilled team with a proven track record in aseptic processing.

5. Supply Chain Management: Coordinating the supply chain for aseptic packaging materials and ingredients can be complex. It's important to choose a copacker with efficient supply chain management capabilities to ensure timely procurement and delivery of materials.

6. Flexibility and Customization: Depending on your product requirements, you may need a copacker that offers flexibility in packaging formats, sizes, and customization options. Not all copackers may be equipped to handle custom packaging needs.

7. Geographical Location: The location of the copacker can impact logistics and transportation costs. Ideally, you'd want to work with a copacker that is strategically located to minimize transportation time and costs.

8. Communication and Collaboration: Effective communication and collaboration are essential for a successful partnership with a copacker. You'll want to ensure that there is clear communication channels and alignment on expectations, timelines, and quality standards.

9. Large Minimum Batch Sizes: be prepared to run large batches after your pilot batch. Due to capacity constraints, many copackers are increasing their minimums and partnering with brands that run regularly with large batch sizes.


Addressing these issues through thorough research, due diligence, and communication with potential copackers can help you find the right partner for your aseptic packaging needs.


As always, happy hunting!


The CVL Team



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