ASEPTIC FRUIT DRINKS PREPARATION

ASEPTIC PROCESS UNIT

• The sterile method is that methodology|the tactic|the strategy} by that a sterile (aseptic) product (typically food or pharmaceutical) is packaged in terribly sterile instrumentation {in a|during a|in an exceedingly|in a terribly} very method that maintains sterility.

ASEPTIC

• Aseptic food preservation ways enable processed food to stay for long periods of your time while not preservatives, as long as they're not opened. The sterile packages square measure usually a mixture of paper (70%), polyethylene (LDPE) (24%), and aluminum (6%), with good polythene within a layer.

ASEPTIC

• The 1st sterile filling plant for milk was given in Schweiz in 1961. sterile techniques were common in Europe and Asia before they were introduced within u. s. within the Nineteen Eighties.

• In 1991, the Institute of Food Technologists rated the highest ten innovations in food technology. sterile process and packaging stratified No. 1, sooner than juice concentrates.

Aseptic process

Cause of downside in juice

CIP

• Clean-in-place (CIP) may be a methodology of cleanup the inside surfaces of pipes, vessels, method instrumentality, filters, and associated fittings, while not dismantling.

• Up to the Nineteen Fifties, closed systems were disassembled and clean manually. the arrival of CIP was a boon to industries that required frequent internal cleanup of their processes.

Industries that swear heavily on CIP unit those requiring high levels of hygiene, and include: farm, beverage, brewing, processed foods, pharmaceutical, and cosmetics.

CIP

The following parameter of acid, soda ought to be check before beginning CIP

PECTIN TANK

Change the coupling to cellulose TANK (P.T)

PECTIN TANK

Select CIP from panel board

Select the unit- P.T/M.T/Conc. T …….

Select the program- Hot water/w-s-w/w-s-w-a-w

Start

MIXING TANK

Change the coupling to commixture TANK (M.T)

Set coupling between CIP line tank

CONCENTRATION TANK

• Set coupling between CIP line & Concentration tank

CONCENTRATION LINE

Before beginning line CIP all line valves should be closed.

CIP UHT (PASTEURIZER)

CIP  FILLER

CIP STERILE WATER

CIP STERILE TANK

STERILIZATION

• Sterilization (or sterilization) may be a term pertaining to any method that eliminates (removes) or kills all styles of microorganism life, as well as transmissible agents (such as fungi, bacteria, viruses, spore

forms, etc.) gift on a surface, contained in a fluid, in medication, or in a compound such as biological culture media.[1][2] Sterilization can be achieved by applying heat, chemicals, irradiation,

high pressure, and filtration or combinations thereof.

                                        STERILIZATION

• A widely used technique for warmth sterilization is that the autoclave typically referred to as a device.

Autoclaves unremarkably use steam heated to 121–134 °C (250–273 °F).

To achieve sterility, a holding time of a minimum of quarter-hour at 121 °C (250 °F) at one hundred kPa (15 psi)

UHT (PASTEURIZER)& FILLER

Check the following parameter during sterilization

STERILE WATER

Check the following parameter during sterilization

STERILE TANK

Check the following parameter during sterilization

• Take hot water (75-85˚c) in Pectin tank (P.T)

• Add Gum with solid sugar (90%+10% ratio) in P.T and agitated for ~30 minutes

• Transfer sugar syrup from Reserve tank to Mixing tank (M.T) according to batch size.

• Gum transfer to M.T

• All acid mix with treated water (ambient temperature) and transfer to M.T

• An open lead of pulp drum, cut the aluminum foil and transfer pulp to concentration tank

• Pulp transfer from concentration tank to M.T

• Color mix with treated water (ambient temperature) for 15-20 minutes and then transfer to M.T

• Flavor with treated water transfer to M.T

• The volume adjust with water

MIXING

    • Check the following parameter of mixing sample

• After complete mixing agitated it for 30 minutes in

M.T and hold in M.T for 30 minutes

                 • Set the cufflink between M.T and Aseptic production                           line

                 • Check the filter in a transfer line.

BOTTLE BLOWING

• Machine capacity 18000 BPH

• The following parameter should be check before start machine

BOTTLE FILLING

LABELING

• Both the Sleevematic & Control system has a present.

• For Sleevematic, machine capacity 20100 BPH.

• Steam tunnel temperature 85-90 ˚C.

• For Control, machine capacity 20100 BPH.

WRAPPING

Shrink film size 490-500 mm & thickness 60-70µ.

Machine capacity 2400 CPH (1000ml) & 2040 CPH (250ml).

Wrapping temperature 180-200 ˚C.

ASEPTIC STEAM PRODUCING SYSTEM IN FILLER BLOCK

CHEMICALS SPECIFICATION IN ASEPTIC PLANT

CHEMICALS INFORMATION

1. Disinfecting Solution Contains : A)Peracetic Acid = 15% W/W

B) H2O2 = 23% W/W

2. Fumigation Solution Contains: Sterile Water + Divosan Forte (According To Requirements)

3. P3 - Stabicip ABF: It Is Used To Easying Chemicals Distribution Inside Of Bottles.

4. P3 – Triquard: It Is Used In Order To Shoe Cleaning.

5. Topax – 56: It Is Used For Acid Foaming

6. Topax – 19: It Is Used For Alkali Foaming.

Sterile Production

GMP Requirements for Sterile Products

• Additional rather than replacement

• Specific points relating to minimizing risks of contamination

• microbiological

• particulate matter

1st step – eliminate the source of contamination!

“A simple, maintained and operated aseptic process minimizes personnel intervention.

As operator activities increase in associate degree sterile process operation, the danger to finished product sterility additionally will increase.”

2nd Step- Reduce the Risk of contamination through:

• Sterile barriers

• Aseptic technique

• Environmental monitoring

Sterile Production

Personnel

• outside article of clothing not in amendment rooms resulting in grade B and C rooms

• the amendment at each operating session, or once daily (if adjunct data)

• amendment gloves and masks at each operating session

• Disinfect gloves during operations

• Washing of garments – separate laundry facility

• No damage, and according to validated procedures

Sterile Production

Personnel

• Clothing of appropriate quality:

• Grade D

• hair, beard, mustache covered

• Protective clothing and shoes

• Grade C

• Hair, beard, mustache covered

• no fibers to be shed

• Grade A and B

• Headgear, beard, and mustache covered, masks, gloves

Sterile Production

Premises

• Changing rooms

• Designed as airlocks

• Effective flushing with filtered air

• Separate rooms for entry and exit desirable

• Handwashing facilities

• Interlocking system for doors

• Visual and/or audible warning system

• Use filtered air offer to keep up pressure cascade

• Pressure differential approximately 10 to 15 Pascal's

• Zone of greatest risk – immediate environment

Facilities design & HVAC validation

HVAC

• H-HEATING

• V-VENTILATION

• AC-AIR CONDITION

Facilities: General Cleanroom Design

• HEPA/ULPA filters on ceiling

• Exhaust vents on the floor

• Drains in aseptic processing areas are inappropriate

• Airlocks and interlocking doors to regulate air balance

• Seamless and rounded floor to wall junctions

• Readily accessible corners

• Floors, walls, and ceilings created of swish onerous surfaces which will be simply cleansed

• Limited equipment, fixtures, and personnel

• The layout of equipment to optimize comfort and movement of operators

Facilities

Establishing and Maintaining an aseptic

environment

• Use clean-rooms of varied categories to determine AN sterile space

• Clean rooms use combinations of filtration, air exchange, and positive pressure to maintain a “clean” environment

• Lower quality clean areas mustn't be placed next to high-quality areas.

Facilities: HEPA Filters

• High-Efficiency Particulate Air

• Minimum particle collection efficiency:

• 99.97% for 0.3µm diameter particles.

• Disposable

• Filter made of pleated borosilicate glass

Facility Design: Clean Area Classification