A complete
miniature-scale aseptic processing and packaging system capable of
replicating the manufacturing process is now available
from Armfield.
The system, recently installed in the research and development department
of a major European food manufacturer, enables very small quantities
of product (5 liter batches at flow rates of 10-20 l/h) to be processed
and filled aseptically to sterile packaging. Processing of all stages
is continuous and steady-state conditions are reached and maintained
in a matter of seconds.
The system enables users to produce samples with very similar physico-chemical
properties to the industrial scale. Since the unit is capable of
producing a sterile packaged product, it is possible to store samples
for long term trials.
The system comprises three elements: a direct steam injection HTST/UHT
unit, an optional homogenizer and the FT105 Asepto-Fill filler/closer
unit. The entire system is sterilized and cleaned in place for efficient
operation with both processes being PLC monitored and controlled.
The sterilization process is completed rapidly, and cleaning likewise,
meaning that the system can be turned around quickly.
Once the system is sterilized then any number of products can be
processed aseptically without the need to re-sterilize.
Should the product hold temperature fall during operation, product
is automatically diverted from the system until the required hold
temperature is restored. This prevents possible contamination of
the sterile system.
The UHT system pre-heats the product indirectly prior to direct steam
injection to product hold temperatures of up to 150 degrees C. Instantaneous
product cooling and evaporation of condensed steam occurs in the
expansion vessel of the direct steam injection unit. Product is further
cooled indirectly through a tubular heat exchanger.
Product may be homogenized at either the pre-heat or the indirect
cooling stages using an aseptic two-stage homogenizer capable of
pressures up to 1000 bar. Cooled product is then pumped to the Asepto-Fill
for sterile filling. The Asepto-Fill is a sophisticated hand-in-glove,
sealed cabinet system with a recirculated, HEPA filtered air supply.
Nitrogen can also be supplied to the unit for low-oxygen headspace
filling.
Any type of sterilized or irradiated packaging can be used within
the Asepto-Fill cabinet.
The system is capable of a wide range of processing conditions to
suit particular products and processing strategies.
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