Aseptic Processing and Packaging Services
Aseptically produced and packaged food products are the fastest growing area of the U.S. food industry. Every year numerous processors and equipment manufacturers are faced with challenges of introducing new aseptic processing and packaging systems to the US market. This process involves, among other things: evaluation and modification (if necessary) of the equipment, extensive microbiological testing (challenging) of the equipment and package sterilization cycles and, most importantly, presentation of the results and “filing” with the Food and Drug Administration (FDA). All of the members of our team have extensive experience with this rather complex and time-consuming process. This experience includes all “pouch” and “carton” forming aseptic fillers, all indexing “cup/tray” thermoforming aseptic fillers, indexing pre-formed “bottle” aseptic filler and the newest, high speed, rotary, pre-formed aseptic “bottle” filler (PET). The spectrum of services provided to both food and pharmaceutical industries are backed by strategically located laboratories and dedicated staff. All of our experts have a tremendous amount of understanding of all current industrial practice and “hands-on” practical experience with every aseptic processing and packaging system in existence (for both low-acid and high-acid products). IEH offers its expertise and assistance to Partner in the following areas:
- One-stop aseptic processing and packaging solutions: development of aseptic process schedules; optimization of existing processes and equipment configurations; expert evaluation (disposition) of aseptic process deviations; prevention of spoilage incidents by on-site risk assessment; elimination and sourcing of intermittent spoilage incidents through the use of microbial source tracking (MST); on-site support during equipment commissioning and production start-up phases.
- Integrated validation of aseptic processing and packaging systems, including: initial system evaluation (feasibility studies), development of comprehensive microbiological challenge specifications (incorporating current US regulatory requirements), conducting all required “on-site” challenge work (once system is installed), expert evaluation and interpretation of all test results and preparation of “filing” documentation.
- We offer a wide variety of calibrated bacterial spores and bio-indicators produced with a world-class quality control program (including DNA “fingerprinting”) that can be utilized for a wide variety of microbial challenge work. The spectrum of bio-indicators offered includes (but is not limited to) spores of: Bacillus subtilis (hydrogen peroxide and other sporicidal agents), Clostridium sporogenes (“wet” heat resistance) and Bacillus stearothermophilus (various degrees of “wet’ and “dry” heat resistance), and other spores that can be used to challenge radiological sterilization processes.
- Aseptic Product Rheology: Current regulatory requirements are for
appropriate supportive rheological data if a product sterilization process
is to be designed around a claim of turbulent flow in the hold tube.
A Bohlin rheometer is used to run tests on raw product under the high
temperature and pressure conditions of the actual process. Processes
based on turbulent flow can be 4-5F° lower than those based on the
default of laminar flow. Significant improvements in product quality
and energy savings may result.
