What Is Aseptic Filling?

By: Berlin Packaging Specialist
Date: December 20, 2019

What Is Aseptic Filling?
Aseptic filling is the process of filling commercially sterilized products into pre-sterilized containers. The containers are sterilized using one of four techniques: heat, mechanical, irradiation, or chemical.
  1. Heat: hot air, steam, etc
  2. Mechanical: water, brushing, etc
  3. Irradiation: infrared, ultraviolet rays, etc
  4. Chemical: hydrogen peroxide, chlorine, etc
These methods can be used as a stand-alone process or in combination with other aseptic processing techniques. The first step in the process is commercially sterilizing raw product separately. Next, the cooled product is filled into aseptic packaging that has been pre-sterilized using one of the four techniques above. Finally, the packaging is hermetically sealed and the product is ready for consumers. This method of aseptic filling is known as bag-in-box.

Yes. The high temperatures used on raw product during the thermal process of sterilization will kill the majority of microorganisms that cause illness. The pre-sterilized, bacteria-free packaging ensures the product is fresh and flavorful for the entirety of its shelf life. Aseptic packaging must take place in completely sterile environments from the moment the product is thermally processed, to the packaging being hermetically sealed. The process of packaging in a sterile environment further ensures product safety and helps preserve product nutrients using minimal additives or preservatives.

Many glass, metal, and plastic materials, such as HDPE and PET plastic bottles work well for aseptic packaging. Cans, jars, and bottles that can be hermetically sealed are all capable of undergoing aseptic processing. Not all containers made of the above materials can be hermetically sealed, so it's important to check specifications before purchasing packaging.

Yes. Aseptic techniques are popular for the bulk packaging of fresh fruits and vegetables. Aseptic filling helps manufacturers reduce cost and makes seasonal fruits and vegetables available year-round in standard and bulk quantities.

Aseptic manufacturing processes can be used to package everything from fruits and vegetables to pharmaceutical products. In truth, most products able to undergo sterilization can be packaged this way. To get more information about aseptic methods of processing products and their benefits, Contact Us for Benefits of Aseptic Filling.