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What makes aseptic different from hot-fill processing?

Aseptic processing and packaging is the filling of commercially-sterilized products into pre-sterilized containers. (1) Commercially-sterile, cooled product is processed separately from the packaging. (2) Incoming packaging is sterilized independently from the product.  (3) Your flexible package then enters a pre-sterilized, enclosed atmosphere that is free of microorganisms, where the cap is removed to begin the filling process. (4) The cap and spout are then re-sterilized with our patented Vapor Sterilant Technology (VST). Filling takes place through the spout. The cap is then hermetically sealed onto the spout, creating a contained sterile package for your aseptic product.

Hot-fill processing fills heated, commercially-sterile product in non-sterile packaging. The product is held for a predetermined time and temperature in order to sterilize the packaging prior to the filling process. The longer hold time at high temperatures reduces quality of the product. Only high-acid products can be hot-filled and held at ambient temperatures without refrigeration.

Retort processing fills non-sterile product in hermetically-sealed, non-sterile packaging. The packaging is loaded into a retort pressure vessel and subjected to pressurized steam.  The product is also exposed to high temperatures for a much longer period than in hot-filling. The additional time can significantly deteriorate the overall quality and nutritional content of the product.

The Aseptic Process for Flexible Packaging

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