Table Of ContentFood Science & Technology SD
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Handbook of Aseptic Processing ka
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S E C O N D E D I T I O N
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Since publication of the first edition of this book, Aseptic Processing and Packaging
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of Food, significant changes have taken place in several aseptic processing and
packaging areas. These include changes in aseptic filling of nutritional beverages in n S E C O N D E D I T I O N
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plastic bottles; the popularity of value-added commodity products such as juice,
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concentrate, and puree; pouches and bag-in-box bulk packaging; and other novel
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package concepts possessing a range of consumer convenience and ergonomic
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features. k
The newly titled Handbook of Aseptic Processing and Packaging, Second o
Edition explores the application of existing and new food processing methods f
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and sensor technologies. It is an essential guide for those developing day-to-day
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procedures for a number of different aseptic processing and packaging applications.
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New Topics in the Second Edition:
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• Current information on aseptic packaging materials and sterilants c
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• Aseptic bulk packaging, with a historical perspective and an update on the
current state of bulk packaging in container sizes ranging from several gallons NP
to several millions of gallons Dro
• Aseptic processing operations, including the processing products as well as c
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the operation of aseptic packaging systems e
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• Failure mode effect analysis and spoilage troubleshooting, with examples of s
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different failure modes and their effects on food safety T
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• Aseptic processing of particulate foods, including the use of microwave for In
heating and technology available to monitor and develop processes for this Og
category of foods N
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• Contract manufacturers and their role in introducing innovative products n
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to market
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The contributors to this volume have more than 150 years of combined food a
industry experience, encompassing production, quality assurance, research and c
development, and sales in aseptic processing and packaging. Their insight provides k
a comprehensive update on this rapidly developing technology for the food a
processing industry. g
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K10365 Jairus R.D. David
Ralph H. Graves
Thomas Szemplenski
Handbook Aseptic
of
Processing Packaging
and
S E C O N D E D ITI O N
Handbook Aseptic
of
Processing Packaging
and
S E C O N D E D ITI O N
Jairus R.D. David
Ralph H. Graves
Thomas Szemplenski
Boca Raton London New York
CRC Press is an imprint of the
Taylor & Francis Group, an informa business
CRC Press
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© 2013 by Taylor & Francis Group, LLC
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Version Date: 20121003
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Dedication
In memory of
V.R. (Bob) Carlson
Dr. Walter Dunkley
Robert Graves
David R. Dass, Priscilla Juliet Dass, and Rufus David
Lynn Joel Zylstra
Contents
Foreword.........................................................................................................xvii
Preface................................................................................................................xix
Acknowledgments...........................................................................................xxi
Authors...........................................................................................................xxiii
Contributing.Authors..................................................................................xxvii
Chapter 1 Aseptic processing and packaging:
Past, present, and future ............................................................1
Jairus R.D. David
1.1. Framework.and.current.state..................................................................1
1.2. Departures.from.optima.and.challenges..............................................3
1.3. Current.and.future.opportunities.for.optimization............................4
References............................................................................................................8
Chapter 2 United States hist ory and evolution .......................................9
Ralph H. Graves
2.1. Early.pioneers............................................................................................9
2.2. The.Graves.era.........................................................................................11
2.3. Jack.Stambaugh.......................................................................................12
2.4. The.first.commercial.aseptic.plant.......................................................13
2.5. The.real.fresh.company.........................................................................13
2.6. The.first.aseptic.form–fill–seal.packages............................................13
2.7. Early.aseptic.packers..............................................................................14
2.8. Restrictions.for.growth..........................................................................15
2.9. Trends.for.the.future..............................................................................16
References..........................................................................................................17
Chapter 3 The U.S. markets for aseptic packaging ...............................19
Thomas Szemplenski
3.1. Development...........................................................................................19
3.2. Aseptic.metal.can.market......................................................................20
3.3. Aseptic.bag-in-box..................................................................................21
3.4. Aseptic.paperboard.market..................................................................25
vii
viii Contents
3.5. Aseptic.plastic.cup.market....................................................................28
3.6. Aseptic.pouch.market............................................................................29
3.7. Aseptic.plastic.bottle.market................................................................31
Chapter 4 Aseptic processing equipment and systems .......................33
Thomas Szemplenski
4.1. Introduction.............................................................................................33
4.2. Aseptic.processing.equipment.............................................................34
4.2.1. Basic.requirements.of.aseptic.processing.equipment.........34
4.2.2. Blending.vessel,.balance.surge,.formulation.of.product.....35
4.2.3. Timing.pump............................................................................36
4.2.3.1. Pumping.of.foods.containing.particulates..........37
4.2.4. Heat.exchangers........................................................................39
4.2.4.1. Heating:.Sterilization.of.the.products...................39
4.2.4.2. Steam.injection.or.infusion.heaters.......................39
4.2.4.3. Plate.heat.exchangers..............................................41
4.2.4.4. Tubular.heat.exchangers.........................................42
4.2.4.5. Regeneration.............................................................44
4.2.4.6. Scraped.surface.heat.exchangers...........................47
4.2.4.7. Ohmic.heating..........................................................48
4.2.4.8. Microwave.heating..................................................49
4.2.5. Continuous.holding.tubes.......................................................51
4.2.6. Deaerator....................................................................................51
4.2.7. Controls......................................................................................52
4.2.8. Aseptic.surge.tan ks,.barrier.seals,.and.automatic.air-
operated.valves.........................................................................54
4.2.8.1. Aseptic.surge.tanks.................................................54
4.2.8.2. Barrier.seals..............................................................55
4.2.8.3. Valves.........................................................................55
4.2.9. Homogenizers...........................................................................57
4.2.10. Ingredients.................................................................................58
4.2.11. Clean-in-place.(CIP)..................................................................59
4.2.11.1. Clean-in-place.solutions..........................................59
4.3. Plant.layout.considerations...................................................................61
4.3.1. Preparation.and.processing.equipment.and.systems.........61
4.3.2. Packaging.system.area.(bacteriological.conditions)............61
4.4. Utilities.....................................................................................................63
4.4.1. System.sterilization.water.......................................................63
4.4.2. Preparation.water.....................................................................64
4.4.3. Heating/cooling.water.............................................................65
4.4.4. Refrigerated.water....................................................................66
4.4.5. Steam..........................................................................................67
4.4.6. Air...............................................................................................68
