Juice aseptic packaging process
Aseptic packaging technology is a kind of packaging technology that fills and seals in a sterile environment under the condition that the packaging, the packaging and the auxiliary packaging equipment are all sterile.
The aseptic packaging technology makes the packaged products without preservatives, and can be kept fresh for half a year or more without deterioration at room temperature without refrigeration. It also has low energy consumption, less packaging materials, low manufacturing costs, and high packaging efficiency. , Good economic efficiency and light quality, as well as recyclable waste packaging and other advantages, suitable for long-distance transportation.
The application of aseptic packaging is more and more extensive, from packaging liquid to fluid, semi-fluid and paste; from general fruit juice to milk, tea, vegetable juice, soup, wine, water, liquid medicine, etc. Here mainly introduces the application of aseptic packaging of juice.
Fruit juice aseptic packaging is a packaging system that puts aseptic fruit juice, packaging containers and packaging auxiliary materials in an aseptic environment and fills and seals them with an aseptic filling machine. Juice foods are sterilized instantaneously at high temperature, and then the temperature is lowered to 20 ° C to 30 ° C, which meets the sterility requirements.
The process of aseptic packaging of fruit juice can be roughly divided into three parts: preliminary work, sterilization and packaging.
1 Preliminary work of aseptic packaging of juice
The preliminary work of aseptic packaging of juice includes the selection of composite materials, the design of brick carton and box blank structure, and the decoration design, and then the delivery to a professional packaging material factory to print according to the patterns, text, and colors of the decoration design, and to follow the structural design. The indentation is cut, and finally it is transported to the packaging factory in roll paper.
1) Choose material
The packaging containers used for aseptic packaging of fruit juice include cups, boxes, bags, barrels, etc. Here, brick-type box packaging containers are mainly introduced.
Aseptic packaging materials for fruit juice mainly use composite films, which are composed of six layers of materials, namely polyethylene / paper / polyethylene / aluminum foil / polyethylene / polyethylene composite materials. The weight of the packaging carton made of composite film is only 8% of the glass bottle of the same volume, which not only lowers the cost, but also generates less waste, which is beneficial to environmental protection.
2) Design brick-shaped carton
The capacity of the brick-shaped aseptic packaging carton on the market is 250ml. The solid line in the structural design diagram represents the contour cutting line, the dashed line represents the inner folding indentation line, and the dot-and-dash line represents the outer folding indentation line. The diameter of the packaging material reel transported to the packaging factory is 0.8m, and it can produce about 5000 pieces of 250ml brick-shaped aseptic packaging cartons.
3) Decoration design
When decorating and designing, we must first consider the requirements of product packaging and choose the appropriate style; secondly, we must consider the correct and appropriate use of patterns, text and colors, and follow the principles of "scientific, beautiful, applicable, economic and promotional", and strive to design beautiful and Sense of time, decoration and nationality.
At the same time, in order to achieve the above design goals, advanced technology must be used, such as CAD (Computer Aided Design), CAM (Computer Aided Manufacturing), professional software such as professional software for packaging carton structure design-Flutter-Pack.
4) Printing
The printing of paper containers can be divided into two categories: traditional analog printing and new digital printing. At present, most of them still use analog printing.
Among the conventional four major printing methods, lithography is the most commonly used, while PS is mainly used in lithography. Because the PS plate making is simple and fast, the plate material is light and cheap, and with the application of new light sources, new photosensitive materials, and new equipment, the quality of plate making continues to improve. Flexographic printing has also been widely used in packaging printing.
5) Compound
The compounding process is the most important in the whole process, because it plays a decisive role in the packaging function of the entire container. For example, the semi-finished product after printing in the paper container Tetra Pak is placed on the composite unwinding rack, after four times of lamination, once the adhesion of aluminum foil (the aluminum foil can prevent ultraviolet light and ensure the quality of the contents), and finally The roll is wound into a roll shape. Tetra Pak's four-layer plastics are made of polyethylene or modified polyethylene resins of different thicknesses from the outer layer, composite layer, inner layer 1 and inner layer 2 respectively, and are about 1300mm wide after being extruded by four extruders. The film is bonded to paper and aluminum foil. Then it will be cut by the professional manufacturer after cutting and creasing, and finally delivered to the packaging factory in the form of a roll.
2 Sterilization of juice aseptic packaging
Juices are made from different fruits, and their ingredients and characteristics vary. The main factors related to packaging are the acidity, enzymes, vitamin C, color and flavor of the juice. The deterioration of the juice is mainly caused by yeast and mold.
The sterilization process controls the content of microorganisms in the product through high temperature. Currently commonly used sterilization methods are high temperature short time (HTST) and ultra high temperature instantaneous (UHT) sterilization. Selection should be based on product characteristics? Improper handling will cause incomplete killing of microorganisms or loss of color and fragrance of the product, and destroy the nutrients in it.
At the same time, before and after packaging, the operation workshop environment should be sterilized, and the air pressure in the workshop environment should be slightly higher than the outside atmospheric pressure to prevent outside air from entering the workshop and reduce the invasion of bacteria and dirt.
The floor, walls, operating table, tools, etc. of the production workshop should also be regularly disinfected. At the same time, the material circulation pipes and reservoirs should be cleaned in a fully automatic cycle. [next]
3 Aseptic packaging process of juice
The juice aseptic packaging process mainly includes the following processes.
1) Filling
Filling is the most important process in the entire packaging process. It consists of a series of processes and is completed on a filling machine. The working process of the aseptic filling machine.
â‘ Paper feeding. A special trolley is used to push the paper roll to the machine, and an automatic paper barker can be used. When the old paper roll is almost used up, the new and old paper rolls are connected without stopping the machine. The paper roll 1 is fed by a feed roller 3 driven by a motor, and the idler 2 can start or stop the feed roller 3. The paper tape travels to 4 places to print the production date, and presses the horizontal crease.
â‘¡ Sealing. In order to prevent leakage from the back of the sterile carton after heat sealing, tape should be used to further seal the heat sealed part. The specific method is to use the seal applicator to stick half of the 8mm wide PP tape on the inner edge of the packaging paper, and the other half is bonded to the other edge of the packaging paper during longitudinal sealing to obtain a tight and strong seal.
③ Sterilization. Before filling, the packaging paper is immersed in the H2O2 (hydrogen peroxide) tank 6 for sterilization. The concentration of H2O2 is generally 25% to 30%: increasing the sterilization temperature can accelerate the sterilization of the initial oxygen, preferably 80 ℃.
④ Dry. A pair of rollers 7 is used to squeeze the hydrogen peroxide from the packaging paper. At the same time, the air curtain 8 is used to spray high-temperature sterile air at 140 ° C to 150 ° C to blow dry the H2O2 that remains on the surface of the packaging paper after extrusion to decompose it into harmless water vapor and oxygen. At this time, the high temperature air It can also enhance the sterilization efficiency of the new ecological oxygen and kill some of the remaining bacteria.
⑤Heat sealing and filling. The packaging paper is formed into a tube by 4 guide rollers and a former. At this time, the edges of the packaging paper are overlapped by about 8mm. The vertical sealing device 10 continuously heat seals the PE film inside and outside the packaging paper at the overlapping place, and will pre-stick The PP tape on the inner edge is firmly bonded. At the same time, the juice that has been sterilized and transported from the sterile pipeline is injected into the paper tube through the filling tube 9. In order to meet the requirements of aseptic packaging, the end of the filling tube has been submerged in the juice.
â‘¥Fixed volume, crimped edge and horizontal seal. The device is composed of two pairs of jaws that move up and down continuously. When one pair of jaws is engaged, 250ml of juice is enclosed in the cavity of the paper cylinder formed by the rib, and the bottom is sealed horizontally. The two layers of the inner surface of the packaging paper are used for horizontal sealing The PE film is heat-sealed, and the width of the heat-sealed is about 16mm. The width is cut into two parts with a cutting knife. The upper half is used as the bottom seal of the former carton, and the other half is used as the top seal of the latter carton. When the jaws and the paper cylinder run synchronously to the lowest position, another pair of jaws open and run up, repeating the above work on the top surface of the previous pair of jaws. The gap between the bottom surface and the top surface of the two jaws is about 0.7mm. This cycle makes vertical sealing into cylinder filling, constant volume, rib forming, horizontal cutting and cutting circulates continuously under the condition of continuous running of the paper tube, which greatly improves productivity, and can pack 100 to 120 boxes per minute.
⑦Fold corner. The side corners of the top and bottom of the small package are folded to the side and bottom in the brick-shaped folder 14, and 160 ℃ high-temperature steam is sprayed on the four positions of the bottom and side, so that the two sides of the top and the side are pasted. The two corners of the bottom surface are pasted to the bottom surface. When the bottom of the carton inside the folder is facing upwards, when it is unloaded from the folder onto the conveyor belt 15, the top of the finished product is facing upwards.
2) Inspection of aseptic packaging of juice
Strict inspection measures are also an important guarantee to ensure the smooth implementation of the aseptic cold filling process. The operation requirements of the aseptic filling room are extremely strict and must be carried out in accordance with the operation regulations. During the filling process, the laboratory personnel must make online inspection of the aseptic packaging of juice. Immediately after the filling machine is adjusted, two boxes are sampled every 10 minutes to check the quality of forming, sealing and pasting, and the filling capacity before the tube is attached; after normal operation, two boxes are sampled every 30 minutes, and the inspection contents are the same.
3) Stick straw
The straw is designed for consumers to drink. It is made by a professional factory and is made of polyethylene plastic with a length of 115mm and a diameter of 4mm. It is pre-installed in two layers of polyethylene plastic film suitable for its length and sealed separately, in order to Ready to use. The straw is attached to the diagonal of the back of the aseptic packaging carton, and it is completed by a dedicated tube applicator.
4) Medium packaging
The corrugated paper tray is made of E-shaped corrugated cardboard, and its size is 395mm × 193mm × 110mm according to the arrangement of the carton. Arrange the products on the pallet machine first, with a total of 3 × 9 = 27 sterile cartons. Next, a PVC film is used on the heat shrink packaging machine to form a shrink package for the packaging unit formed by the tray and the product.
5) Outer packaging
Stack the corrugated paper pallets on the stacking machine into 8 layers on the intermodal flat pallet, staggered between the layers, so that one pallet can hold 12 × 8 = 96 pieces of packaging and 2592 pieces of sterile packaging boxes. Finally, the film is stretched with a linear low-density polyethylene with a width of 500 mm on the winding stretch packaging machine, and is wound in a spiral form from top to bottom. It can also be wrapped with a stretch film with a width of 1 m on a rotary stretch packaging machine. package.
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