This article was downloaded by: 10.3.98.104 On: 01 Oct 2021 Access details: subscription number Publisher: CRC Press Informa Ltd Registered in England and Wales Registered Number: 1072954 Registered office: 5 Howick Place, London SW1P 1WG, UK

Handbook of and Packaging

Jairus R.D. David, Ralph H. Graves, Thomas Szemplenski

The U.S. markets for aseptic packaging

Publication details https://www.routledgehandbooks.com/doi/10.1201/b13026-4 Thomas Szemplenski Published online on: 15 Nov 2012

How to cite :- Thomas Szemplenski. 15 Nov 2012, The U.S. markets for aseptic packaging from: Handbook of Aseptic Processing and Packaging CRC Press Accessed on: 01 Oct 2021 https://www.routledgehandbooks.com/doi/10.1201/b13026-4

PLEASE SCROLL DOWN FOR DOCUMENT

Full terms and conditions of use: https://www.routledgehandbooks.com/legal-notices/terms

This Document PDF may be used for research, teaching and private study purposes. Any substantial or systematic reproductions, re-distribution, re-selling, loan or sub-licensing, systematic supply or distribution in any form to anyone is expressly forbidden.

The publisher does not give any warranty express or implied or make any representation that the contents will be complete or accurate or up to date. The publisher shall not be liable for an loss, actions, claims, proceedings, demand or costs or damages whatsoever or howsoever caused arising directly or indirectly in connection with or arising out of the use of this material. Downloaded By: 10.3.98.104 At: 06:37 01 Oct 2021; For: 9781439807200, chapter3, 10.1201/b13026-4 The U.S.The markets for chapter type package and the Scholle aseptic -in- , other packaging packaging other filler, bag-in-box aseptic Scholle the and package type early 1980s.the in Following ’s starting Brik- of the introduction suit able, could displayed and be and on store shelves. familiar looked that a with consumer the presented web, the cutfrom This or brick. foldedit and wasformed rectangle a into and sealed was container the after a continuous that was different was in What motion. sealed and filled, web formed, being a material with laminated same of the remained system basic The container. improved early the 1970s. in Scholle William bag-in-boxaseptic system the developed by using filled aseptically being products by followed were packages These container. hermeti a sealed in cally aseptically sealed and filled be to sterilized allowed was baththesystem ofweb. packaging This Tetrainclude sterilizing modified to a the California, Carolina, of Fresh South Real in with Companyconjunction in Milliken and the was system this of licensee U.S. The open. to challenge real a and stack, or pack to complicated but use material in efficient extremely was package This tetrahedron. a was container The beverages. and milk form– pasteurized fluid continuous for system a fill–seal time, that at was, system The States. United the to company, introduced itspaper-aluminum foil- laminated container Swedish a TetraPak, time, same the aboutsoup.At and puddings, milk, shelf-stable package and process aseptically to foresight. started with processors processors These by used was System Dole when 1970s the early and 1960s late the until packaging and processing tic decades invented asep of was the commercialization in before, activity was no there significant packaging and processing aseptic though Even 3.1 Szemplenski Thomas aseptic packaging The The real growth in aseptic processing and packaging was experienced and new a with States United the to returned Pak Tetra 1981, In Development 3 19 - - - Downloaded By: 10.3.98.104 At: 06:37 01 Oct 2021; For: 9781439807200, chapter3, 10.1201/b13026-4 these tanks holding nearly 2 million gallons of aseptically processed acid processed of aseptically gallons holdingnearly million 2 tanks these (some storage of bulk ofpolymers, various tanks even and aseptic including alternatives, containing pouches, plastic aseptic form–fill–seal drums, steel creamers, coffee cups, ofplastic number a quite now are There equipment. filling aseptic bag-in-box and packaging of manufacturers other as well as introduced, be to started alternatives 20 3.1 Figure was into packaging cans the metal improved organoleptic and nutritional can Dole the using system. cans ning metal into filled aseptically were all sandwich and spreads drinks, dietetic paste, puree, banana mix, ice eggnog, food, baby corn, Products cream-style ketchup, sauces, cheese as filled. such did so aseptically were that increased, products Canner different of Dole number the the using packaging aseptic for learning the curve As operation. in 60 still are than which of more many supplied systems, eventually canning Dole as cans metal into food of ing (see Figure 3.1) cans. for minute per 4-ounce up to 450 cans #10for minute per cans cans 30 from varied speeds Filling . metal and cans the and filler the of sterilization of maintenance and sterilization pre forheat on based reliable.Itwas very was system canning Dole The 3.2 chapter. this reviewed be in will and alternative different is packaging aseptic each of force driving or growth products). market The The driving force for interest and the growth factor in aseptically aseptically in factor growth the and interest for force driving The packag aseptic of acceptance and interest considerable was There Aseptic metal can market Asceptically canned pudding. canned Asceptically Handbook of aseptic processing ofaseptic Handbook and packaging

(Photograph courtesy of Real Fresh.) of Real (Photograph courtesy - - - Downloaded By: 10.3.98.104 At: 06:37 01 Oct 2021; For: 9781439807200, chapter3, 10.1201/b13026-4 heated in a matter of seconds from an ambient temperature to around around to temperature 275°F, ambient filling a tocooled fastvery then and ofheldtime period forshort a an from seconds of matter a in heated homogeneously be could now it overcooking, in resulting hours 2 times some to minutes 45 from 250°Fof temperature a to subjected being ucts prod food the of Instead retorts. in be time of to periods long had forovercooked longer no products The canned. being food the of properties 3: Chapter cut handling these . Fifty-five-gallon metal drums were very were drums metal Fifty-five-gallon containers. these handling cut productdue due toresiduals, toworkers not tomention liabilities getting are of loss yielded still of,and dispose and and open to troublesomeexpensive,were quite cans 10 Number pails. plastic 30-pound in drums, frozen or metal into filled aseptically cans, #10 into forth filled hotso either and were , pies, for and paste tomato as such products development the toPrior bag-in-box mostacid food ofaseptic packaging, tion. Aseptic bag-in-box packaging was an immediate success ( radia gamma by presterilized and sealed are still and flexible were The chlorine. superheated water, steam, and with presterilized was filler bags fill nowup aseptically to Scholle’s can 330 gallons. aseptic prototype 5 gallons. Improvements to the original Scholle were made to the point they University’s West in Lafayette, facility processing food Indiana. Purdue at design initial the improved upon and tested He bags. flexible neered and a manufactured prototype of an aseptic filler toengi fill preformed, Scholle packaging. and processing aseptic time, the at developing rapidlywas that technology newrelatively a applying toward leaned he packaging, flexible in packaged be to product the to sterilize commercially technologies retorting existing using of Instead products. fruit other and tomatoes as products such packag food transport to used rigid being was that ing expensive, the replace to packaging flexible for potential the visualized polymers, various of packaging flexible of manufacturer leading a Corporation, Scholle the of Scholle 1970s,William early the In 3.3 been have 20 last years. the in systems installed canning Dole other few very so can, metal the than expensive less far are bag-in-box, pouches cups, plastic and Aseptic sors. proces food of choice the became developed that was packaging aseptic expensive less alternative, system, Dole the for Unfortunately products. 1970s the inventedfor tomato in byRica Fran drums metal 55-gallon into system filling aseptic the than other cans, metal fordeveloped ever was embraced technology. processors the food and cessed resulted in dramatic quality and taste improvement in the food being pro canning and processing 90°F.Aseptic and 70°F between of temperature The first Scholle aseptic filler was developed to fill bags from 1 to from bags fill to developed was filler aseptic Scholle first The system that packaging system wasonly aseptic the DoleThe canning Aseptic bag-in-box The U.S. markets for aseptic packaging markets U.S. for aseptic The Figure 3.2 21 ). ------Downloaded By: 10.3.98.104 At: 06:37 01 Oct 2021; For: 9781439807200, chapter3, 10.1201/b13026-4 22 6 percans . Food service is one of the largest markets for bag-in-box. products destined for food service are packaged into #10foodpresented. Many be cans andwill #10delivered numbercans productpackaged into to As an example, a brief comparative analysis of aseptic bag-in-box compared wasexpensive, additionally pricey. but cost of freezing the pails werethe only Not forth. so and yogurt, for pies,fruit into facturing remanu for States United the over all shipped and area growing the at plastic pails were the most common way to fruit that transport was frozen expensive and additionally yieldsacrificed at theuse point.Thirty-pound 3.2 Figure 5-gallon aseptic bag-in-box aseptic 5-gallon of #10Case cans Economicsdriving forcetheis main for theaseptic bag-in-box market. • • • • usually will cost between $0.80 and $1.20. If an average price ofaverage price $1.20.an and If $0.80 butbetween cost will forth, usually so and metallization, barriers, materials, packaging upon depending price in vary will bag presterilized 5-gallon, A 6 ×$0.75 $0.75 is each. writing #10 of this at time the can a averagefor price the purchased, cans of number the on based customer the of size the and time the at rawmaterial the of cost the upon depending vary will can #10 a of price the Although about be of usually 4.5 #10 gallons. a case therefore will cans ounces, 96 approximately contain normally will can #10size A The

Scholle aseptic bag-in-box filler. aseptic Scholle = $4.50 per case (usually case per about $4.50 4.5 gallons) Handbook of aseptic processing ofaseptic Handbook and packaging - Downloaded By: 10.3.98.104 At: 06:37 01 Oct 2021; For: 9781439807200, chapter3, 10.1201/b13026-4 Chapter 3: Chapter increased to the point some of the fillers can fill gallons. fill bags300 up to can point some fillers of to the the increased (FDA)low-acidhave and bag filling sizes , validation for aseptically Administration haveseveral receivedDrug that U.S.extent and the Food to bag-in-boxfillers aseptic in made been haveImprovements materials. pliers of aseptic bagspresterilized of various polymers and oxygen barrier sup major six approximately also are There operating. bag-in-boxfillers aseptic 200 than with more alone the States United in installed boxfillers for fillers tic bag-in-box.areThere now at least bag-in-aseptic different 10 and this realized equipment quite a few competitors have to versionsScholle of their introduced asep packaging food of market. manufacturers bag-in-box aseptic Other the for force driving main the is economics are: cans metal to rigid pared #10of the was approximately cans $1,500,000 annually. disposing and reopening of cost the advised processor Additionally, the product into alternative packaging. To elaborate on the comparison: initial the into reprocesses and #10 product the cans opens it off-season the the #10During cans. all packages it season fresh-fruit the During year. cans #10 per million 9 utilizes facility processing food This processor. food • • • • • • • • Based on advantages similar to those described in our comparison, comparison, our in described those to similar advantages on Based com bag-in-box aseptic by realized be to savings economic Further actual an for generated was comparison economic extended An

Reduced disposal cost Reduced disposal Reduced liability full and Reduced cost shipping empty to compared cans bags metal for required space Reduced – $6,750.000 bag-in-box: into $1,350,000 product package to savings Yearly bags 5-gallon by 1,350,000 bags @$1.00 bag per divided gallons 6,750,000 bag-in-box: of Cost Cost 9,000,000 of cans: ×$0.75 case per gallons case per cans 6 9,000,000by divided#10 cans •

$1.00 is used in the calculation, the savings would be $4.50 – $1.00 noted that the bag holds approximately aseptica bag-in-box half a compared gallontocasea of #10 morecans, but itproduct.should be enterediscomparison intothe savingsthewould $3.20 be forthe price of the flexible bag packaging by as much as $0.20 more.Addingpricecorrugated theIfforthethis container wouldincrease the = $3.50 per case savings. $3.50 case per The U.S. markets for aseptic packaging markets U.S. for aseptic The = $5,400,000 = 6,750,000 of product processed gallons being = = $6,750,000; yearly cost of #10 cans $1,350,000 yearly cost of bags = 1,500,000 cases × 4.5 × cases 1,500,000 23 = - - -

Downloaded By: 10.3.98.104 At: 06:37 01 Oct 2021; For: 9781439807200, chapter3, 10.1201/b13026-4 such as stabilized fruit forfruit suchstabilizedpiesas yogurt,and marketbutgiven has this way industry. Initially the market for the smaller bags wasservice food the forforproductgenerallyfordestined is bags smaller for acidified ket products, mar The gallons. 300 to55 bags frombags largerpackagedformarket in the and gallons 5 to 1 from bagssmaller product packagedin formarket 24 ating aseptic fillers are for the larger 300 gallon bags, and although although and citrus for bags, installed gallon fillers 300 aseptic few a have larger FoodTech JBT the and oper Scholle the for are all Almost fillers bags. aseptic bulk into ating industry of citrus filling the 1990s, aseptic the embraced In season. com tomato days 100-day 250 is of the to season industry pared approximate an citrus the creating however, crops two industry, afforded tomato fill bag the aseptic as many as installed have not ers does industry citrus The industry. intothe bag-in-box. filled aseptically are that and are harvested packagedtomatoes toCalifornia in be reprocessed fillers were rapidlyfillers. Nearlyreplacing all nearlythe aseptic all bag-in-box aseptic the when slowerthan pacea atbut grow to continues producttomato for bag-in-boxpackaging aseptic for demand The aging. bags, for ers bulk although JBT FoodTech pack the not does manufacture , and so on. JBT sauces,FoodTechketchup, is into ofthe leading manufacturer aseptic fill reprocessed be to States United the around points Itand processed packagedtically California. in is then shipped to various other parts of the country. The product is harvested, condensed, and asep tomatoesfor shipmentdiced packagestopaste and Unitedaseptically Statesand the in tomatoes the of most supplies and grows California ucts. fortomato prodbagsis forbulk markets two the of larger the operating, for market bags. approximate toamount an million $50 in units 2008. 4,500,000 Based on at the average estimated price for is a bulk bagStates in 2008, United wouldthis the in bags bulk for market total products.The citrus for other the and tomatopaste for one markets: nate predomi two into divided additionally is market This bags.gallons) 300 uctsbe will aseptically packaged into flexible bag-in-box packaging. prodmoreassuredly Most mature. not is market States.This United the are more 100than aseptic bag-in-box fillersinstalledfillingsmaller bags in products are aseptically processed and packaged. It is estimated that there warmcheddaroverto saucedispense cheese chili andnacho chips. These Gehl’s installed from dispenser ahave not does that StatesUnited the in conveniencea hardly is There . single-strength and mustard, salsa, ketchup, like condiments, and milk, chili, soups, restaurants, for sauces is experiencing growth now is for low-acid food products such as prepared to saturation and the larger bags. The market segment for smaller bags that The marketThe for aseptic bag-in-box markets:actually is two distinct the The other major market for bulk aseptic bags is in the citrus citrus the in is bags aseptic bulk for market major other The packaging bulk for fillers bag-in-box aseptic 90 approximately With There are approximately 140 tolargerfill installed aseptic fillers (55 to Handbook of aseptic processing ofaseptic Handbook and packaging ------Downloaded By: 10.3.98.104 At: 06:37 01 Oct 2021; For: 9781439807200, chapter3, 10.1201/b13026-4 taining millions of gallons of citrus juices. Even at that, industry sourcesindustry that, atEven juices. citrus of gallons of millions taining capableasepticallystorageconof tanks bulk asepticreplaced beingwith boxhas been steadyin decline for the past decade. Aseptic bags are rapidly predominate industry. the citrus the is in used filler being filler StarAsept DuPont/Liqui-Box the products, 3: Chapter paperboard-type containers. paperboard-type in pictured ones the like sauces many and drinks, nutritional soups, broths, as such Products day.every packaged aseptically being are products containers. new that paperboard-laminated appears It into packaged aseptically being are that products new of scope the has so improved, packaging and processing aseptic in curve learning the However, as operating. and already installed are that fillers many the to due writing this of time the at static ( locations various product copacked the at had or Tetra fillers Pak whoinstalled processors beverage many bythe offered products packagedand different many the with lined were that shelvesstore grocery the by evidenced as passion a public embraced new the consuming packageThe nal. productsand with real segment. dairy the in the occurred growth when injection steam of introduction the with upon improved significantly was milk of processing the until not was It milk. for fillers for the demand flavored beverages liquid exceeded and far juices fruit as the demand for Tetraequipment Pak filling foraseptic acid products time such that At packaging. Pak’sBrik-PakTetra in market mass the to tion package contained. whatever the consuming of many ease and portability with the like who popular consumers container the made This spot. scored specially atthe opening an puncture to designed was that containers smaller the for be to straw the was suitable feature and functional real shelves.The store the on familiar displayed looked that container a with consumer the the web, from it cut was formed and and folded sealed into a wasor rectangle brick. package presented This the after that was different was What in a continuous motion. andsealed form, filled, being material of laminated web a with same the remained system basic The package. improved earlythe In 1980s, Tetra to Unitedthe States Pak a with new returned and 3.4 utilized in the citrus industry (P. Brocher, personal communication, 2008). have reported that in 2008, approximately 1.5-million bulk aseptic bags were The market for new Tetra Pak fillers for acid products is somewhat is products acid for fillers Pak Tetra new for market The phenome was packaging Brik PakTetra in juices of acceptance The introduc firstreal their experienced flavored and milk Aseptic marketproductscitrusforThe beings asepticallybag-in-thestored in Aseptic paperboard market The U.S. markets for aseptic packaging markets U.S. for aseptic The Figure 3.3 iue 3.4 Figure ). are all being aseptically packaged into into packaged aseptically being all are 25 - - - - Downloaded By: 10.3.98.104 At: 06:37 01 Oct 2021; For: 9781439807200, chapter3, 10.1201/b13026-4 26 literature.) 3.4 Figure 3.3 Figure

Aseptic Aseptic product in Tetra packaging. (Photograph courtesy of Tetra Pak.) Low-acid aseptic Low-acid product Tetra in aseptic sales (Photographs from packaging. Handbook of aseptic processing ofaseptic Handbook and packaging Downloaded By: 10.3.98.104 At: 06:37 01 Oct 2021; For: 9781439807200, chapter3, 10.1201/b13026-4 acid beverages and other foods. This trend will continue. will trend acid beverages This foods. other and operating in the United States. Almost half of these arefillers now for low- and installed fillers aseptic approximately200 has Tetraerages.nowPak is food in specialty and beverages other juices than and flavoredfruit bev 3: Chapter 3.5 Figure Tetra innovation. is Pak that and gable being a form–fill–seal topcanbe Onedesign.thing counted onwith intotically fill many different packaging configurations, themost recently They dynamic. now have of many fillers designedtypes todifferent asep is Pak at Tetra packaging Aseptic material. packaging and fillers aseptic Figure 3.5. in one pictured the like particulates small with soups filling aseptically Canada in facility Campbell a a low-acidlocatedis atcontaining installation The food particulates. with system processing aseptic commercial a in used filler first the was filler are FDA with validated for low-acidaseptically filling foods, sterilized butthe Combibloc are fillers Combibloc and TetraPak filler the Both air. hot Combibloc and peroxidehydrogen the with packages The the packages. seals and fills, sterilizes, forms, opens, automatically then filler The Combiblocflat. folded filler, the to the supplied are that packages packages, preformed uses filler sterile producing of principle form–fill–seal Pak Tetra the Unlike Combibloc.SIG is packages paperboard-laminated It appears that the real growth in the paperboard laminate packages laminate paperboard the in growth real the that appears It Tetra Pak is by far the leading supplier in the worldsupply the the offor supplier in leading the far byTetra is Pak into products for equipment filling aseptic of supplier other The Low-acid aseptic product containing particulates. product containing Low-acid aseptic The U.S. markets for aseptic packaging markets U.S. for aseptic The 27 - - Downloaded By: 10.3.98.104 At: 06:37 01 Oct 2021; For: 9781439807200, chapter3, 10.1201/b13026-4 cs no lsi cp. hs ntlain a floe b a ubr of number a by followed was installation This cups. plastic into ucts prod food filling for States United the in filler aseptic first the installed Company Bosch Robert 1980s. early the in starting growth tremendous enjoyed cups plastic into filled aseptically products food for market The 3.5 28 3.6 Figure 2010). communication, personal (C. Ravalli, minute 1700per cups almost fill can filler cup aseptic OYSTARHassia latest The (Figure 3.6). States United the in fillers cup aseptic of supplier dominant the become has OYSTARHassia, now Hassia, marketing, aggressive and sterilants, chemical of lack speeds, production high engineering, excellent to Due fillers aseptic 26 all, inand the 12 In more 1980s. starting extended shelf-life fillers installed were materials. packaging of high economics to due and system speeds canning Dole the for market the away took but all shelf-life extended as used (ESL) forrefrigerated fillers products. were but foods low-acid filling aseptically for validation FDA received never fillers Hamba and Gasti The Hamba. Box,ERCA, and Metal Benco, Gasti, Hassia, as such manufacturers other The introduction of these aseptic fillers for filling into plastic cups plastic into filling for fillers aseptic these of introduction The Aseptic plastic cup market Some products aseptically filled using an OYSTARusing filler. Hassia filled aseptically products Some Handbook of aseptic processing ofaseptic Handbook and packaging - Downloaded By: 10.3.98.104 At: 06:37 01 Oct 2021; For: 9781439807200, chapter3, 10.1201/b13026-4 include cheese and other sauces, condiments, soup, baby food, and fla and food, baby soup, condiments, sauces, other and to cheese expanded include products of scope the years the Over aseptically pudding. the of processed quality organoleptic improved much packaging, the by expensive also less but and production higher of economics the by cupsdrivennot only intowas plastic filling aseptic in interest The dings. 3: Chapter and cheese sauces and cheese #10in The market cans. forsauce cheese exploded to with puddings fillers filling system pouch canning Dole the aseptic using of were that fillers replace number a supplied Bosch pouches. flexible photographof the 2010). communication, (B. personal Pritchard, one or corrugatedleft bottom roll in on boxthe the right bottom in on the for 832 #10 compared metal cans to the space forrequirement 832 pouches spacerequired the showdemonstratestrade ata (with permission) taken cost alone.mately packaging in $480,000 in cost. For a cans food processor iteach uses million would save approxi difference approximatelyoverwhelming $0.27. costs an pouchble is That compara a that have advised additionally They can. about$0.75 per cost #10have that addition processors generally advised supfood to pliersin cans material packaging and equipment filling Aseptic themselves them. cutting handling users from cases liability incur and of, open dispose to and difficult be can space, considerable up take but costly only not ortutional food service market for replacing product in #10 are cans. Cans The predominate market for product to be supplied in pouches is the insti due but also to packaging, in savings economic the due to mainly to explode activity developedwith expected is that market The aseptic pouch market is believed to be in its infancy. is an This under 3.6 packaging and processing aseptic and saturation. of cost capital-intensive likely most the is to this due that advised have sources Manufacturing been have installed. fillers cup aseptic new many not and has considerably cups for softened fillers aseptic for market the however, late, Of gels. vored The first products to be aseptically filled into plastic cups were pud were cups plastic into filled aseptically be to products first The Robert Bosch was the first company to develop an aseptic filler for filler aseptic an develop to company first the was Bosch Robert floor space.in is The major savings photograph Another in force. The economic driving are savings exceptional and are the main Aseptic pouch market − − − − − − − − − − The U.S. markets for aseptic packaging markets U.S. for aseptic The Less manpower requirement at the end use point at end manpower use the requirement Less spaceLess required cost disposal Less Convenience compared to #10 cans food orproduct hot filling compared to retorting the of quality organoleptic and nutritional Improved Figure 3.7 29 ------

Downloaded By: 10.3.98.104 At: 06:37 01 Oct 2021; For: 9781439807200, chapter3, 10.1201/b13026-4 30 human judgment by restaurant cooking staffs. cooking restaurant by judgment to human due foods undercooking or over- to organoleptically compared and foods consistent palatable more also but cans metal only not to native alter wonderful a as food products food The these embrace material. will industry packaging service and fillers pouch will aseptic so for develops, market matter the particulate containing products food for tion nology, by fitmentoffered as Fres-co. such attachment capacities, size of pouches, of size and particulate different handling tech filling varying at operate that pouches for fillers aseptic developedhave sauces for chips. cheese for aseptic a dispenser havenot does that conveniencestore a hardly is activity,todaythere and 832 packages. 3.7 Figure s h tcnlg t aetcly rcs ad eev FA valida FDA receive and process aseptically to technology the As Inpaco,DuPont/Liqui-Box, OYSTARFres-co, Cryovac and all Hassia, Space requirements for pouches compared to cans—each showing showing cans—each to compared pouches for requirements Space Handbook of aseptic processing ofaseptic Handbook and packaging - - - Downloaded By: 10.3.98.104 At: 06:37 01 Oct 2021; For: 9781439807200, chapter3, 10.1201/b13026-4 of aseptic fillers for plastic bottles of (PP), high-density high-density (PP), polypropylene beveragepolyethylene(PET). The (HDPE), terepthalate and of bottles plastic for fillers aseptic installation the of and introduction with the been market has years recent the in activity fillers, most laminate paperboard Pak’s Tetra Besides 3.7 3: Chapter but not limited to:but not limited board or Brik-type foracceptance packages. are,reasons this The primary awayfor beveragesmarket at the were that previously papersupplied in chipping is and outstanding is plastic the of acceptance Consumer suppliersThese include: products. shelf-life extended low-acid beveragesincluding and high- ing fill aseptically approximately are there 75 installations, all, validation.In FDA received have manufacturers six States; United the in installations shelf- fill stableto low-acid beverages. used be cannot therefore and validated FDA not are mode ESL an in used being fillers Many products. dairy refrigerated shelf-life,extended fill to fillers aseptic their using are others whereas beverages, high-acid fill to installed have been fillers bottle aseptic many then Since foods bywas and installed manufactured forBosch nutritional beverages. bottle inthe installed Unitedfiller Statesplastic and validated forthe ofaseptic filling low-acid first The bottle. plastic the embraced has industry • • • • • In all there are nine manufacturers of aseptic filling equipment with equipment filling aseptic of manufacturers nine are there all In They are easier to recycle are They shapes and sizes many come in can Bottles easier to easier reclose to and open are Bottles cup fitintothe holderseasier bottles in The automobiles product the see can With consumer the plastic bottles, Aseptic market The U.S. markets for aseptic packaging markets U.S. for aseptic The Stork Sidel–Linear (Tetra Pak) Sidel–Rotary Shibuya Serac Procomac KHS OYSTAR Hamba Robert Bosch Bottle Filler Manufacturer FDA Validation Yes Yes Yes Yes Yes Yes No No No No 31 - - Downloaded By: 10.3.98.104 At: 06:37 01 Oct 2021; For: 9781439807200, chapter3, 10.1201/b13026-4 a lighter weight bottle used on the aseptic fillers. Over the years the the blow the Overyears fillers. aseptic the on lighterweight used a bottle hot filling.Initially, this costdifference could beas muchas 20% more than system based on the reduced cost of resin compared to a heat-set bottle for processors could the justify capital-intensive aseptic processing and filling quite segmented between high- and low-acid beverages. Initially, beverage 32 refrigerated life. shelf 110-dayto 90- a expect generally can processors products dairy shelf-life system and fillerare both prior presterilized toprocessing production. the With cases, extended both In process. validation the through go not did likely than more filler the means only It sterile. and clean not is filler the FDA-validated an mean using not does This filler.filled not normally are is temperature approximatelythe filling 40°F or less;second, the products therefore refrigerated, distributed be mustproduct end products,the life shelf- extended with first, differences: two of exception general the with products aseptic as way same the processed shelf-life are Extended cases most products. in products shelf-life extended in beverages is low-acid bottles for plastic growth in market The way. that them prefer and refrigerated products dairy their drinking to accustomed are Canadian consumers and U.S. market. growing a not is this products, dairy stable shelf-life beverages. extended Although are a there number of fillers producingaseptic shelf- and beverages shelf-stable aseptic between divided is beverages high-acid other some and products dairy mostly of cessing sible to hot low-acidfill beverages for shelf stability,therefore aseptic pro high-acid to processors hot now beverages.are filling returning 1cent. than was less filling is fill aseptically It noversus wonder beverage hot to cost the between difference overall the that calculated was it costs operating and costs, utility cost, equipment, bottle filling and processing for cost capital to, limited not but including, aseptic versus fill hot of sis economic comparativehigh-acid beverages. detailed analya fill In hot to the heat-set bottles to the point that it is now economically more attractive molders have improved upon the technology and have reduced the cost of The market for beverages is interesting and very dynamic. It is also also is It dynamic. very and interesting is beveragesfor market The The The market for low-acid beverages is quite different. It is almost impos Handbook of aseptic processing ofaseptic Handbook and packaging - - -