[Food Safety] Vol. 18 No. 4 April 2009 ww Aseptic Packaging Addresses Shelf Life Issues By Laurens van de Vijver, Contributing Editor Despite the downturn in the economy in 2008, the market for natural foods continued to grow in the United States. According to Nielsen’s most recent “Healthy Eating Report,” released in January 2009 year, Americans put their money where their mouth was by continuing to turn to healthier food options. In 2008 alone, sales of “natural” foods generated $22.3 billion in revenue, up 10% from 2007. Additionally, the functional beverage market grew by 15% from 2003 to 2007, fueled by greater consumer demand for healthier and more convenient options. Growing demand for these types of foods represents a great deal of opportunity for those in our industry, and may prove to be a bright spot in the economic downturn. However, preserving the freshness and nutrition of these foods is one challenge we will continue to face in any economy, particularly as it relates to shelf life issues. Food science and technology has been addressing this issue for years from the inside out through product formulations, additives and preservatives. However, advancements in the packaging industry over the last half century have brought us solutions like aseptic packaging and processing that can effectively and safely extend the shelf life of food products while preserving nutrition, food quality, sensitive ingredients and taste. Food has essentially two enemies when it comes to its preservation—time and bacteria. Over time, food that was once good deteriorates, losing its taste, flavor, color, texture and nutritional value. Bacteria or microorganisms can also contaminate good food, causing it to go bad or spoil. Over the years, food preservation techniques have included a number of ways to neutralize or eliminate bacteria in food. Aseptic processing and packaging represents one of the most effective solutions for overcoming these and other shelf life challenges. What is aseptic? Aseptic processing and packaging is different from other traditional food packaging techniques in that it is based on the principle that both the food and the packaging be free of any harmful microorganisms precisely when the food is packaged. In order to achieve this aseptic status, everything in the production chain must be commercially sterile, including the food, the package, the machinery and the environment where packaging takes place. The aseptic process, simply put, comprises of three stages. In the first step, formulated product will go through an Ultra High Temperature (UHT) treatment, using optimized heat exchangers. The temperature and holding time used during this process will vary depending on the specific food being processed. However, it’s worth noting that the UHT process allows for much shorter heating and cooling times—a matter of seconds—vs. other food sterilization methods. This minimizes heat penetration problems that can lead to degradation of the flavor, sensitive ingredients and nutritional value of food. In the second stage, unformed packaging material is fed into a machine where it is sterilized in a hydrogen peroxide bath. The 30% hydrogen peroxide concentration is then eliminated from the packaging material using hot air or pressure rollers before it’s formed into a tube in preparation for filling. In the final step, the sterilized and rolled tube is filled with product, sealed and shaped into a package as product flows through it. This process ensures there is no air space in the product. www.foodproductdesign.com Page 1 [Food Safety] Vol. 18 No. 4 April 2009 The combination of aseptic processing and packaging reduces energy use and nutrient loss associated with other conventional methods that may require product to be heated in their packages for upwards of 50 minutes. As a result, aseptically packaged products tend to retain more nutritional value and exhibit more natural texture, color and flavor. The materials that make up an aseptic carton package typically include laminated paper, plastic and aluminum foil. Most commonly, finished packages will contain six layers of protection. Paper is used for strength and labeling. One thin plastic coating is used to protect the paper and print design on the outside of the carton, as well as one thin layer on each side of the aluminum foil to optimize adhesion. The foil itself is used for its impermeability to light and air. And finally, one thin layer of plastic is used to separate the product inside from the other layers of the package and give it added protection. This is an approach that is truly unique to aseptic packaging. While foods will deteriorate at different rates of time depending on factors like storage conditions and climate, once the product has gone through the aseptic process, its shelf life can range anywhere from six months to one year or more. At this stage, the food is completely dependent upon the package to continue to protect its taste and freshness and deliver it in a convenient manner. Benefits of aseptic processing and packaging In addition to extending the life of natural foods and beverages, aseptic packaging brings a whole host of benefits to the table. One of the key advantages of using aseptic processing and packaging is improved food quality. Thanks to a gentler heat treatment, degradation of flavor, sensitive ingredients and nutritional value is minimized compared to other traditional methods. In products like dairy that rely on refrigerated transportation and storage to remain fresh and safe for consumption, aseptic processing and packaging make it possible to break the cold chain and enable these products to become shelf stable. In the mid 1950s, it was Tetra Pak and Ursina who developed this technique of sterilizing and packaging of milk through joint R&D efforts. Together they launched the world’s first carton aseptic filling machine in 1961, which was the predecessor to today’s aseptic carton packaging. Aseptic packaging can be particularly beneficial to producers who are looking to meet growing consumer demand for natural and functional foods. By utilizing aseptic packaging and processing techniques, producers can be sure that preservative-free products or sensitive ingredients remain shelf stable without the need for refrigeration. Certain aseptic packages, like aseptic cartons, can provide some significant environmental benefits as well. Aseptic cartons are mainly made from paper, which is a renewable resource. Generally speaking, aseptic cartons have a lower package to product ratio, ensuring lighter weight, lower transportation costs and fewer carbon emissions being sent into the atmosphere. What’s next? Aseptic packaging technology has continued to evolve since becoming widely available in the early 1970s. Its impact on the industry and consumers has been far ranging. In 1991, the Institute of Food Technologists rated the top 10 innovations in food technology; aseptic processing and packaging ranked No. 1 ahead of juice concentrates, safe canning processes, freeze-drying and food fortification. www.foodproductdesign.com Page 2 [Food Safety] Vol. 18 No. 4 April 2009 It’s a form of packaging that has gained broad acceptance around the globe for its ability to keep foods fresh and nutritious without refrigeration. On the other end of the spectrum, aseptic paper cartons have been utilized in some underdeveloped nations to economically and efficiently deliver nutritious foods like milk to millions of people in need. Over the last decade, American consumers have warmed to the concept of aseptic packaging, which was traditionally more popular in places like Europe, Asia and South America. Today, manufacturers are investing in aseptic processing and packaging for a range of products. Producers of soups and broths, juices, wine, and soy and dairy products, as well as functional and natural foods, are now embracing aseptic for their product brands. In the future, aseptic packaging will continue to evolve to meet the needs of the marketplace. Natural and functional food producers in the United States may rely more on aseptic packaging and processing to protect delicate foods and juices as demand for their products continue to grow. Innovations in packaging sizes, shapes, closures and materials will almost certainly be developed to cater to specific market needs. Aseptic packaging’s first job was to give milk a greater shelf life and preserve its taste. In the future, it’s likely food and beverage producers from a variety of segments will look to aseptic packaging to once again protect what’s good—what’s inside the package. Laurens van de Vijver is vice president, marketing and product management, Tetra Pak U.S. & Canada. His career with Tetra Pak has lead to successfully positioning Tetra Pak’s carton packages as the environmental and convenient package alternative for healthy liquid food in the Dutch and Belgian markets. Prior to joining Tetra Pak, van de Vijve held various marketing and sales positions with Heineken and Mars. He holds a degree in business economics from Erasmus University in Rotterdam, the Netherlands. For more information about Tetra Pak and aseptic processing visit tetrapak.com or tetrapak.com/us/Pages/default.aspx. www.foodproductdesign.com Page 3 .