The process generally involves three main stages:
- Product Sterilization: The product (liquid, sauce, etc.) is sterilized, often using ultra-high temperature (UHT) methods or filtration, and then cooled and held in a sterile tank.
- Container Sterilization: Bottles and caps are sterilized using various methods like peracetic acid (PAA) sprays, hydrogen peroxide vapor, or irradiation, and then rinsed with sterile water if chemicals are used.
- Aseptic Filling and Sealing: The sterile product is transferred into the sterile containers in an enclosed, sterile environment (aseptic isolator with HEPA-filtered air) and immediately sealed with a sterile cap.
Aseptic fillers are widely used for a broad range of products, including:
- Dairy products like UHT milk and dairy-based drinks.
- Beverages such as fruit juices, teas, coffees, and sports/energy drinks.
- Liquid food items like sauces, soups, and baby food.
The system provides automated CIP and SIP sequences using standard cleaning agents, hot water, or steam. This ensures thorough internal sanitation with minimal manual handling, enabling fast turnaround between test runs.
- Lower Cost: No need for large infrastructure or utilities.
- Flexible Operation: Quick changeovers for different formulations and bottle sizes.
- Compact Design: Easy to install in any laboratory environment.
- Accurate for Small Batches: Ideal for high-value or limited R&D samples
The system sterilizes bottles, caps, and product-contact surfaces before filling. All operations occur inside a protected chamber with HEPA-filtered air and validated sterilization steps, ensuring that ambient air does not compromise sterility.
The lab-scale aseptic filler is designed for R&D, pilot production, and small-batch sterile filling. It is used to create aseptic samples of UHT milk, juices, sauces, and biopharmaceutical liquids for formulation testing, shelf-life evaluation, and quality validation.
