Aseptic Technology

Aseptic Filling Decontamination System:
The Best in Class Aseptic Technology

Key Benefits

Food Safety & Compliance
USA FDA compliance for sensitive beverage filling: Chemical residual less than 0.5ppm
Zero spoilage in over 20 billion filled bottles to date
No thermal degradation of beverage
Robust traceability system: Individual filler and capper head number coding onto each bottle
Profit Contribution
Provide the lowest total cost of ownership (TCO)
Proven quick return on investment (ROI)
Sustainability
Reduction of CO2 emissions
Less water consumption (EB technology and/or hot air rinse instead of water rinse)
System Efficiency
Over 200 hours of continuous aseptic production without CIP & SIP
Quick production changeover: Full package and beverage changeover within 2.5 hours including full CIP/SIP
High productivity and system efficiency (≥95%)
Supply Chain Benefits
Enable longer best before dates (longer product shelf life)
No preservatives required
Enable transport and storage at ambient temperature

General Process (Aseptic Fill vs. Hot Fill)

Aseptic Fill

Aseptic filling provides robust product quality, minimal thermal impact on the beverage, and greater bottle design flexibility with maximum PET bottle light weighting. At the same time, aseptic filling needs to balance control between bottle sterilization efficacy and chemical residual.

Hot Fill

Hot fill requires a higher energy requirement, a thermal impact on the beverage and less flexibility of PET bottle design than aseptic filling. This process, however, has lower initial investment, longer production days per year and no SIP requirement.

Aseptic Systems Provide Lower Total Cost of Ownership (TCO)

While initial investment of an aseptic system is higher than a hot fill system, aseptic systems provide lower daily operational costs (e.g. less steam usage) and allow for the use of lighter weight PET bottles. As a result, Total Cost of Ownership of an aseptic system is lower than a hot fill system.

PAA Bottle Decontamination

PAA Bottle Decontamination:
Shibuya's PAA bottle decontamination technology is good for high acid beverages. Shibuya recommends H2O2 bottle decontamination technology for sensitive beverages.

Key features;

1)
Robust positive air pressure control inside the aseptic chamber;
2)
PAA bottle decontamination has less bottle shrinkage due to lower sterilization temperature;
3)
PAA wet decontamination system has a strong washing action to remove localized microorganisms.
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H2O2 Bottle Decontamination

H2O2 Bottle Decontamination:
Shibuya H2O2 bottle decontamination technology is proven effective for all sensitive (low acid) beverage manufacturers in the world! Our technology meets the USA FDA's most stringent food safety requirements.

Key features;

1)
Robust positive air pressure control inside the aseptic chamber;
2)
Robust and dynamic sealing of rotating and stationary parts (Filler/Capper) and PAA liquid lock;
3)
Outlet bottle conveyor loop into PAA pool to prevent any contamination from non-sterile zones.
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Bottles are rotated 180˚ during irradiation

Electron Beam (EB) Bottle Decontamination

EB Bottle Decontamination:
Shibuya has developed and commercialized EB bottle decontamination system is the first in the world.

Key benefits;

1)
Effective for all targeted microorganisms;
2)
Fewer critical control points (CCP) for easy operation and validation;
3)
Provides the lowest total cost of ownership (TCO).
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Comparison of Key Benefits for Each Decontamination System

Select from the different decontamination methods for your targeted bacteria

Shibuya provides a variety of bottle decontamination systems for you. Based on your beverage characteristics, please select the right decontamination technology against the targeted biological indicators. For example, hot fill is not good for Bacillus type microorganisms, but Electron Beam decontamination is good for all of the biological indicators.

Biological Indicator EB H2O2 PAA Hot Water
Bacillus A Effective Effective Effective Not Effective
Bacillus B Effective Not Applicable Not Applicable Not Applicable
Bacillus C Effective Effective Not Effective Not Effective
Bacillus D Effective Effective Not Effective Not Effective
Yeast Effective Effective together with hot water rinse Effective together with hot water rinse Effective
Mold Effective Effective Effective together with hot water rinse Effective
  • EffectiveEffective
  • Effective together with hot water rinseEffective together with hot water rinse
  • Not EffectiveNot Effective
  • Not ApplicableNot Applicable