Application and development trend of the hottest n

2022-08-15
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Editor's note: aseptic packaging is a modern high-tech packaging means, which has been really used in production practice for only a few decades. With the rapid development of science and technology and the continuous improvement of related application technology, aseptic packaging is increasingly widely used in food and drug packaging

looking at the development history of aseptic packaging industry in recent decades, we can clearly see that the development of aseptic packaging technology is accompanied by the development of modern high-tech, otherwise it will produce deformation and progress under the action of gravity, and increasingly shows four significant trends

develop in the direction of high-tech integration and high reliability requirements

aseptic packaging technology is a systematic project to achieve comprehensive technical support for the safety of food and drugs. It integrates optical electromechanical integration technology, modern chemistry, physics, microbiology, automatic control, computer communication and other high-tech. In order to meet the safety requirements of products, every subsystem of the system itself contains the achievements of new technologies, new materials and new processes. In order to meet the requirements of high reliability, every subsystem should integrate the concept of modern quality from design to manufacturing, from operation experiment to operation monitoring, as well as information feedback and compensation correction, so as to achieve the unity of equipment inherent reliability and operation reliability. High reliability means the high safety of the final product, and the realization of high reliability must be supported by high-tech in many related disciplines. Although there are differences between the technical indicators of various sterile packaging equipment and the environmental characteristics of the final product, the ultimate goal must be to achieve safety assurance

develop and extend to the application fields of multiple industries

as we all know, the concept and requirements of sterility are the product of medical development. With the development of modern microbiology and applied sterilization technology, human beings have a new understanding and control means to kill all pathogenic and non pathogenic microorganisms, including bacterial spores. As a technical index to evaluate food safety, commercial sterility is recognized by relevant industries and markets. The entry of aseptic packaging technology into the food industry first took dairy products as the starting point, and K Company as the representative took the lead in solving the aseptic packaging technology of milk, a highly nutritious and time-lapse food, breaking the time and space constraints of milk production and sales, which is undoubtedly a revolutionary breakthrough. In recent decades, with the continuous emergence of new packaging materials and new sterilization processes, as well as the promotion of the market consumption of biotechnology products, sterile packaging has expanded from drugs to dairy products to the field of heat sensitive food in the beer, fruit juice and soft drink industries. The most representative is the sterile packaging of beer, fruit juice and tea drinks. Advanced aseptic packaging equipment from developed countries in Europe and the United States has gradually entered the domestic market, and domestic manufacturers have spared no expense to introduce equipment in order to build and lead updated market consumption concepts and sales hotspots, which also illustrates this point

aseptic packaging equipment is developing towards a single high-speed direction

aseptic packaging equipment is a high-end product in packaging machinery in terms of technical content and technical index requirements, and its application fields cover all industries of drugs and food. For manufacturers, this technology and capital intensive equipment positioning must be in the direction of improving production efficiency, which is different from the development of modern packaging machinery towards multi-function and single high-speed polarization. From the technical level, the development of high reliability equipment to multi-functional type will mean that many problems to be solved in engineering technology will appear, which will increase the technical difficulty. Although equipment manufacturers have the demand for product diversification in order to build their own product differentiation advantages, to achieve the unity of inherent reliability and operational reliability of equipment, so as to ensure the return on investment, a single high-speed type should be the best choice

develop in the direction of optimizing cost performance through technological innovation

the high-tech content of sterile packaging equipment itself and the special functions that can create unique product business opportunities determine its high investment characteristics. The introduction of a foreign production line, at least tens of millions of yuan, plus considerable operating costs, has deterred many enterprises. Obviously, in order to promote the healthy development of the sterile packaging industry and provide the market with equipment with moderate price and excellent cost performance to promote the consumer market, domestic equipment enterprises need to optimize the cost performance to reduce investment. Then the only way to achieve this goal is to take the road of technological innovation. Technological innovation should adopt the technical strategy of integration and breakthrough. The so-called integration refers to the integration of relevant technological achievements that have been developed at home and abroad, so as to reduce the research and development cost and simplify the human-machine interface. Breakthrough is the key research and breakthrough on key processes and devices. At present, domestic manufacturers committed to the development of aseptic packaging have made considerable progress in the research and development of aseptic filling equipment in dairy, beer and fruit juice industries, and it is not far away to provide aseptic packaging equipment with excellent cost performance for the market

aseptic packaging technology is a multidisciplinary system engineering. Each sterile packaging equipment has indispensable machinery, control, microbial fence and quality monitoring and assurance system. Each system is both relatively independent and interrelated, and operates cooperatively under the monitoring of the master computer. With the acceleration of the transformation of scientific and technological achievements into the field of applied technology, technological innovation in the field of modern engineering technology is characterized by the optimization and integration of technical elements by engineering and technical experts. Sterile packaging, as the cutting-edge and high-end technology of the industry, naturally opens up a new world for the application of new technologies. A sterile packaging equipment with excellent performance can embody the essence of modern science and technology, modern manufacturing and control technology, and it is also a comprehensive embodiment of the overall technical level of an enterprise and even a country

in terms of machinery and control system, the application of optical electromechanical integration technology has greatly improved the inherent reliability and operational reliability of the whole machine. From transmission to terminal execution parts, from material delivery to precise measurement and filling, from control to signal measurement and control feedback and compensation, the high-quality professional production of various parts and devices has laid a solid foundation for foreign material suppliers because the special certification of materials is relatively complete, which is closely related to the role of leading enterprises in driving the ideal technical state of the whole machine. Many new technologies such as CAD and CAM technology, servo control technology, sensor and computer fieldbus technology have been widely used

engineers engaged in the technical development of sterile packaging equipment know that the evaluation of the operation reliability of the whole equipment and the safety guarantee of the final product largely depends on the advantages and disadvantages of the microbial fence system in sterile packaging equipment. At present, even the most advanced equipment also has indicators of finished product contamination rate. Although the storage environment characteristics of each product are different, it is undoubtedly the most challenging topic to effectively control the contamination rate within the minimum limit

microbial fence system refers to a comprehensive system that enters the equipment from packaging materials and materials that meet the commercial sterility requirements and completes the sterile packaging process and outputs it out of the machine, and includes the sterility assurance of CIP and sip system functions. It adopts two technical means of barrier and sterilization to foreign microorganisms

the barrier adopts the physical filtration method. At present, most of them adopt the passing diameter of 0.3 μ M, but this kind of filter has low efficiency and pressure resistance, high failure probability of pollution and damage, and short service life. Recently developed and applied PVDF folding air sterilization filter, metal sintering filter and polymer membrane filter, the filtration accuracy can reach 0.01 μ m. Moreover, it has large flow, good temperature resistance and pressure resistance, convenient installation, and can be steam sterilized, so as to ensure that the barrier system is always in the best working state, and can provide safe and reliable microbial barrier technical support for the system

microbial sterilization device is mainly the sterility guarantee of packaging containers, materials and internal related systems of equipment, which can be divided into chemical sterilization and physical sterilization according to technical means

chemical sterilization used in aseptic packaging mostly uses strong oxidants, including H2O2, peracetic acid, ethylene oxide, halogen, etc., which mainly rely on the oxidation ability of strong oxidants to combine with -sh- mercapto group in cellular enzyme protein and convert it into -ss- group, which destroys the molecular structure of protein. Three problems were found in the calibration process: interfering with the metabolism of bacterial enzyme system and making it inactive. According to the viewpoint of molecular biology, it is to oxidative damage the DNA of cells, thereby inhibiting cell proliferation. The use of chemical sterilization will produce a certain amount of residual pollution to containers, packaging materials and equipment. Strict measures must be taken to control residues to ensure the safety of the final product

physical sterilization can be divided into steam, electromagnetic wave and irradiation. Steam sterilization belongs to the classic sterilization method, while electromagnetic wave sterilization mostly adopts 2450nm and 915nm microwave sterilization and ultrasonic sterilization. Irradiation sterilization can be divided into ionic irradiation and non-ionic irradiation. The most widely used non-ionic irradiation is ultraviolet light with a wavelength of 253.7nm. Due to the limitation of the intensity of the light source, although there is no residue problem, the above physical sterilization methods have certain limitations

at present, the most promising application is the recently developed excited ultraviolet pulse sterilization technology, which is different from the conventional physical sterilization means. It uses a special light source and power supply device to produce a single wavelength of 253.7nm ultraviolet light under high frequency and high pressure. Its intensity can reach more than 200MW/cubic centimeter, which is times the luminous intensity of the conventional ultraviolet device, and its pulse can reach the nanosecond level, Its energy is enough to break the C-H bond, C-N bond and O-H bond in the cell DNA structure, causing fatal damage to the DNA structure. Practice has proved that it can kill 10 to the 9th power logarithmic bacteria and 10 to the 5th power logarithmic spores on the surface of objects and in the air within hundreds of milliseconds. If it works together with low concentration H2O2, it can not only increase the sterilization intensity, but also decompose the residual H2O2. The application of this new technology will provide more powerful technical support for the microbial barrier system of sterile packaging equipment

in the quality monitoring and assurance system, the adoption of modern sensing technology, computer, remote control and communication technology provides technical support for the operation reliability of the equipment. The application of fieldbus technology can make the operation state signal of each key link of the equipment always under the close monitoring of the master computer, and carry out closed-loop control from the tracking feedback, early warning, compensation and correction of various signals, so as to ensure that the whole machine is in a good operation state, thus ensuring the stability of the final product quality

aseptic packaging equipment has strict technical conditions for use, which is also an indispensable condition for good operation of the equipment. All peripheral equipment must be designed and constructed in strict accordance with GMP specifications, and HACCP procedures must be introduced to ensure the realization of the overall goal

at present, most of the sterile packaging equipment used in China are products from developed countries in Europe and the United States. With regard to the technology intensity and high price of its equipment and the high growth of the future market, domestic packaging machinery manufacturers with certain strength have stepped in one after another. This year, the China Standardization Committee and the aseptic packaging Committee of China Packaging Association, together with relevant domestic and foreign manufacturers, prepared the "liquid food packaging equipment"

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