ABSTRACT
Aseptic processing and packaging is an attractive and a challenging alternative compared to conventional methods of canning of foods. Continuous sterilization of heat-sensitive foods at ultrahigh temperatures followed by prompt cooling results in a superior finished product, which can be filled into containers of varying compositions, of different shapes, and with many consumer-attractive features.
Even though the aseptic technology is considered the benchmark in optimization for manufacture of sterile, shelf-stable foods and beverages, there are several departures from optima or gaps that should be closed in order to leverage the full benefits of quality, nutrition, safety, and convenience. Some of the gaps include potential compromises to sterile work zone, and package seal integrity leading to microbial recontamination, over delivery of designed thermal process, inadequate or slow cooling, and special handling of sensitive ingredients known to contain and protect thermoduric and thermophilic spores during heating.
Sustainable packaging and longer shelf life are of great importance for the food and beverage industry, along with cost of environmental benefits in terms of ambient shipping and storage. The cost of refrigeration is higher and is a key driver for companies to invest in aseptically processed and packaged products that are ambient shelf stable for 12–24 months. This advantage must be fully leveraged to realize savings on energy and carbon footprint.
The future of aseptic processing and packaging of foods and beverages will be driven by customer-facing convenience and taste, use of current and new premium clean label natural ingredients, use of multifactorial preservation or hurdle technology for maximizing quality, and sustainable packaging with claims and messaging.
