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Aseptic Cartons
Aseptic packaging is a remarkable packaging system that allows products once considered perishable to be distributed and stored without refrigeration for periods up to one year or more - even delicate foods such as milk, soy beverages, juice, and nectars.

The aseptic packaging system is a major advance over traditional filling techniques. It achieves room-temperature shelf stability by filling a sterilized package with a sterile food product within the confines of a hygienic environment. As a result, aseptically packaged products retain more nutritional value and exhibit more natural texture, colour, and taste.

 

Most other package types and systems use preservatives and/or refrigeration to achieve a long shelf life. Gammagroup has know-how on how to handle and package even the most difficult products, such as dairy products, juices or tomato paste.
 
 
Aseptic cartons

 

This high-tech, innovative packaging solution outshines many others on the market by almost any standard. It delivers product with natural colours, vivid flavours, authentic textures and nutrient values nature intact - all while ensuring safety and shelf stability.

 

Products packaged in the cartons include a wide variety of beverages and liquid-based foods, such as juices, white and flavoured milks, soups, sauces, broths, fruit toppings, syrups and chunky tomato products. In addition to the popular drink-box sizes, aseptically packaged products come in cartons that run the gamut from 150 ml to 2 litters. Although some new packaging formats have recently appeared on the market, aseptic cartons typically conform to the well-known block shape, which is favoured because it permits easy stacking for more efficient storage.

 
Basics
 

Aseptic cartons are a lightweight, multi-layer, energy-efficient example of minimal packaging. They combine high-performance materials with high-performance construction and high-performance features. The package is 70% paper (to provide stiffness and strength), 25% low-density polyethylene (to seal the carton liquid-tight), and 5% aluminum (to keep out light and oxygen). Together, these materials produce a carton that safeguards the aseptically processed product inside.

 

 Aseptic packaging sleeves are formed into cartons and sterilized in the filler with a hot hydrogen peroxide vapor. Once the vapor is evaporated with hot, sterile air, the sterilized package is filled with the sterilized product, both are cooled to ambient temperature, and then sealed within a sterile zone. This results in products (even traditionally perishable ones such as milk) that can remain unrefrigerated and shelf stable for months at a time without preservatives. Aseptic cartons mean no refrigerated trucks, no special warehouses and no kitchen freezer storage.

 

 
Aseptic cartons are shipped to processors in preprinted web rolls or individual sleeves.The critical back seam for the carton is made in our manufacturing plant under controlled conditions. Automated, high-speed finishing lines crease and cut the carton blanks and form the back seam, leaving no exposed edges, forming a superior oxygen barrier. The packages are folded and top-sealed above the product line to create and adjust, but never totally eliminate, carton head space. Head space allows for a clean seal; that is, no product is trapped in the seal area. The actual amount of head space varies by package size and product type. Another advantage is that head space allows the fillers to fill cartons with particulates easily, efficiently and at rated speeds.