Frontline Food Consultants and Engineers have unique solutions for customers with regard to aseptic pulp and paste production. Starting with selecting the best quality fruit and vegetables to choose the ideal ways of extracting nutrients. We help you provide pulp and paste that contains all the taste, texture, color, and nutrients, present in the raw material. 

The Aseptic Processing and Packaging Solutions guarantee that our food is free from microbial contamination, and sustainable for long-term storage with no need for any sort of refrigeration system. We adopt essential operations, such as pulp elimination, pasteurization, and aseptic bottling to achieve optimality and durability.

We also help with Ingredient Sourcing and Supply Chain Optimization to ensure you have the right raw material for preparing your pulp and paste. Our R & D Department guarantees the production of tailored pulp and paste for the regional markets including the organic sugar-free and other special type markets. Through our Regulatory Compliance and Safety Consulting, it is possible for your aseptic pulp and paste to meet international standards with regard to meal safety as well as labeling. Our Packaging Solutions are intended to preserve a product’s quality while it is en route and after that, and in the absence of additives and low temperatures.

What is Aseptic Sterilization of Pulp and Paste?

Aseptic Pulp and Paste is any product that contains a fruit or vegetable pulp combined with any continuous phase other than water.

Aseptic pulp and paste are the primary processed fruits or vegetables that have been usually sterilized and over-packed for a long shelf-life and without being refrigerated for a long time or not requiring preservatives at all. It starts with the use of proper fresh and mature produce which are washed, dewormed, and prepared for milling. When the fruits or vegetables are prepared appropriately they are then crushed by machinery to extract the pulp or mashed to form a paste. This pulp or paste is heated to make it more sterile so that any dangerous bacteria or microorganisms that can form to the product will not be there. This kind of sterilization is referred as aseptic sterilization, all the parameters of heating is carefully controlled to maintain natural flavor, colour, and nutrients of the product. When the pulp or paste has been sterilized, it is cooled, and then filled into aseptic containers, which are sterile, leak-proof containers that do not allow for contamination. 

Aseptic pulp and paste production needs specific equipment, including; washers and peelers for the fruits and vegetables used as the raw materials. Used in extracting pulp from seeds, skins, and other wastes, pulp extraction machines are also used in washing and pasteurizers to ensure that the product is safe for aseptic packaging. Aseptic filling techniques are then used to place the pulp or paste into sterile packaging thus ensuring product sterility without the requirement of refrigeration. Packaging line closure measures guarantee right finishing and sealing and labeling devices are employed to guarantee proper sealing and labeling of the products, in addition, to enhance quality assurance and sustainability, strict control measures are put in place to oversee the whole process.

Types of  Aseptic Sterilization

  • Thermal Sterilization: Applying high temperatures to its branches thus sterilizing the product.
  • Non-Thermal Sterilization: It includes techniques such as high pressure processing and , ultraviolet light processing which are not characterized by heat treatments.

Technological Processes of Aseptic Sterilization of Pulp and Paste

Preparation of the ingredients depends on the choice of the ingredients used in the meals.

  • Choosing Produce: Choosing the right quality and fresh fruits and vegetables.
  • Cleaning and Peeling: Washing and peeling to reduce presence of disease causing germs on the fruits/vegetables.
  • Cutting and Pulping: Slicing the produce into equal fit sizes and then pulping the lots.
  • Pulping: Pulping: After the produced cut is made, the produce is pulped to make sure that it has the right texture, smoothness to make a pulp or paste that will be processed next. 

Blanching (Optional)

  • Definition: A process of briefly cooking the produce by boiling it or steaming it prior to being put through an additional process of preparation.
  • Purpose: Neutralizes enzymes that can potentially impact other qualities of the pulp or paste such as color, taste and nutritional content making the final product of higher quality and longer shelf life.

Evaporation (described as a three-stage flash evaporation process)

  • Process: Employing three-stage evaporators for eliminate the water in pulp or paste and thereby minimizing the volume and improving shelf life.
    • Stage 1: Heating: The preparation of the pulp or paste is made and heated to a certain temperature depending on the specific evaporation plan of the process. This step makes sure that the product gets to the right temperature which allows it to remove most of its water in the subsequent steps.
    • Stage 2: First Evaporation: In this stage the preheated product evaporated water at a specific temperature and pressure. This stage reduces the water content considerably; this is the starting point to the concentration process.
    • Stage 3: Final Concentration: The product is taken to the final evaporation point conforming to the density of the final product. This stage refines the moisture level while at the same time maintaining the product’s taste, color and nutrients intact.
  • Monitoring: Sizing up the stage of evaporation, specialized attention should be paid to the temperature and pressure: high temperature and low pressure are required to retain the delicious taste and outcome of the product while providing the necessary consistency. This way constant monitoring is done so as to ensure that the product is concentrated in the right proportion without even variety being affected.

Aseptic Sterilization

Thermal Sterilization

  • Setup: How the pulp or paste is heated at high temperature for a particular period of time.
  • Monitoring: Getting the temperature right and time right in order to make sure the utensil is completely sterilized.

Non-Thermal Sterilization

  • Setup: Ways such as high-pressure processing or a UV light.
  • Monitoring: Sterilization of instruments without affecting the property of the associated product.

Aseptic Packaging also points to bulk packaging

  • Sterilizing Packaging: Primary, secondary and other packaging ploys are cleaned using heat, chemicals, and/or irradiation.
  • Filling and Sealing: In no small measure, the sterile product is escalated through the sterile packaging in the sterile area.
  • Bulk Packaging: Aseptic bulk packaging means that the product is filled into large sterile packages which makes distribution easy while at the same time it protects the product.

Equipment Used

Preparation Equipment

  • Washers: For washing and scrubbing; especially fruits and vegetables.
  • Peelers: For effective removing skins.
  • Cutters and Pulpers: For cutting and subsequent reduction to small fragments or pulp.

Blanching Equipment

  • Blanchers: For steaming or boiling fruits and vegetables lightly.
  • Sterilization Equipment
  • Thermal Sterilizers: Used for high-temperature applications.
  • Non-Thermal Sterilizers: For the high-pressure treatment of food or UV light treatment of the food items.

Aseptic Packaging Equipment

  • Sterilizers: For sterilizing packaging material.
  • Aseptic Fillers: This is for use in packing sterile items into sterile containers.
  • Sealers: For sealing packages under conditions of sterility.

Quality Control and Testing

  • Microbial Testing: Safety-minded, ensures the product is free from all form of microorganisms.
  • Nutritional Analysis: Ensures that vitamin and mineral nutrients are retained after the sterilization process.
  • Sensory Evaluation: Examines flavor, color and texture of the sterilized product.
  • Packaging Integrity Testing: This helps guarantee that the packaging is correctly sealed and the contents thereof sterile throughout its use.
  • Shelf-Life Testing: Establishes the durability of the product under different storage conditions.