Handbook of Aseptic Processing and Packaging, Second Edition

Handbook of Aseptic Processing and Packaging, Second Edition

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Features

  • Explains basic approaches to critical operations in aseptic processing
  • Describes new packaging material and sterilants approved and in use during the past few years
  • Presents techniques for accurate flow control
  • Examines commercial fillers, including both consumer and foodservice sizes

Summary

Since publication of the first edition of this book, Aseptic Processing and Packaging of Food, significant changes have taken place in several aseptic processing and packaging areas. These include changes in aseptic filling of nutritional beverages in plastic bottles; the popularity of value-added commodity products such as juice, concentrate, and puree; pouches and bag-in-box bulk packaging; and other novel package concepts possessing a range of consumer convenience and ergonomic features.

The newly titled Handbook of Aseptic Processing and Packaging, Second Edition explores the application of existing and new food processing methods and sensor technologies. It is an essential guide for those developing day-to-day procedures for a number of different aseptic processing and packaging applications.

New Topics in the Second Edition:

  • Current information on aseptic packaging materials and sterilants
  • Aseptic bulk packaging, with a historical perspective and an update on the current state of bulk packaging in container sizes ranging from several gallons to several millions of gallons
  • Aseptic processing operations, including the processing products as well as the operation of aseptic packaging systems
  • Failure mode effect analysis and spoilage troubleshooting, with examples of different failure modes and their effects on food safety
  • Aseptic processing of particulate foods, including the use of microwave for heating and technology available to monitor and develop processes for this category of foods
  • Contract manufacturers and their role in introducing innovative products to market

The contributors to this volume have more than 150 years of combined food industry experience, encompassing production, quality assurance, research and development, and sales in aseptic processing and packaging. Their insight provides a comprehensive update on this rapidly developing technology for the food processing industry.

Table of Contents

Aseptic Processing and Packaging: Past, Present, and Future
Framework and Current State
Departures from Optima and Challenges
Current and Future Opportunities for Optimization
United States History and Evolution
Early Pioneers
The Graves Era
Jack Stambaugh
The First Commercial Aseptic Plant
The Real Fresh Company
The First Aseptic Form–Fill–Seal Packages
Early Aseptic Packers
Restrictions for Growth
Trends for the Future
The US Markets for Aseptic Packaging
Development
Aseptic Metal Can Market
Aseptic Bag-In-Box
Aseptic Paperboard Market
Aseptic Plastic Cup Market
Aseptic Pouch Market
Aseptic Plastic Bottle Market
Aseptic Processing Equipment and Systems
Aseptic Processing Equipment
Plant Layout Considerations
Utilities
Filters
Chemicals Used As Sterilizing Agents (Equipment)
Aseptic Filling and Packaging Equipment
Development of Aseptic Packaging
Dole Aseptic Canning System
Aseptic Bag-In-Box
Aseptic Paperboard Fillers
Aseptic Plastic Cups
Coffee Creamers
Aseptic Pouches
Aseptic Plastic Bottle Fillers
Stork
Aseptic Packaging Materials and Sterilants
Product Requirements
Materials
Sterilizing Agents
Packaging Systems
Environmental Considerations
Aseptic Bulk Packaging
Aseptic Bag-In-Box
Aseptic Bulk Container
Aseptic Bulk Storage
Aseptic Ocean Liner Transportation and Storage
Regulations for Aseptic Processing and Packaging of Food
US Food and Drug Administration Requirements and Approval
Code of Federal Regulations (CFR)
Low-Acid Food Regulations and Definitions
US Food and Drug Administration: Specific Concerns
Other Requirements
Validation and Establishment of Aseptic Processing and Packaging Operations
Some Considerations
Decision Process
Equipment Selection
Process Schematic and Process and Instrument Diagrams (P&ID)
Preinstallation Review
Postinstallation Review
Equipment Testing and Validation
Thermal Process Design for Products Containing Particles (Principles Applicable to Homogenous Fluid Foods)
Factors Other Than Temperature Contributing to Nonsterility
Aseptic Processing Operations
Presterilization of the Processing System
Loss of Sterility
Water-To-Product Separation
Product-To-Water Separation
Cleaning
Control
Thermal Processing and Optimization
Thermal Processing and Optimization
Comparison of Conventional Canning and Aseptic Processing and Packaging of Foods
Comparison of Processing Methods
Optimization Hierarchy
Definitions
Nomenclature
Quality Assurance and Food Safety for Aseptically Processed and Packaged Food
Quality Assurance for Aseptically Processed and Packaged Food
Preprocess Assurance
In-process Assurance
Post-process Assurance
Hazard Analysis Critical Control Points (HACCP) Program
Others
Failure Mode and Effect Analysis, and Spoilage Troubleshooting
Failure Mode and Effect Analysis
Failure Mode and Effect Analysis, and Troubleshooting
Failure Mode, Analysis of their Effects, and Controls
Cause and Effect Relationships
Nomenclature
Aseptic Processing of Particulate Foods
Considerations for Equipment Design
Validation of Aseptic Processes with Particulates
Concluding Remarks
Industry Research and Development, and Management Needs and Challenges
Research and Development Needs and Challenges
Management and Administrative Challenges
Raw Product
Processing
Aseptic Filling and Packaging
Finished Product and Package
Future
Appendix A
Aseptic Fillers
Appendix B
Contract Manufacturers in USA

Author Bio(s)

Jairus David, Ph.D., is Senior Principal Research Scientist at ConAgra Foods headquartered in Omaha, Nebraska. David’s responsibilities include science leadership and development of intervention technologies for food protection and process & quality optimization. David is a Fellow of the Institute of Food Technologists (IFT), and is the recipient of IFT’s prestigious Industrial Scientist Award for developing and influencing the public health food safety policy on the use of honey in cereals and bakery products for the prevention of infant botulism in infants under 12 months of age. David earned his Ph.D. in Microbiology with Thermal Processing emphasis from the University of California at Davis.

Ralph H. Graves held the position of Senior Vice President for Real Fresh, Inc., as a company involved in the processing and sale of aseptically packaged foods. His responsibilities included the research and development of processing techniques, quality control, engineering, and maintenance and warehousing of aseptically packaged dairy products. Although now officially retired, Graves continues his work in this field as a consultant.

Thomas E. Szemplenski is the owner of Aseptic Resources, Inc., a consulting company dedicated to assisting food processors and equipment manufacturers with aseptic processing techniques. He has more than four decades of food processing and packaging experience—the vast majority of time dedicated to aseptic processing and packaging techniques, commercial application, and marketplace dynamics.

Editorial Reviews

"The contributors to this volume have more than 150 years of combined food industry experience, encompassing production, quality assurance, research and development, and sales in aseptic processing and packaging. Their insight provides a comprehensive update on this rapidly developing technology for the food processing industry."
Beverage and Food World, January 2013

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