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Aseptic filling of baby food

Source:Ringier Release Date:2011-07-13 866
Food & Beverage
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Energy-saving aseptic forming, filling and sealing machine fills baby food into thermoformed cups

CONSTANT improvements in safety and sterilisation are essential to baby food manufacturers and processors. More than any other, this sector of the food industry depends on absolute trust between its brands and consumers.

A gentle and energy-saving aseptic filling method designed by Bosch allows pre-sterilisation before the filling of the baby food product. This process keeps vitamins and sensitive nutritional components of the packaged food intact. The hygiene level of the packaging machine also makes it possible to realise a product shelf life of up to 12 months at ambient temperatures.

Excellent production security is maintained by this highly reliable system with liquid H2O2 baths, which provide perfect sterilisation of the packaging material, whilst catalytic converters are used in the machine's exhaust to neutralise the vapours emitted by the processing. Filtered nitrogen is used in the efficient gas flushing systems for the headspace of the cups and this keeps oxygen levels down to only 2 % in the cup headspace, whilst increasing product protection.

Baby food expansion

Humana Milchindustrie is a leading company in the German dairy sector and, for 60 years, has been developing and producing high-quality baby food. The company places special value on gentle processing methods and the highest quality standards. In 1950, Humana first introduced infant formula to the German market, which was highly similar to breast milk. The product portfolio has developed continuously since then.

Today, the company has 12 manufacturing plants, which process a total of two billion kilograms of milk per year to produce a diverse range of dairy products. At its Erfurt plant, the company produces baby food, fresh milk, long-life milk and fromage frais, as well as various desserts.

In 2010, Bosch supplied a TFM 8030 PS aseptic thermoforming unit to Humana Milchindustrie. This aseptic forming, filling and sealing machine fills baby food into thermoformed cups. The machine allows product-friendly, energy-saving filling operations as part of an automated process. As a result of its high hygiene level, and in conjunction with the upstream process technology, the TFM 8030 PS can deliver product shelf lives of up to 12 months without refrigeration. Products filled with the unit include fruit yoghurts and dairy-based desserts, as well as special baby-food recipes.

High output and product safety

The TFM achieves output levels of 57,000 cups per hour, which amounts to a maximum daily production volume of 100 tons. The plastic cups are formed from reel material, which is much more cost-efficient in the production of baby food compared to prefabricated cups. A barrier of EVOH material is integrated within the film and protects the filled product against oxidation and water vapour diffusion, even over long storage periods and without refrigeration. The multi-layer protective film also prevents mechanical damage to the product. Integrated gas flushing of the cup's headspace reduces the residual oxygen content, further increasing product safety.

Maximum filling accuracy. An integrated piston filler ensures highly accurate filling. For viscous products, such as desserts, the filling accuracy for a 4x100 gram pack is approximately ±1 gram. Such high accuracy generates cost savings for the user. With four supply tanks and a direct product feed into the filling nozzles, the piston filler also offers very high flexibility for filling many different products.

Recipe management is key. The TFM system allows for the comfortable management of all Humana's product recipes, which number around 100. This includes an automatic transfer of alterations in technical parameters in case of recipe changes. The control unit completes the automated system.adidas

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