Revolutionary aseptic packaging method by Performance Packaging

A new and cost-saving method to sterilize flexible packaging and its contents has been developed by Performance Packaging of Nevada. Code named "Pixie Dust" by the company, the patented process features a unique ‘liquid-to-gas’ sterilization process. The low-cost process that makes use of GRAS (‘Generally Recognized as Safe”) materials allows for sterilization to occur during storage or shipping and achieved in less than 48 hours at room temperature. The results of process residuals are below the U.S. Food & Drug Administration (FDA) “Threshold of Regulation”. Moreover, the use of the Pixie Dust procedure is smell- and taste-neutral

Some products, such as dental tools, medical devices, or enclosed plastic, glass, or metal objects, can be sterilized within the package, and the method makes aseptic cold-fill processes possible.  There is no need to irradiate the package nor does the package need to be hot-filled nor require the post-pasteurization of pouches, since the pouch is already sterile.

Industry applications for Pixie Dust can include flexible packaging such as stand-up pouches, bag-in-box, any sealed package, military applications, dental tools and medical devices. Performance Packaging is working with various companies to identify additional markets and partners for the new aseptic process it has developed.

During the extensive testing process conducted by Performance Packaging for Pixie Dust, the test organism Bacillus atrophaeus ATCC 9372 spores (which are highly resistant to heat and chemicals such as H2O2) were added to the package contents. A specific quantity of the Pixie Dust agent was then inserted into the package.  After about two days, no viable spores were recovered from any of the treated samples, which included inoculations of 4-liter, hot-fill bag-in-box, 55-gallon-drum bags and 2 gallon polyolefin milk bags. Even corners and gusset fold tests, along with laboratory-scale filling tests of treated pouches revealed no sign of bacterial growth.

In addition, Pixie Dust’s new developments and improvements are underway that predict rapid, in-line sterilization prior to filling.

Performance Packaging is currently seeking worldwide partners in the pharmaceutical and food industries to implement this technology that crosses many platforms including device sterilization as well as the foodstuff shelf life extension, according to Rob Reinders, president of Performance Packaging.  This development is the direct result of the invaluable contributions of Joseph Dunn, Ph.D., who joined the company earlier this year as vice president of research and development and regulatory affairs. Dr. Dunn has more than 30 years of experience in industrial biochemistry and microbiology relating to packaging research. He is also the inventor of the use of pulsed light for packaging sterilization and the author of more than 25 patents related to packaging industry safety processes. Throughout his career, he has worked closely with the U.S. Food and Drug Administration.

Pixie Dust has dramatically reduced the cost of the sterilization process to an amount of, for example, about one cent (1 ) of agent will treat approximately 750,000 pouches. "In contrast, large volumes of peroxide (such as 250 gallons of very expensive, high-concentration H2O2 and hot, sterile air are required to sterilize a similar number of form-fill-seal packages," explained Dr. Dunn. Pixie Dust is a cost-saving alternative to traditional shelf-stable methods such as hot-filling, retort processing, peroxide or peracetic baths or sprays, irradiation, pulsed light or electron-beam irradiation.

Founded in 1995, Performance Packaging is a leading supplier of flexible and folding carton packaging, including coffee bags, roll stock, spouted and zippered pouches, and pre-made retortable pouches.  Performance Packaging’s innovations can be found on products from such diverse companies as Russell Stover Candies Inc., RW Garcia, Tom Clark Confections Inc. and Baby Gourmet Foods Inc.  The flexible packaging provides products ranging from Pharmaceutical Grade packaging to surface-printed Low Density Polyethylene (LDPE). Folding cartons range from CCNB materials to Litho Laminate B-flute cartons.  Shrink materials include PET, OPS, PVC OPP and shrink LDPE.