Package sterilization is an integral technology component of an aseptic or extended shelf life packaging operation. With the growth of aseptic offerings in a broader range of packaging formats, sterilization technology must adapt to the challenges posed by horizontal form-fill-seal lines. Traditional steam or chemical based sterilization technologies introduce complexity and risk to a process, limiting line speeds and causing frequent downtime that lead shorter filling cycles.

• Steam and chemical based sterilization apply substantial heat to packaging materials, requiring heavier package weights.
• The potential for chemical contamination of packaged product represents a substantial risk to brand owners.
• Steam sterilization is energy intensive and difficult to control.
•  Steam and chemical based sterilization processes have many process control points to actively monitor and control, requiring a high level of operator expertise.

Blu Sterilization technology can be applied to horizontal form-fill-seal lines using AEB's innovative electron beam emitters. By removing the need for heat or chemicals, packaging can be lighter and production lines can be more environmentally sustainable. Electron beams are a proven sterilization technology with a long history of highly effective use for sterile packaging applications. Microbial pathogens are destroyed at high speeds as a function of energy delivered to the surface. With a long history of use, picking materials and designing packages compatible with electron beams is straightforward. The simplicity of electron beams creates predictability and reliability, allowing for high speed processing in a more compact process footprint.

Horizontal form-fill-seal packaging material is sterilized before or after forming. The non-sterile packaging material is fed through a short electron beam tunnel where the web is sterilized from one or both sides, depending on the thickness of the material. Positive air pressure forces sterile air from the aseptic environment to flow opposite the direction of web travel, thereby preventing microbial contamination from entering the sterile filling zone. Lid stock is sterilized in a similar manner, with a web of material passing through a short tunnel where it is sterilized from one or both sides. In some cases cups, pots or bowls are sterilized after forming, with the electron beam directing energy from above to the interior surface of the package.

The benefits of Blu translate to greater sustainability and greater profitability.

Specifically, manufacturers can take advantage of:

• Ambient temperature processing allows for reduction of package weight.
• Chemical free sterilization eliminates risk of contaminating the product with residual sterilant.
• Simplicity of control and measurement allows for straightforward validation of new lines and more simple process control.
• Highly efficient electron beam emitters lower energy consumption and operating costs.