PRODUCT BRAND NAME TM

Hot
Hot Fill
Fill
versus
versus Aseptic
Aseptic
versus
versus Preservatives
Preservatives

GSD water & CSD

March 2006

This report is solely for the use of Sidel Group personnel. No part of it
may be circulated, quoted, or reproduced for distribution outside Sidel
Group organization without its prior approval. This material was used by
Sidel Group during an oral presentation; it is not a complete record of the
discussion.
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SENSITIVE BEVERAGES
REQUIRING HYGIENIC FILLING ENVIRONMENT

Milks Isotonics Juices Flavoured

Milk based Energy Nectars waters
beverages drinks Fruit drinks
RTD Teas
& coffees

March, 2006 x Sidel solutions for HOT FILL x 2/26

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PRODUCT : SHELF LIFE FACTOR

Product
•Ingredients
•Process
•Heat treatment

Characteristics: Packaging:
•Flavour .O2 transmission
•Taste MARKETING
.Light trasmission
•Vitamin C
.Logistics
•Colour

Filling type
•Clean
•Ultra Clean
•Hot filling
•Aseptic

March, 2006 x Sidel solutions for HOT FILL x 3/26

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PRODUCT : SHELF LIFE PARAMETERS

Parameter Effects Responsibility

Fermentation
Filling system
MICROBIOLOGICAL
Coagulation
Separation Thermal treatment
Organoleptic deterioration

Oxidation Primary package

CHEMICAL Organoleptic and vitamins Product thermal treatment
deterioration
Filling system

Colour change Primary package

CHEMICAL/
Organoleptic deterioration Storage conditions
PHYSICAL
Ingredient

March, 2006 x Sidel solutions for HOT FILL x 4/26

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>> MARKET & APPLICATIONS

SOLUTIONS TO EXTEND SHELF LIFE OF SENSITIVE DRINKS

NEEDS IN:
 Providing these products with a longer shelf life
 Preserving their nutritional and organoleptic qualities
 Protecting against bacterial and fungal degradation

3 TECHNOLOGICAL ANSWERS:

Preservatives
Hot Filling Cold Aseptic Filling
or cold sterilizers

Traditional solution More recent solution Alternative solution

Where heat is used Where product is flash Where preservatives

to sterilise product pasteurised, bottles and are added to the product
and the package closures are sterilised or cold sterilizers during
and the product is filled at the filling process
ambient temperatures.

March, 2006 x Sidel solutions for HOT FILL x 5/26

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HOT FILLING

Heat is used to sterilise product and the package,

by the maintaining the product at an elevated
temperature (20-60 sec at 80-94°C) after the
pasteurization stage and during filling.
After filling, the bottles are cooled slowly by water.

Main features:

-Pre-sterilization
of the packaging components
becomes unnecessary.

-Essentialto bring inside of cap and hot product

into direct contact.
-by using a bottle turner
-or by filling to the very top of container neck.

-Necessary to leave as little headspace as possible.

-Essential to carefully calculate the temperature of

the beverage and held it constantly during the
whole filling process.

-Takecare not to heat the beverage too long to

avoid a darkening of the product and a caramel-like
odour and taste.

March, 2006 x Sidel solutions for HOT FILL x 6/26

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COLD ASEPTIC FILLING

Product is flash pasteurised, the bottles and

closures are sterilised and the sterility is
maintained until the container is capped.
Product is immediately cooled to room
temperature prior to bottling, and the product
is filled at ambient temperature.

Main features:

•Bottles and caps may be sterilized:

•wet using peracetic acid
•or dry using hydrogen peroxide.

•Coldaseptic filling is particularly suitable for PET bottles,

glass is not a normal choice.

•Cooling
the product right away allows less vitamin
degradation and variations of flavor

•Organolepticqualities of cold fill product may be superior

to organoleptic qualities of the hot filled products.

March, 2006 x Sidel solutions for HOT FILL x 7/26

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PRESERVATIVES & COLD STERILIZERS

Chemicals elements are added directly to the product before or during the filling
Main features:
•Their use is now harmless and efficient
•Necessity to declare on the labels (except Germany)
•Necessity of working in clean conditions: environment, packaging etc; equipment and
pipes must be regularly cleaned and disinfected.
•Main drawback: negative consumer perception on nutritional properties of the product,
because of demand for more “natural” products

PRESERVATIVES

Mixed with the base formula and have a very slight off taste.
Where preservatives are used, the process cannot be regarded as aseptic.
EU legislation prohibits the use of preservatives in juices and nectars.

COLD STERILIZERS
A liquid injected during filling
VELCORIN: most well-known and commonly used

March, 2006 x Sidel solutions for HOT FILL x 8/26

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FOCUS ON VELCORIN

VELCORIN: most well-known and commonly used cold sterilizer

Chemical: Dimethyl dicarbonate (also dimethyl pyrocarbonate)
Marketed by Bayer AG
Mentioned on labels as E242 (except Germany)
Legal status and permitted levels of Velcorin differ from country to country.

Functioning
•A liquid injected during filling and acts immediately.
•After 30 min it breaks down into water +carbon dioxide+methanol.
Methanol component is very small, with no taste
•Before adding Velcorin, flash-pasteurize drink or cool the drink to 10-15 °C,
otherwise Velcorin decomposes.
•Uneconomical to add Velcorin with t°C > 30°C

Preserving beverages with Velcorin

The germ in drink prior to treatment should be < 500 per ml.
•Soft drinks based on fruit juices: 6-12 ml of Velcorin per 100 liters
• Non carbonated fruit juices drinks: 12-20 ml per 100 liters.

March, 2006 x Sidel solutions for HOT FILL x 9/26

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SIDEL SALES

HOT FILL VERSUS ASEPTIC

Aseptic process : Filler capper aimed at maintaining characteristics of products

Sterile product

"Dirty" bottle • Bottle and cap are sterilized Sterile

and cap • Sterile product is filled in a sterile bottled product
bottle in a “Aseptic” filler

Hot-fill process : Filler - Capper is part of the heat treatment of the product
Hot sterile product

"Dirty" bottle Bottle Bottle Sterile bottled

Product is filled at
and cap
inverter Cooler product
high temperature in a
(> 85°C)
non-sterile bottle.

Temperature is high enough

to kill germs in the dirty The bottle is turn down: the contact of the
bottle. hot product sterilizes the cap

March, 2006 x Sidel solutions for HOT FILL x 10/26

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SIDEL SALES

COMPLEXITY SCHEME

Product Environment
•Geographical location
•Product image
•Floor space available
•Bottle design, closure, labelling
•Waste rate, policy
•Product intrinsic characteristics
•Empty bottle supply chain

Quality Operations

•Process reliability •Production rate objective / year

•Product quality (spoilage agents…) •Industrial structure
•Quality management level •Number of operators targeted
•Operators’ skills level •Maintenance
Costs •Line availability, efficiency

• Capital cost •Consumables cost

• Raw materials cost (Electricity, Thermal
• Labour cost energy, Chemicals…)
• Immobilization cost • Production losses

March, 2006 x Sidel solutions for HOT FILL x 11/26

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HOT FILL PROCESS DIAGRAM

“Heat-Set” Preforms or
85°C (no critical part Bottle Design limit at least Heavy Bottles
between past. & filller)
“Heat Set” type
Botltes from Depalletiser
Bottles from blower Blowmoulder
Syrup room

Mixer Simple technology

Treated water ( poss. Desinfectants)
Old & Well Established Conveyor

Product Balance Tank Bottle Treatment Rinse or Light

Product waste (no Decontamination
Hot filling (80-85 °C)
Pasteurization buffer tank ,
and capping
overfilling) Vacuum resistant
Product overheating Caps Treatment caps
Recovery tank Cooling
Cooler
Bottles must be cooled
Buffer Energy not recovered

Labelling and Packing

Label suitable for HF Large acc. table,
(thicker OPP) to empty the cooler
Warehouse
March, 2006 x Sidel solutions for HOT FILL x 12/26
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ASEPTIC PROCESS DIAGRAM

Flexible Bottle design Preform“Light”
Higher Speed SBM
Bottles for depal Bottles from SBM
Syrup room process

More complex Sterilization

Mixer Treated water+ sterilant
machinery and Conveyor Treated, sterile water
technology
Product tank
Treatment
Caps
Caps “Light”
Filling and capping at
Pastuerisation Treatment
Aseptic tank ambient temperature
and chilling
(20-30 °C) Sterilization

Many Aseptic No needs for cooling

Less product loss
Interfaces to control

and deterioration Labelling and Packing Less accumulation conveyors

Standard label

Warehouse

March, 2006 x Sidel solutions for HOT FILL x 13/26

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DECISION PROCESS:
INVESTMENT CAPACITY AND COMPANY PROFILE
QUESTIONS :
 What are my investment capacity limitations ?
 What is my production structure?

Criteria Qualitative impact Cost impact

Aseptic Hot fill Aseptic Hot fill

Investment cost
W/ depal NA NA

Investment cost
In line blowing
NA NA

Investment cost NA NA
Combi

Operations
complexity
NA NA

Foot print

Advantage No impact
Drawback Not applicable NA March, 2006 x Sidel solutions for HOT FILL x 14/26
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DECISION PROCESS: COSTS

QUESTION
QUESTION::What
Whatis
isthe
themost
mosteconomical
economicalchoice
choice??
The
Thebalance
balanceof
ofeach
each cost
costremains
remainsvariable
variablefrom
fromone
onescenario
scenarioto
tothe
theother.
other.
Need
Need to compare the global cost (TCO) Of each scenario to be able todecide.
to compare the global cost (TCO) Of each scenario to be able to decide.

Criteria Quality impact Cost impact

Aseptic Hot fill Aseptic Hot fill

Preform costs NA NA

Utilities costs NA NA

Labor costs
general
NA NA

Labor costs NA NA
Combi / hot fill in line

Advantage No impact
Drawback Not applicable NA March, 2006 x Sidel solutions for HOT FILL x 15/26
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DECISION PROCESS: MARKET STRATEGY

QUESTION
QUESTION::Which
Whichmarket
marketwould
wouldIIlike
liketo
toaddress
address??
Market segments : Premium, standard, low cost : Set-up packaging & product characteristics
Market segments : Premium, standard, low cost : Set-up packaging & product characteristics
Strategy of penetration: large volume, medium, niche : Set–up production objectives
Strategy of penetration: large volume, medium, niche : Set–up production objectives

Criteria Quality impact Cost impact

Aseptic Hot fill Aseptic Hot fill
Product image
NA NA
Product Taste NA NA

O2 Sensitivity NA NA

Shelf life NA NA

Bottle design NA NA

Closure NA NA

Advantage No impact
Drawback Not applicable NA March, 2006 x Sidel solutions for HOT FILL x 16/26
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DECISION PROCESS: LINE MANAGEMENT

QUESTION
QUESTION::ready
readyto
torun
runan
anaseptic
asepticline
line??
Quality management levels : Structure, norms, HACCP concept …
Quality management levels : Structure, norms, HACCP concept …
Operators skills level: low skilled operators, high class operators
Operators skills level: low skilled operators, high class operators

Criteria Quality impact Cost impact

Aseptic Hot fill Aseptic Hot fill

Quality manag.
level

Operator skills

Advantage No impact
Drawback Not applicable NA March, 2006 x Sidel solutions for HOT FILL x 17/26
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ADVANTAGES (+) AND DRAWBACKS (-) TABLE

Aseptic Hot Filling

Preform & Bottle cost ++ Light -- Heavy

Caps + Standard - Special

Label cost + -
Energy cost = =
Product Cost (wastage) + -
Cost of Chemicals -- ++
Capital Invested - ++
Labor cost - +
Gentle with Heavy (product
Down-Time flash pasto recirculation)
Customizable
Flexibility bottle design Standard bottle
bottle shape design with panels
Product quality ++ -
Product image ++ -
Product Range ++ --
March, 2006 x Sidel solutions for HOT FILL x 18/26
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PRODUCT TABLE

Hot Fill Aseptic

NECTARS

ACE(vitamins)

100% JUICES
(mango,orange,
apple)

ORANGE

TROPICAL
(pineapple, banana)

MILK

PROBIOTICS

MILK BASED

March, 2006 x Sidel solutions for HOT FILL x 19/26

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SIDEL ASSISTANCE TO DECISION MAKING

• Engineering services

• Production costs simulations (TCO)

• Bottle design

• Products shelf-life tests

March, 2006 x Sidel solutions for HOT FILL x 20/26

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SIDEL’S ENGINEERING TEAMS

Consulting services

• Preliminary study
• Concept study
• Productivity services (audits,
simulation, EIT software) Process Engineering
• Detailed engineering study 325 project engineers
• Master plan for beverages
and liquid food

Complete Lines
Our experience as a principal contractor:
1,100 people building
>100 bottling lines annually
for food liquids in plastic packaging.

March, 2006 x Sidel solutions for HOT FILL x 21/26

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PRODUCTION LINE & COST SIMULATION (TCO) - scenarios

Examples Type Material Representation

SBO
Line 1 Blowing Interface Filling
11 400 BPM
+ PET parameters (Conveyor, silo) Capping
Filling

Line 2 « Combi »
22 400 BPM Line
PET SBO FILLING CAPPING

Line 3 Purchased Bottle Silo, Filling

33 400 BPM bottle
PET cost
unscrambler
Capping

SBO
44 Line 4 Blowing Interface Filling
+ PET parameters (Conveyor, silo) Capping
600 BPM Filling

March, 2006 x Sidel solutions for HOT FILL x 22/26

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SIDEL’S BOTTLE DESIGN CENTER

… will help you design the best bottle for your application.

Bottle Design Computer Generated Structural Analysis

5,000 new plans Image Design
each year Technical experience
and 25 designers and the most powerful
at your service. computer tools support
your customer-oriented
approach.
A forecasting tool,
the simulator is developed
from our worldwide
database, materials,
and bottles.

March, 2006 x Sidel solutions for HOT FILL x 23/26

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SIDEL’s INNOVATIONS IN BOTTLE DESIGN:

In terms of lightweighting and output speed

Hot-Fill  Innovative differentiated design

0,5 L : 24 gr
1,5 L : 52 gr
2.0 L : 59 gr
 Output up to 1800 bphm

Aseptic
 Innovative differentiated design
 Full extent of lightweighting
 Output 1800 bph

March, 2006 x Sidel solutions for HOT FILL x 24/26

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SIDEL’S PRODUCT TEST CENTER

… will help you select the best technology and the best package
in order to preserve your product and to enhance its shelf life.

 Microbiologic laboratory
 O2 sensibility test
 Light sensibility test
 Flavour analysis with a
trained panel of people
 Shelf life test

March, 2006 x Sidel solutions for HOT FILL x 25/26

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SIDEL APPROACH

Aseptic is attractive : Hot Fill has been proven :

State of the art technology Simple and mastered technology
Product innovation opportunity Better for oxydo-sensitive products
TCO can be lower than with Hot fill Lower capital investment

Sidel’s approach

Innovation and R&D

Production capacity investment

Customer services

Assist the customer in key decision making

March, 2006 x Sidel solutions for HOT FILL x 26/26