Dairy processing: Aseptic processing and packaging systems
Aseptic processing and packaging system (APPS) flow schematic
The aseptic processing and packaging system (APPS), although similar to a high temperature short time (HTST) pasteurizer, operates at even higher temperatures and pressures. It also uses steam seals and other means to ensure a commercially sterile product.
- Notify the person responsible for the scheduled process (for example, a process authority) whenever changes are made to the processing system
- even slight modifications to the APPS may have an impact on its operation and safety
Up-to-date and accurate
- Maintain on file a flow schematic outlining the APPS system and its related components (for example, constant level tank, feed pump, regeneration system, pressure differential recorder-controller, flow control device, heat exchangers, thermometers, holding tube, safety thermal limit recorder, flow diversion device, aseptic barriers, aseptic packaging)
- Update the flow schematic whenever equipment and/or pipelines are installed or changed
No cross connections
A cross connection is a direct connection allowing one material to contaminate another.
- Segregate incompatible products such as raw materials and pasteurized or sterilized food products, cleaning products and food products, and waste materials or utility materials and food products
- Prevent inadvertent cross contamination of independent food products (for example, soy beverages and milk) which may pose allergenic concerns
To segregate incompatible products:
- use separate pipelines and vessels for incompatible products
- establish effective physical breaks at connection points between incompatible products
The installation of segregating valves for the purpose of separating cleaning solutions from food products does not constitute a physical break, except that a properly designed valve arrangement (raw side) and a properly designed aseptic barrier (sterilized side) may be used (for example, while cleaning the packaging line and/or surge tank while processing product).
- A properly designed aseptic barrier could, for example, include one or more steam blocks with a temperature sensor alarm to indicate barrier failure due to leaks or loss of steam
The design of the constant level tank and piping, and the product divert device are areas where potential cross-connections could exist if the design or installation is improper. Refer to the Constant level tank and Flow diversion device sections for more details.
Refer to Preventing cross-contamination and Appendix G: Preventing cross connections for more information on preventing cross connections in dairy establishments.
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