DNP’s aseptic filling system achieves industry-leading productivity by integrating two proprietary sterilization technologies—F₀ Solution and CSIP—into a proven high-speed line design. These innovations enable faster sterilization cycles and reduced energy consumption, helping manufacturers meet growing demand without compromising product safety.

• What is CIP & SIP?
• Problems with conventional process
• What is "F₀ solution"?
• What is “CSIP”?
• Case studies

High productivity, high quality and sustainable aseptic filling system (from IBP August 2023 - 1.1MB)(PDFを開く)

CIP is an automated cleaning method that circulates detergents and rinse water through pipes, tanks, and filling valves—without the need for disassembly. Alkaline and/or acidic solutions flow at controlled temperatures and rates to dissolve product residues and biofilms. These are then rinsed away, effectively removing both organic and inorganic substances from internal surfaces and preparing the system for sterilization.

SIP (Sterilization-in-Place) follows CIP and uses high-temperature steam or hot water to eliminate any remaining microorganisms. The system heats to a defined sterilization threshold—typically above 121°C—maintains that temperature for a validated duration, and then cools under positive pressure to prevent recontamination. This process ensures the production line is thoroughly sterilized before the next run.

In a traditional aseptic filling line, every product change triggers a two-step sanitation cycle—CIP (Cleaning-in-Place) followed by SIP (Sterilization-in-Place). While essential for food safety, this sequence has become the single largest drag on productivity:

Extended downtime:
Each product change requires a full CIP (60–90 min) and SIP (~60 min), halting production and increasing downtime.

Steam-intensive process:
Time-and-temperature–based SIP relies on continuous live steam, driving up energy costs and CO₂ emissions.

Lengthy changeovers:
Sequential CIP and SIP cycles for every recipe swap turn even minor product changes into full sanitation procedures—slowing small-batch and just-in-time production.

F₀ Solution is an innovative approach that significantly shortens SIP process time compared to conventional methods, while maintaining full aseptic performance. It is compatible with a wide range of aseptic processing and filling equipment, including UHT sterilizers, aseptic tanks, filling machines, and sterile air filters.
In addition to boosting productivity, F₀ Solution helps reduce environmental impact by lowering steam consumption and cutting CO₂ emissions.

1. Initiate SIP
Steam or hot water is circulated through the piping to begin the sterilization cycle.

2. Start F₀ accumulation
The temperature in the aseptic zone rises, and F₀ accumulation begins once it reaches the threshold (e.g., 121.1°C).

3. Accumulate until target reached
F₀ is accumulated every second until it reaches the predetermined value for the current product (e.g., 233), at which point the system shifts to cooling.

4. Complete SIP
After the cooling process, the aseptic zone is maintained at positive pressure to complete the SIP process.

CSIP enables simultaneous execution of CIP and SIP, eliminating the need for traditional SIP cycles. This allows for a high-temperature, short-duration CIP between production runs. With continuous monitoring, aseptic integrity is maintained, enabling rapid product changeovers and minimizing downtime.

1. Rinse & heat-up
After the previous production run, the system rinses the pipes. An alkaline or acidic detergent is introduced, and the temperature begins to rise.

2. CIP timer initiation
Once the detergent reaches the CIP temperature, the circulation timer starts. Heating continues toward the SIP threshold.

3. F₀ monitoring begins
At 121.1°C, the F₀ software activates. CIP and SIP proceed simultaneously while lethality is continuously accumulated.

4. Sterilization completion
When the accumulated F₀ value reaches the product-specific target, SIP concludes. After the CIP timer ends, the system transitions to a sterile-water rinse.

5. Rinse, cool & verify
UHT-sterilized water flushes out the detergent as the system cools. Temperature and flow are continuously monitored to ensure aseptic integrity.