Aseptic Filling Technology for PET bottles
High-performance eco-friendly aseptic filling system for PET bottles
- Ensures high product safety and consistent quality through advanced aseptic processing
- Reduces energy consumption and environmental impact with eco-friendly system design
- Proven technologies developed in Japan since 1972 with global implementation track record
High productivity, superior quality, and sustainable aseptic filling performance
Overview of our aseptic filling system
Key system details
- Products: Tea, coffee, juice, beverages with particles, water, and carbonated soft drinks (CSD)
- Bottle sizes: 100-2,000 ml
- Closure types: 28-38Φ mm (screw and sports caps)
- Installations: Over 200 systems worldwide (No.1 share in Japan: over 60%)
- FDA approvals: 10 systems (including first rotary system approval in 2005)
- Patents: Over 400 related to aseptic technologies
High quality – key assurances
- High sterilization performance: ≥6 log reduction of B. atrophaeus spores
- Proven long-term aseptic performance maintained for over 20 years
- Media-fill results: Less than 1 contaminated bottle per 60,000 units
- Full traceability: All filling, capping, and CCP data are recorded every second
- Net weight filling accuracy: ≤0.5 g
- Reliable and robust capping by servo motors
Key benefits
Our aseptic filling technologies
F₀ Solution & CSIP – high productivity
Delivering market-leading productivity through proprietary sterilization technologies
Key features
- Up to 72,000 BPH (bottles per hour)
- High Efficiency: over 98%
- Faster changeovers: 1.0 hr (for CSD), 1.5 hr (for high acid beverages), 2.0 hr (for low acid beverages)
- Aseptic changeovers: Continuous aseptic operation during product switching
- Long production runs: over 150 hours for low-acid beverages
F₀ Solution
F₀ Solution is an innovative way to significantly reduce SIP process time compared to conventional ones while maintaining aseptic performance. It can be applied to almost any aseptic processing equipment and filling machine that performs the SIP process, including UHT sterilizers, aseptic tanks, filling machines, and sterile air filters. F₀ Solution not only enhances productivity but also minimizes environmental issues by reducing steam usage and CO2 emissions.
F₀ Solution
CSIP
CSIP performs CIP and SIP simultaneously. This eliminates the need for traditional SIP processes and allows only high temperature, short duration CIP to be used between productions. Being constantly monitored, aseptic performance is maintained and allows quick changeover for the next production.
CSIP
Two-Step Sterilization – lower TCO
DNP launched a new aseptic filling system for PET bottles with a Two-Step Sterilization system that combines preform and bottle decontamination. This has successfully reduced the footprint and TCO of aseptic filling systems. The Two-Step Sterilization process is one of the most sterile and reliable aseptic filling systems in the world.
Key features
- Floor space requirement for blow mold filling area reduced by approx. 30％
- Reduction of approx. 40% in H2O2 consumption for bottle sterilization
- No need for bottle water rinser
- Applicable for ultra lightweight and flexible bottle designs
- Protect the customer's brand with high sterility that cannot be achieved by preform sterilizer alone
Two-Step Sterilization
Green Aseptic™ – sustainability
The Green Aseptic™ system is a new non-thermal sterilization system that combines medium-pressure UV lamps with sterilization filters. This patented aseptic filling technology has enabled significant decarbonization and energy savings in liquid processing equipment for low and high-acid beverages.
Key features
- Mass production of water with almost zero carbon emissions
- Reduction of CO₂ emissions: Advanced, patented technology that reduces energy consumption.
- Sterile blending using heated and non-heated sterilized liquids
- Energy-saving compact UHT
- Annual maintenance to ensure system performance
Green Aseptic™
N₂ Hood – nitrogen flushing
N₂ Hood is an in-line nitrogen-flushing module that surrounds each PET bottle with a dedicated hood immediately after filling, displacing more than 90% of the head-space air with sterile N₂ before the cap is applied.
Key features
- Maintains > 90% nitrogen replacement even at high line speeds of up to 72,000 BPH
- Delivers delicious beverages to customers for long periods of time
- Extended shelf life: Maximum suppression of oxidation and deterioration of contents
- Bottle weight reduction possible
- Reduction in ascorbic acid content possible
Aseptic CSD – carbonated filling
DNP’s Aseptic CSD fills high-CO₂ beverages in PET bottles without a downstream pasteuriser, dramatically reducing water, steam and floor-space usage. It still delivers full sterility while lowering packaging costs and enabling lighter, more sustainable bottle designs.
Key features
- Runs on non-crystallised-neck aseptic PET bottles, cutting production costs
- Employs a fully sterile carbonator for superior microbiological quality
- Requires no downstream pasteuriser, saving floor space, water and steam utilities
- Capable of processing high-CO₂, highly carbonated beverages
- Can produce carbonated beverages containing milk ingredients and fruit juices
History
DNP’s first aseptic filling machine launched in 1976 to produce single-use coffee creamer packs. The system was designed to allow the UHT sterilized coffee creamer to be filled and sealed in a hydrogen peroxide-sterilized lid and base within an aseptic chamber. This concept has been the basis for the development and sale of various aseptic filling systems (PET bottle, Carton, Cup, Pouch, BIB, etc.) that use hydrogen peroxide sterilization for the last 50 years.
References
If you would like to gain a better understanding of what makes DNP Aseptic Filling Systems unique, please read these articles published in International Bottler & Packer, one of the world's leading magazine for the beverage packaging industry. You will soon understand why our systems continue to be chosen by and respected by beverage professionals worldwide.
