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: 13 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
■ DNP's aseptic filling technologies
Two-Step Sterilization – enhanced safety and 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
- Enhanced sterility beyond conventional preform-only sterilization
- Protects product quality and brand reputation through superior contamination control
- Reduction of approx. 40% in H₂O₂ consumption for bottle sterilization
- Floor space requirement for the blow mold filling area reduced by approx. 30%
- Compatible with ultra-lightweight and flexible bottle designs
Two-Step Sterilization
Green Aseptic™ – sustainability
Green Aseptic system is an innovative non-thermal sterilization technology that combines medium-pressure UV lamps with sterilization filters. This patented technology has significantly advanced decarbonization and energy efficiency in liquid processing systems for both low- and high-acid beverages.
Key features
- Decarbonization through ultra-low‑carbon sterile water production
- Advanced non‑thermal sterilization technology for energy efficiency
- Non-thermal sterilization and aseptic blending reduce energy consumption of UHT sterilizers by approximately 80% (at 5× dilution)
Green Aseptic™
F₀ Solution & CSIP – high productivity
Delivering market-leading productivity through proprietary sterilization technologies
Key features
- SIP time reduction: approx. 50%
- Maintains aseptic performance through real-time F₀ control
- Software-based implementation for existing equipment
- Applicable to UHT sterilizers, aseptic tanks, filling machines, and sterile air filters
- Approx. 50% reduction in steam consumption and CO₂ emissions
F₀ Solution
F₀ Solution significantly reduces SIP process time while maintaining full aseptic performance. It improves productivity and sustainability by reducing steam consumption and CO₂ emissions.
F₀ Solution
CSIP
CSIP combines CIP and SIP into a single process, eliminating the need for conventional SIP between production runs. Continuous monitoring maintains aseptic performance while enabling faster changeovers, increased productivity, and reduced downtime.
CSIP
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 headspace air with sterile N₂ before capping.
Key features
- Achieves over 90% nitrogen replacement at line speeds of up to 72,000 BPH
- Helps preserve fresh taste and aroma over time
- Reduces oxidation to help maintain product quality
- Supports lightweight PET bottle designs
- Helps retain vitamin C content
Aseptic CSD – carbonated filling
DNP's Aseptic CSD fills highly carbonated beverages in PET bottles without a downstream pasteuriser, significantly reducing water, steam and floor-space requirements. It delivers full sterility while lowering packaging costs and enabling lighter, more sustainable PET bottle designs.
Key features
- Fully sterile carbonator for enhanced product safety and quality
- No downstream pasteuriser required, reducing floor space, water, and steam consumption
- Runs on non-crystallised-neck aseptic PET bottles, reducing production costs
- Supports highly carbonated beverages, including products containing milk ingredients and fruit juices
■ History
DNP launched its first aseptic filling machine in 1976 for single-serve coffee creamer production. Since then, the company has expanded its hydrogen peroxide-based aseptic technologies across a wide range of packaging formats, including PET bottles, cartons, cups, pouches, and bag-in-box systems. Today, over 50 years of expertise continues to drive innovation in aseptic filling solutions worldwide.
■ References
To learn more about the technologies, innovation, and expertise behind DNP Aseptic Filling Systems, we invite you to explore the following articles published in International Bottler & Packer (IBP), one of the world's leading magazines for the beverage packaging industry. Discover how DNP continues to support beverage manufacturers worldwide through advanced aseptic filling solutions that deliver productivity, quality, and sustainability.
