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What is Tomato Paste aseptic packaging?

Seamerco research team wrote this article


Aseptic packaging is a process during which microorganisms are prevented from entering package and after packaging. During aseptic processing, a commercially sterilized product is sealed away from any contamination in a safe and hygienic environment. In this specialized process, food, medicine, or other contents are sterilized separately from the packaging. The contents are placed in a sterile environment in container and it uses very high heat to preserve the freshness of the contents, also ensure that is not contaminated with microorganisms. If we want to briefly define the aseptic packaging system in one sentence, we must say that it is a system, is used to fill the commercial sterile product in all kinds of packaging, so that it goes through the packaging process in safe conditions and away from any contamination. This type of packaging was used for the first time by European companies in collaboration with the World Health Organization for packaging beverages and entered the American packaging industry in the early 1980s. Tomato paste is one of the most important products is packaged through the aseptic process.

types of packaging?

In traditional food packaging methods, food is filled in a metal bag or can  then heated in very high temperature, and the product is commercially sterilized; But in the aseptic packaging method, the food or drink is sterilized by exposure to heat at extremely high speed and pressure, then sealed in a commercial sterile environment, for this reason, this modern method is safer & more sterile than other types.

Is the aseptic packaging method safe and hygienic?

In answer to this question yes, there is no doubt about aseptic packaging. The inner layer of aseptic packaging that touches the contents is polyethylene. There is no aluminum leachate extracted through the polyethylene layer. The polyethylene used in aseptic packaging is dense, a food contact surface-approved material approved by the World Food & Drug Administration. Several tests have shown that no polyethylene enters the food product. For this reason, they choose aseptic packaging for tomato paste.

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What products is the aseptic packaging process used for?

An aseptic packaging system is used for various food & drinks products, including hot & cold drinks such as milk, soup, tomato products, puddings, and many other food items. This packaging technique is used in the pharmaceutical industry to ensure that drugs are not contaminated with harmful bacteria. As a result, packing tomato paste in this process is safe but the most important and widely used aseptic packaging is tomato paste which is packaged & exported in aseptic form.

What are the advantages of aseptic packaging?

Aseptic packaging has gained a lot of popularity among manufacturers in recent years. The Freedonia Economic Group reported in economic research that demand in the food packaging market has increased at an annual rate of 68%, which has reached 6.4 billion dollars by 2020. There is no doubt that growth can be attributed to the tremendous benefits of this type of packaging. Most tomato paste exporters use aseptic packaging.

Increased lifespan:

Aseptic packaging helps to increase the useful life of products packaged in this way about 6 – 12 months without refrigeration. Extending the shelf life of product in the manufacturer’s warehouse and on retailers’ shelves provides more time to use or eat the product before it expires.

Reducing costs of transportation, distribution, and publication:

With unique aseptic packaging, products can be stored at an ambient temperature of 68-77. In contrast to more traditional packaging, aseptically packaged products are lightweight and compact. These properties allow manufacturers to reduce shipping costs by reducing product packaging weight and eliminating the need for refrigeration for products that typically require cool environments during distribution.

No use of preservatives:

Manufacturers do not need to use preservatives using aseptic packaging because the sterilization process in the aseptic packaging method protects against bacteria. This allows manufacturers to use natural, organic, and healthier ingredients to consumers prefer. This issue is more important in  case of products like tomato paste, because the absence of preservatives guarantees quality of tomato paste.


  Aseptic packaging is a sustainable method that can contribute to the initiative of manufacturers in the field of environmental protection. Packaging is primarily made from renewable resources and uses up to 60% less plastic than other methods. In terms of energy consumption, compared to other packaging methods, it requires less energy for production.

Maintaining the quality of contents and products:

The high-tech aseptic packaging process helps maintain overall quality of most food and pharmaceutical products. This means that taste, smell, aroma, and nutritional value will not be compromised and consumers can be sure that the product have high quality.

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How does aseptic packaging technology work?

Aseptic packaging technology is fundamentally different from non-canned and conventional food packaging. The initial treatment deactivates the enzymes, so that the product is not destroyed during processing & sterilization, and at the same time, the product enters the package warm. Generally, air that can cause oxidative damage is evacuated from the package and  is continuously and rapidly sealed  then reheated. In any type of packaging, the packaging material must be compatible with the intended product and also comply with the requirements related to the transportation of the material. The physical integrity of the package is necessary for the assumption of containing product and maintaining sanitation and the packaging being resistant to sterilization its compatibility in protecting oxygen from the product contents, preventing the smell and aroma of the product from coming out of the package. In the manufacture of aseptic packaging several materials are layered together to provide the level of protection required for packaging standards. Polyethylene is used as a barrier on inside & outside of aseptic packaging. These layers protect against moisture entering or leaving the container. Foil film also helps preserve the product by keeping light & oxygen. Since the outer layers of aseptic packaging are made of aluminum foil, the packaging cannot be exposed to microwaves. However, the package must be able to withstand heat for high-acid products up to 100°C and low-acid products up to 127°C, this additional heat destroys heat-resistant microbial spores.

What is the method of sterilization or sanitization in the aseptic system?

The methodology of the Aseptic technique in sanitation includes different steps that fill the product and contents in complete safety and health in the packages also take care of the packaging in all stages of spreading and distributing the goods:

  1. Sterilizing products before filling.
  2. Sterilize the package before filling.
  3. Sterilization of aseptic facilities before operation.
  4. Sterility of the product after the packaging process until delivery to the consumer.

      5.Techniques used in sterilization:

  • microwave
  • Heating
  • High voltage discharge
  • Extremely high pressure

the heat:

At first heat was used as a sterilizer for aseptic systems with the function of natural heat expansion. Processing product lines & fillers are usually sterilized by moist heat in the form of hot water or saturated steam under pressure. In aseptic packaging dry heat is used to sterilize system equipment.

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For use as a chemical disinfectant, it is very important option than other chemicals that are mainly used as disinfectants for use in sanitizing acidic products. Hydrogen peroxide does not have sporicidal ability at room temperature but its sporicidal ability increases with increasing temperature. Most aseptic packaging systems use hydrogen peroxide in concentrations of 30% -35%.


Gamma rays have been used to disinfect packaging materials for decades. Most of its use is in aseptic systems for packing acidic products due to the penetration. Type of radiation on packages in this technique cause that  are mainly sterilized.

What are the types of aseptic packaging?

  1. Cardboard packages: suitable for all kinds of food such as rice & corn.
  2. Big bags: which have a filling capacity of up to 220 liters are used for packaging food & medicines, including all kinds of tomato products are usually used in export and international trade.
  3. Small bag packages: which are used for packaging for all kinds of powders, seeds and seasonings, such as cinnamon, tea, coffee, etc.
  4. Bottles & glasses: glass bottles and plastic bottles that are used for all kinds of drinks.
  5. Metal cans: Metal cans are not used in the aseptic packaging method, but in this method there are different types of aluminum cans in different sizes that are used for products such as rice, peas and corn.
  6. Composite cans: which are famous for their light weight and for products such as; Tea, coffee, corn, etc. are used.

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Based on what was said, aseptic packaging with its many advantages such as: increasing the product life, not using preservatives, being environmentally friendly, maintaining the quality of the contents and also its annual consumption in the markets of canned food products can have a bright future. Apart from that, compared to other types of packaging products, it is more affordable & better quality.

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