Handbook of Aseptic Processing and Packaging: 2nd Edition (Paperback) book cover

Handbook of Aseptic Processing and Packaging

2nd Edition

By Jairus R. D. David, Ralph H. Graves, Thomas Szemplenski

CRC Press

400 pages | 130 B/W Illus.

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Since publication of the first edition of this book, Aseptic Processing and Packaging of Food, significant changes have taken place in several aseptic processing and packaging areas. These include changes in aseptic filling of nutritional beverages in plastic bottles; the popularity of value-added commodity products such as juice, concentrate, and puree; pouches and bag-in-box bulk packaging; and other novel package concepts possessing a range of consumer convenience and ergonomic features.

The newly titled Handbook of Aseptic Processing and Packaging, Second Edition explores the application of existing and new food processing methods and sensor technologies. It is an essential guide for those developing day-to-day procedures for a number of different aseptic processing and packaging applications.

New Topics in the Second Edition:

  • Current information on aseptic packaging materials and sterilants
  • Aseptic bulk packaging, with a historical perspective and an update on the current state of bulk packaging in container sizes ranging from several gallons to several millions of gallons
  • Aseptic processing operations, including the processing products as well as the operation of aseptic packaging systems
  • Failure mode effect analysis and spoilage troubleshooting, with examples of different failure modes and their effects on food safety
  • Aseptic processing of particulate foods, including the use of microwave for heating and technology available to monitor and develop processes for this category of foods
  • Contract manufacturers and their role in introducing innovative products to market

The contributors to this volume have more than 150 years of combined food industry experience, encompassing production, quality assurance, research and development, and sales in aseptic processing and packaging. Their insight provides a comprehensive update on this rapidly developing technology for the food processing industry.


"The contributors to this volume have more than 150 years of combined food industry experience, encompassing production, quality assurance, research and development, and sales in aseptic processing and packaging. Their insight provides a comprehensive update on this rapidly developing technology for the food processing industry."

Beverage and Food World, January 2013

Table of Contents

Aseptic Processing and Packaging: Past, Present, and Future

Framework and Current State

Departures from Optima and Challenges

Current and Future Opportunities for Optimization

United States History and Evolution

Early Pioneers

The Graves Era

Jack Stambaugh

The First Commercial Aseptic Plant

The Real Fresh Company

The First Aseptic Form–Fill–Seal Packages

Early Aseptic Packers

Restrictions for Growth

Trends for the Future

The US Markets for Aseptic Packaging


Aseptic Metal Can Market

Aseptic Bag-In-Box

Aseptic Paperboard Market

Aseptic Plastic Cup Market

Aseptic Pouch Market

Aseptic Plastic Bottle Market

Aseptic Processing Equipment and Systems

Aseptic Processing Equipment

Plant Layout Considerations



Chemicals Used As Sterilizing Agents (Equipment)

Aseptic Filling and Packaging Equipment

Development of Aseptic Packaging

Dole Aseptic Canning System

Aseptic Bag-In-Box

Aseptic Paperboard Fillers

Aseptic Plastic Cups

Coffee Creamers

Aseptic Pouches

Aseptic Plastic Bottle Fillers


Aseptic Packaging Materials and Sterilants

Product Requirements


Sterilizing Agents

Packaging Systems

Environmental Considerations

Aseptic Bulk Packaging

Aseptic Bag-In-Box

Aseptic Bulk Container

Aseptic Bulk Storage

Aseptic Ocean Liner Transportation and Storage

Regulations for Aseptic Processing and Packaging of Food

US Food and Drug Administration Requirements and Approval

Code of Federal Regulations (CFR)

Low-Acid Food Regulations and Definitions

US Food and Drug Administration: Specific Concerns

Other Requirements

Validation and Establishment of Aseptic Processing and Packaging Operations

Some Considerations

Decision Process

Equipment Selection

Process Schematic and Process and Instrument Diagrams (P&ID)

Preinstallation Review

Postinstallation Review

Equipment Testing and Validation

Thermal Process Design for Products Containing Particles (Principles Applicable to Homogenous Fluid Foods)

Factors Other Than Temperature Contributing to Nonsterility

Aseptic Processing Operations

Presterilization of the Processing System

Loss of Sterility

Water-To-Product Separation

Product-To-Water Separation



Thermal Processing and Optimization

Thermal Processing and Optimization

Comparison of Conventional Canning and Aseptic Processing and Packaging of Foods

Comparison of Processing Methods

Optimization Hierarchy



Quality Assurance and Food Safety for Aseptically Processed and Packaged Food

Quality Assurance for Aseptically Processed and Packaged Food

Preprocess Assurance

In-process Assurance

Post-process Assurance

Hazard Analysis Critical Control Points (HACCP) Program


Failure Mode and Effect Analysis, and Spoilage Troubleshooting

Failure Mode and Effect Analysis

Failure Mode and Effect Analysis, and Troubleshooting

Failure Mode, Analysis of their Effects, and Controls

Cause and Effect Relationships


Aseptic Processing of Particulate Foods

Considerations for Equipment Design

Validation of Aseptic Processes with Particulates

Concluding Remarks

Industry Research and Development, and Management Needs and Challenges

Research and Development Needs and Challenges

Management and Administrative Challenges

Raw Product


Aseptic Filling and Packaging

Finished Product and Package


Appendix A

Aseptic Fillers

Appendix B

Contract Manufacturersin USA

About the Authors

Jairus David, Ph.D., is Senior Principal Research Scientist at ConAgra Foods headquartered in Omaha, Nebraska. David’s responsibilities include science leadership and development of intervention technologies for food protection and process & quality optimization. David is a Fellow of the Institute of Food Technologists (IFT), and is the recipient of IFT’s prestigious Industrial Scientist Award for developing and influencing the public health food safety policy on the use of honey in cereals and bakery products for the prevention of infant botulism in infants under 12 months of age. David earned his Ph.D. in Microbiology with Thermal Processing emphasis from the University of California at Davis.

Ralph H. Graves held the position of Senior Vice President for Real Fresh, Inc., as a company involved in the processing and sale of aseptically packaged foods. His responsibilities included the research and development of processing techniques, quality control, engineering, and maintenance and warehousing of aseptically packaged dairy products. Although now officially retired, Graves continues his work in this field as a consultant.

Thomas E. Szemplenski is the owner of Aseptic Resources, Inc., a consulting company dedicated to assisting food processors and equipment manufacturers with aseptic processing techniques. He has more than four decades of food processing and packaging experience—the vast majority of time dedicated to aseptic processing and packaging techniques, commercial application, and marketplace dynamics.

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