Sustainability in Organic Processing

PeroxyChem has created a hydrogen peroxide that is both stable in the bath and low in residue for vapor applications.

Process Innovation

Given the constraints of the existing packaging processes and that these two chemistries are already widely used within the industry, the clearest way to introduce environmental advantages to organic packaging is through process innovation. Technology and formulation expertise is what will enable processors to increase plant efficiencies while decreasing their environmental footprint.

For example, PeroxyChem has been developing a vapor PAA sterilization for aseptic packaging applications. The technology uses dilute PAA vapor to sterilize plastic bottles and cartons in a highly efficient manner. PeroxyChem currently has two patents related to vapor PAA issued and granted; the third should issue in September. The technology combines the benefits of traditional PAA rinse systems with the latest advancements in hydrogen peroxide vapor systems.

The technology leaves minimal residue on the filling equipment and inside the packaging bottles, resulting in less production downtime for equipment cleaning and maximizing the production site’s output efficiency. Additionally, processors are able to reduce energy needed to remove hydrogen peroxide residuals from the container after sterilization that is expected to lower the total organic carbon (TOC) and carbon footprint.

Vapor PAA technology enables processors to decrease input of chemistry in the packaging process by an order of magnitude, as well as increase run times, lower operating temperatures, and utilize lighter weight bottles. All these efficiencies result in improved energy efficiency and reductions in water usage. Vapor PAA alternative sterilization meets the manufacturer’s microbial standards and allows aseptic beverage processors to reduce their TOC while at the same time delivering on commitments to sustainability.

Additionally, companies must look beyond the packaging process to introduce environmentally friendly practices that not only reduce energy and material waste, but that translate into cost savings for customers. For instance, PeroxyChem offers bulk handling and storage systems. One PeroxyChem customer, a major juice manufacturer, was able to eliminate over 1,500 one-way totes each year by switching all PAA needs to bulk supply, translating into considerable plastic saved.

Production plants using renewable energy, like PeroxyChem’s peracetic acid plant in Tonawanda, N.Y., that operates on hydroelectric power, are examples of how chemistry providers should be moving in order to improve the environmental impact of all chemical processing.

Innovation is at the core of what will continue to improve the sustainability of the aseptic packaging process. Each processor faces unique challenges in terms of packaging, product type, sterilization demands, and more. With the continued growth of the organic market, chemical companies and beverage processors that are committed to innovation for their own benefit and for the benefit of their customers will be well positioned to provide efficient, cost-effective solutions that meet the strict regulations of the aseptic packaging market.

Korzinek is a PeroxyChem Global Segment Manager, Aseptic Packaging. Reach him at [email protected].