Aseptic FFS machine for UHT products

UHT products (ultra high temperature processing) such as sterilized milk, are products where all microorganisms are destroyed and shelf life is extended thanks to this specific heating process. To ensure a continued product sterility and an extended shelf life, aseptic packaging is required. An aseptic FFS machine is indispensable to prevent reinfection. Packaging material is sterilized before the filling process and the end-product is sealed in an aseptic environment free of micro-organisms.

Aseptic filling and packaging solution prevents contamination

The thermoforming machine designed by Newpack (Alimenta Group), is a horizontal Form-Fill-Seal machine that forms a container, fills it with a product and seals it, in one single process. The machine handles UHT food products from liquids to semi liquids such as dairy products, not carbonated soft drinks, energy drinks, tea and more.

Newpack Thermoforming machine is adjusted to meet the needs of the products to be filled and its shelf life. Newpack customises the shape and size of the cup in compliance with manufacturers end product. Depending on the desired hygiene level, Newpack has different versions: Standard, High-Clean, Ultra-Clean and Aseptic. For products such as UHT milk or coffee creamer that need very high hygiene standards and sterile conditions, the Aseptic version is suggested.

Starting from a reel of thermoformable plastic film, the Newpack Thermoforming machine forms the bottom of the container according to a pre-established shape, by heating the plastic film and shaping it through a mould. At this point, cups are automatically filled by a cup filling station. Based on the product and the shape of the cup, the filling system type changes. Afterwards the machine applies a lid on each cup by heat sealing it. When cups arrive to the cutting station, they’re cut and separated.

The Aseptic version sterilizes both the plastic film that will form the product container and the lid, with hydrogen peroxide to prevent bacterial contamination. The process takes place in a tunnel which is also filled with the sterile air. Scrapers will remove hydrogen peroxide residue from the packaging material. After washing, the filling system is sterilized with a steam cycle and then kept in aseptic conditions through sterile air at positive pressure.

The machine capacity depends on the product and the volume of the cup; generally speaking, for 10-15ml cup standard configuration, 30,000 c/h is the minimum production capacity while for 100ml and more the minimum production capacity is approx. 9000 c/h.


  • A customized solution
  • A CIP and SIP system to meet hygiene standards
  • Wide range of cup sizes and shapes
  • A 3 in 1 machine for forming, filling and sealing

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