Xenos Process

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Xenos Process Flowchart (0.12MB)

A Xenos aseptic bottling system slots into your production line after a UHT or ultrapasteurising unit and comprises six key steps:

1. Bottle Sterilising
   
   PET or glass bottles are subjected to a rigorous and highly-effective two-step sterilisation process:
   
   Step 1:
   involves steaming the bottle with dilute hydrogen peroxide (H202).
   
   Step 2:
   involves exposure to ultra-violet (UV) light.
   
   Individually, each step only results in a modest sterilising effect. However, the combined effect of dilute hydrogen peroxide and UV light is highly synergistic, achieving extremely effective sterilisation in a very short period of time - without the need to maintain high temperatures to neutralise any remaining micro-organisms.
   
   Although this technology has been around for nearly 30 years, Xenos was the first company in the world to see the value in applying it to the aseptic bottling process.  Our optimisation of conditions has made this technique very robust and applicable to a wide range of bottle types.
   
   Xenos Sterilisation Kill Levels
   Rigorous testing as part of Xenos-sponsored research at Massey University has demonstrated our synergistic sterilisation process achieves in excess of a log 6 kill of dried bacterial spores. Most non-sterile bottles contain between 1 - 10 micro-organisms and applying a log 6 kill achieves an outstanding product failure rate for our system - less than 1 per 10,000 bottles filled.
   
   
   
2. Cap (or Closure) Sterilising
   Bottle caps are subjected to a unique three-step sanitising process. Initially they are soaked in a dilute hydrogen peroxide (H202) bath and then, for added security, caps are steamed with dilute H202 and treated with UV light.
   
   
   
3. Aseptic Filling
   The sterile (UHT-treated) beverage or foodstuff is filled into the sterile bottles.
   
   
   
4. Bottle Capping
   The final stage in the aseptic process involves capping of the filled bottle under sterile conditions.
   
   
   
5. Maintaining an Aseptic Environment
   Each critical step is carried out within a sterile environment to ensure there is no chance of recontamination. The sterile environment is achieved in a pre-startup sterilisation phase (Step 0). This is maintained throughout using a continuous flow of HEPA-filtered sterile air in an over-pressurised environment.
   
   
   
6. Post-Fill Handling
   After the bottles leave the aseptic filler, standard (non-sterile) handling steps can be used.  Bottles receive their sleeve-style packaging and/or labels, are placed into cartons, palletised and then readied for distribution.