Aseptic Filling Lines
EasyReal’s Aseptic Filling Lines are fully integrated and automated processing systems specifically engineered for the continuous sterilization and aseptic packaging of various liquid food and beverage products. Utilizing Ultra-High Temperature (UHT) technology, or High temperature short time (HTST) technology, or Pasteurization technology, these lines heat products rapidly to temperatures between 85°C and 150°C, maintain the temperature for a few seconds or tens of seconds to achieve effective microbial inactivation, and then rapidly cool the product. This process ensures the elimination of pathogenic and spoilage microorganisms while preserving the product’s original flavor, texture, color, and nutritional properties.
After sterilization, the product is transferred under sterile conditions to an aseptic filling system, where it is filled into pre-sterilized containers such as Sterile aluminum foil bags（like BIB bags, or/and big bags like 200-liter bag, 220-liter bag, 1000-liter bag, etc.）. This ensures long shelf life at ambient temperatures, eliminating the need for refrigeration or chemical preservatives.
Each Aseptic Filling Line from EasyReal includes a UHT sterilizer—available in tubular, tube-in-tube, plate (plate heat exchanger), or direct steam injection (DSI) configurations depending on the product characteristics and application requirements. The system also integrates a fully automated PLC + HMI control panel, offering intuitive operation, recipe management, and real-time monitoring of all process parameters.
To meet diverse processing needs, EasyReal offers a wide range of optional modules, including:
Vacuum deaerators, to remove dissolved oxygen and prevent oxidation;
High-pressure homogenizers, for product uniformity and texture enhancement;
Multi-effect evaporators, to concentrate product prior to sterilization;
CIP (Clean-in-Place) and SIP (Sterilize-in-Place) systems, for efficient and sanitary cleaning.
EasyReal’s Aseptic Filling Lines are designed for industrial-scale production, delivering stable performance, energy efficiency, and food safety compliance in accordance with international standards. They are suitable for processing a variety of products such as fruit and vegetable juices, purees, paste, dairy milk, plant-based beverages (e.g., soy or oat milk), sauces, soups, and functional drinks, making them an ideal solution for modern food and beverage manufacturers seeking high-efficiency, low-loss thermal processing systems.
The variation in UHT temperature ranges mainly depends on the type of sterilizer used in the line. Each sterilizer features a unique heat exchange structure, which determines its heating efficiency, product handling ability, and suitable applications:
Tube-in-Tube Sterilizer:
Typically operates between 85°C–125°C. Ideal for high-viscosity products like fruit puree or fruit and vegetable paste. Offers gentle heating and low risk of fouling.
Tubular Sterilizer:
Covers a broader range of 85°C–150°C. Suitable for moderately viscous products, such as juice, juice with pulp, etc.
Plate Sterilizer:
Also operates from 85°C–150°C. Best for low-viscosity, homogeneous liquids, such as milk, tea, and clear juices. Offers high heat exchange efficiency.
Direct Steam Injection (DSI) Sterilizer:
Reaches 130°C–150°C+ instantly. Ideal for heat-sensitive products that require rapid heating and minimal flavor change, like plant-based product, milk, etc.
Choosing the appropriate sterilizer ensures processing efficiency, thermal safety, and product quality retention.
In aseptic processing, the choice of the filling system directly impacts product taste, product color, safety, shelf life, and packaging flexibility. Whether you're working with fruit and vegetable juice, puree, dairy, or plant-based beverages, selecting the right aseptic filler ensures contamination-free packaging and long-term ambient storage.
There are two common types of aseptic bag fillers:
Single-head fillers – ideal for small-scale production or flexible batch runs.
Double-head fillers – designed for high-capacity, continuous filling with alternating bags. Its maximum filling capacity could reach 12 tons per hour.
EasyReal’s Aseptic Filling Systems support a wide range of container types, including:
Small aseptic bags (3–25L)
Large aseptic bags/drums (220–1000L)
All aseptic filling systems can be seamlessly integrated with UHT sterilizers.
Need help choosing the right aseptic filler for your liquid product? Contact EasyReal for tailored solutions.
EasyReal Aseptic Filling Lines are suitable for processing a wide variety of liquid food and beverage products, ensuring long shelf life, stable quality, and ambient storage. Typical applications include:
Fruit and vegetable juices & purees & paste
e.g., apple juice, orange juice, mango puree, different berries puree, carrot puree and juice, tomato paste, peach and apricot puree and juice, etc.
Dairy products
e.g., milk, flavored milk, yogurt drinks, etc.
Plant-based beverages
e.g., soy milk, oat milk, almond milk, coconut milk, etc.
Functional and nutritional drinks
e.g., vitamin drinks, protein shakes, electrolyte beverages, etc.
Sauces, pastes, and condiments
e.g., tomato paste, tomato ketchup, chili paste and chili sauce, salad dressing, curry paste, etc.
With EasyReal Aseptic filling lines, these products can be packaged aseptically and stored without preservatives, reducing storage costs and logistics transportation costs while maintaining product integrity.
Industrial- Sterilization processing
Delivers precise temperature processing with accurate retention time control, ensuring microbial safety while preserving natural flavor, color, and nutrition.
Flexible Sterilizer Options
Supports four types of sterilizers—tubular, tube-in-tube, plate, and DSI(direct steam injection and direct steam infusion)—to meet different viscosity, particle content, and thermal sensitivity requirements.
Integrated Aseptic Filling System
Works seamlessly with single-head or double-head aseptic bag fillers, compatible with 3–1000L bags, drums.
Advanced Automation & Control
Built with a smart PLC + HMI platform, enabling real-time monitoring, multi-recipe management, alarm detection, and user-friendly interface operation.
Optional Functional Modules
Expandable with:
Vacuum deaerator – for oxygen removal
High-pressure homogenizer – for stable texture
Multi-effect evaporator – for inline concentration
Full CIP/SIP Integration
Equipped with fully automated Clean-in-Place (CIP) and Sterilize-in-Place (SIP) systems to meet global food hygiene standards.
Modular & Scalable Design
The production line can be easily expanded, upgraded, or integrated into existing processing plants.
Premium-Grade Components
Core parts come from Siemens, Schneider, ABB, GEA, E+H, Krohne, IFM, SpiraxSarco and other international brands, ensuring durability, serviceability, and global support.
The Smart Control System developed by Shanghai EasyReal Machinery ensures precise, reliable, and user-friendly operation of UHT processing lines and related equipment. Built on a modern automation architecture, it integrates a PLC (Programmable Logic Controller) with an HMI (Human-Machine Interface) to control and monitor the entire process.
Key Capabilities:
Real-Time Monitoring & Control
Monitor temperature, pressure, flow rate, valve status, and system alarms in real time via an intuitive touchscreen HMI interface.
Multi-Product Recipe Management
Store and switch between multiple product formulas. Quick batch changeover minimizes downtime and maximizes consistency.
Automatic Fault Detection & Interlocks
Built-in interlock logic and error diagnostics help prevent unsafe operations. System automatically records, reports, and displays fault history.
Remote Diagnostics & Data Logging
Supports data archiving and remote access, allowing EasyReal engineers to perform online diagnostics, upgrades, and technical support.
Global-Grade Electrical Components
All sensors, actuators, drives, relays, and panels use top-quality components from Siemens, Schneider, IFM, E+H, Krohne, and Yokogawa for maximum durability and system safety.
Selecting the right aseptic filling lines is crucial for liquid food manufacturers aiming to ensure product safety, shelf stability, and production efficiency. The ideal configuration depends on several key factors:
Product type and viscosity: Clear juices may require plate type Aseptic Filling Lines, while viscous or particulate products like mango puree or oat milk are better processed with tube-in-tube Aseptic Filling Lines.
Sterilization goals: Whether you're targeting UHT (135–150°C), HTST, or pasteurization, the selected line must support your required thermal process.
Filling requirements: Integration with aseptic bag-in-box or bag-in-barrel fillers is essential for long-term storage without refrigeration.
Cleaning and automation needs: Modern aseptic filling lines should offer fully inbuilt CIP/SIP capability and PLC+HMI automation to reduce labor and downtime.
At Shanghai EasyReal Machinery Co., Ltd., we offer modular Aseptic Filling Lines that can be tailored to your specific liquid product—from fruit and vegetable juice and puree to plant-based beverages and sauces. Contact us for technical consultation and turnkey processing solutions.
Upgrading your UHT processing line with optional functional modules can significantly boost product quality, processing flexibility, and production efficiency. These add-on systems are especially useful when dealing with high-value beverages or complex recipes.
Common optional units include:
Vacuum Deaerator – removes dissolved oxygen, reduces oxidation, and improves shelf stability.
High-Pressure Homogenizer – creates a uniform product texture, improves emulsion stability, and enhances mouthfeel.
Multi-Effect Evaporator – allows inline concentration for juices and purees, reducing volume and packaging cost.
Inline Blending System – automates the mixing of water, sugar, flavor, and active ingredients.
EasyReal offers complete integration of these modules into existing UHT and aseptic filling lines. Each component is selected based on your product type, batch size, and hygiene requirements, ensuring maximum process control and food safety.
Looking to expand your aseptic filling line system? Let EasyReal tailor the right configuration for your production goals.
After equipment production and shipment, EasyReal provides full technical support to ensure a smooth start-up. Allow 15–25 working days for:
On-site installation and commissioning
Multiple trial production runs
Operator training and SOP handover
Final acceptance and transition to commercial production
We provide on-site support or remote guidance, along with full documentation, safety checklists, and maintenance toolkits.
Need a Customized Aseptic Sterilization Filling Line Plant for Your Product?
Shanghai EasyReal Machinery has successfully delivered turnkey Aseptic UHT processing lines in over 30+ countries, supporting products from fruit juice, puree and paste to plant-based drinks and sauces.
Contact us today to receive a personalized flowchart, layout design, and project quote tailored to your production needs.
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