Revolutionary improvements to aseptic packaging with patented sterilization method

A new and economical way to sterilize flexible packaging and its contents has been developed by Performance Packaging of Nevada. The patented process features a ‘liquid-to-gas’ sterilization process that is so unique it has been code-named “Pixie Dust” by the company. Advantages of the Pixie Dust process include: A low-cost process that features GRAS (‘Generally Recognized as Safe”) materials Results of process residuals that are below the U.S. Food & Drug Administration (FDA) “Threshold of Regulation” Sterilization can occur during storage or shipping and is achieved in less than 48 hours at room temperature Use of the pixie dust procedure is smell- and taste-neutral Some products, such as dental tools, medical devices, or enclosed plastic, glass, or metal objects, can be sterilized within the package, and the method makes aseptic cold-fill processes possible. There is no need to irradiate the package nor does the package need to be hot-filled nor require the post-pasteurization of pouches, since the pouch is already sterile. Industry applications for Pixie Dust can include flexible packaging such as stand-up pouches, bag-in-box, any sealed package, military applications, dental tools and medical devices. Performance Packaging is working with various companies to identify additional markets and partners for the new aseptic process it has developed. During the extensive testing process conducted by Performance Packaging for Pixie Dust, the test organism Bacillus atrophaeus ATCC 9372 spores (which are highly resistant to heat and chemicals such as H2O2) were added to the package contents. A specific quantity of the Pixie Dust agent was then inserted into the package. After about two days, no viable spores were recovered from any of the treated samples, which included inoculations of 4-liter, hot-fill bag-in-box, 55-gallon-drum bags and 2½ gallon polyolefin milk bags. Even corners and gusset fold tests, along with laboratory-scale filling tests of treated pouches revealed no sign of bacterial growth. In addition, Pixie Dust’s new developments and improvements are underway that predict rapid, in-line sterilization prior to filling. “We are currently seeking worldwide partners in the pharmaceutical and food industries to implement this technology that crosses many platforms including device sterilization as well as the foodstuff shelf life extension,” explained Rob Reinders, president of Performance Packaging of Nevada. “This development is the direct result of the invaluable contributions of Joseph Dunn, Ph.D., who joined our company earlier this year as vice president of research and development and regulatory affairs.” Dr. Dunn has more than 30 years of experience in industrial biochemistry and microbiology relating to packaging research. He is also the inventor of the use of pulsed light for packaging sterilization and the author of more than 25 patents related to packaging industry safety processes. Throughout his career, he has worked closely with the U.S. Food and Drug Administration. “Regarding specific economic benefits of Pixie Dust, we have dramatically reduced the cost of the sterilization process to an amount of, for example, about one cent (1¢) of agent will treat approximately 750,000 pouches. In contrast, large volumes of peroxide (such as 250 gallons of very expensive, high-concentration H2O2 and hot, sterile air are required to sterilize a similar number of form-fill-seal packages,” explained Dr. Dunn. “Pixie Dust is a cost-saving alternative to traditional shelf-stable methods such as hot-filling, retort processing, peroxide or peracetic baths or sprays, irradiation, pulsed light or electron-beam irradiation.”