As the demand for safe, efficient, and sustainable beverage packaging continues to rise, Serac – a global leader in aseptic and ESL (Extended Shelf Life) packaging – has introduced its latest breakthrough in sterilisation technology: BluStream™, a next-generation cap decontamination solution that combines advanced safety with environmental responsibility.

Proudly represented in the UK and Ireland by Evolution BPS, a trusted long-term partner of Serac, this innovative solution is now available to beverage manufacturers seeking to future-proof their aseptic filling operations.

Compact, Capable, and Completely Chemical-Free

BluStream™ brings unmatched versatility to the packaging line. Designed for both high- and low-acid beverages, the module can be fully integrated into new Serac filling systems or retrofitted onto existing lines, regardless of the original equipment manufacturer. BluStream™ requires just 3 m² of floor space and delivers a throughput of up to 600 caps per minute, making it ideal for high-output operations with space constraints.

A Physical Process That Preserves Cap Integrity

Utilising low-energy electron beam (e-beam) technology, BluStream™ sterilises caps through a clean, physical process that occurs at room temperature. The electrons deactivate microorganisms on the surface by disrupting their DNA, achieving a 6-log bacterial reduction in just 0.3 to 0.5 seconds. Crucially, this method is non-invasive – the beam does not penetrate the material, ensuring the cap’s structure and closure integrity are preserved.

Operational Simplicity, Proven Safety

BluStream™’s operating principles are built on simplicity and control. The sterilisation dose is governed by three key parameters: voltage, current intensity, and exposure time. Real-time dosimetry verifies the accuracy of each dose, removing the uncertainty of delayed lab testing and reducing the risk of under- or over-treatment.

The absence of chemicals such as hydrogen peroxide (H₂O₂) or APA eliminates the possibility of harmful residues, offering peace of mind to both manufacturers and end consumers.

Healthier for Operators, Kinder to the Environment

By removing heat and hazardous chemicals from the equation, BluStream™ contributes to a safer, quieter, and more comfortable work environment. It generates no odours and produces only a minimal amount of ozone as a byproduct, which is safely extracted and naturally dissipated.

Environmentally, BluStream™ stands out for its minimal resource consumption: it requires no water, no steam, and generates zero chemical waste. Its low energy demand positions it as a genuinely sustainable alternative to traditional sterilisation methods.

Field-Proven Performance

BluStream™ has already demonstrated its reliability in industrial settings. At Sources Alma, a leading beverage producer, the technology is currently in daily use, sterilising over 30 million caps annually on a flavoured still drink production line.

Fully compatible with a wide range of cap materials — including HDPE, LDPE, PET, PP, and aluminium — BluStream™supports bottles of all sizes, giving manufacturers the flexibility to standardise sterilisation across their product portfolio.

For beverage producers looking to elevate their aseptic capabilities while meeting growing sustainability and safety standards, BluStream™ represents the next evolution in cap sterilisation

In the UK Evolution BPS works in partnership with Serac, as well as with a range of other original equipment manufacturers (OEMs) across the filling and packaging process. This collaborative approach allows Evolution BPS to deliver integrated, end-to-end solutions tailored to the specific needs of each client, ensuring efficiency, reliability, and innovation at every stage of the process.

If you have a project you would like to discuss, please contact us at dylan@evolutionbps.co.uk