There’s an increasing demand for safe, long-lasting, and high-quality packaged food.
Indeed, a recent Food Standards Agency report revealed food quality as a major concern for 57% of consumers across England, Wales, and Northern Ireland.
Modified atmosphere packaging is presented as an effective solution, driving increased efficiency and accuracy through automation.
Read on as we explain the meaning of MAP and focus on the benefits of Ishida packaging technologies
What is Modified Atmosphere Packaging (MAP)?
From fresh fruit and vegetables to cheese and meat, food is susceptible to spoilage through oxidation, bacterial growth, and mould growth.
However, the spoilage risks can be effectively limited by modifying the atmosphere within the packaging.
The MAP process involves the removal of air surrounding a food product and its replacement with a controlled mixture of nitrogen (N₂), carbon dioxide (CO₂), and oxygen (O₂).
The optimised combination of these gases can make a great difference in maintaining freshness, preserving taste and texture, and minimising food waste.
MAP packaging typically involves the reduction of oxygen, which may otherwise cause the growth of bacteria and mould.
This means the shelf-life can be extended, increasing the consumer appeal and reducing waste.
Of course, there’s some variation, with oxygen essential in the preservation of red meat and fresh produce. Increased oxidation effectively prevents anaerobic growth in such instances.
Otherwise, it’s typically a matter of adding more carbon dioxide and nitrogen to inhibit the growth of bacteria and mould.
This is the case with dry foods, such as crisps and peanuts, which are relatively high in unsaturated fats.
Exposure to oxygen causes more rapid deterioration and rancidity of such food types. However, these effects can be prevented by adding a high concentration of nitrogen.
The replacement of oxygen with carbon dioxide is the most effective solution for extending the shelf life of catered foods, such as burgers and pizzas.
How Does the MAP Process Work?
Whether in the form of cylinders, cryogenic tanks, or generators, the MAP process begins with the transfer of gases to a mixer for optimal adjustment.
The correct levels may be ensured with a gas analyser, before the best mix is projected into the food packaging.
These factors have a bearing on the best choice of packaging for modified atmosphere foods:
Puncture resistance
Antifogging
Carbon dioxide and oxygen retention
Minimal water transmission rate
With any leakages having a potentially dramatic effect on food quality, it’s vital for the sealing of each food pack to be checked.
Equipped with advanced sensors, leak detection machines can be relied on for food packaging integrity.
Such machines will rapidly detect even the smallest of leaks, with any sub-standard packs being rejected from the production line.
Automation of the MAP process makes for benefits such as enhanced product quality, safety, and regulatory compliance.
This can prevent the types of inaccuracies that might otherwise lead to product recalls, reduced shelf life, and poor consumer confidence.
Modification of the gas quantities can help in maintaining the ideal product colour, texture, and flavour for consumer satisfaction and brand loyalty.
It also reduces the need for preservatives, increasing the appeal to health-conscious customers.
Realising MAP Benefits with Ishida
Developed in consultation with world-leading customers, Ishida’s range of tray sealers delivers the benefits of MAP with high speed, flexibility, and precision.
The QX-800 stands out, redefining tray sealing capabilities while ensuring optimal use of food production floorspace, materials, and budget.
Complete with revolutionary cassette tooling and quick-change format, the QX-800 has the capacity for up to 25 cycles per minute for seal-only and 17 cycles per minute for modified atmosphere packaging.
It can accommodate a range of tray sizes, with tool formatting options including gas flush, vacuum gas, and skinpack.
As Ishida’s Europe’s tray sealer product manager, Tara O’Connor, has said, the QX-800 “maximises throughput while maintaining high product and pack quality across various tray designs and materials.
In a highly competitive food market, achieving these goals is crucial as it means more efficient production while not compromising food safety and pack presentation.”
Combined with the Ishida Airscan, food producers can ensure optimum packaging integrity for extended shelf life and customer satisfaction.
Whether prioritising package processing speed or minimising food and packaging waste, for every challenge, there’s Ishida.
Get in touch for more information about our food packaging solutions.
