From Spoilage to Savings: Thermoforming MAP Technology

 

Each year, food waste leads to massive losses for the food industry. Perishable foods like fresh fruits and vegetables, meat, and milk products have a very short shelf life, which results in excessive wastage, unhappy customers, and eroding profits. Stock quality becomes difficult for retailers to manage, while manufacturers fight increasing losses from unsold or returned items. Consumers get affected through decreased confidence in packaged food and a blow to their shopping experience.

The solution lies in Thermoforming Modified Atmosphere Packaging (MAP), a revolutionary technology that is transforming food packing, preservation, and delivery. By establishing a controlled atmosphere within the pack and precisely sealing it, thermoforming MAP not only enhances shelf life but also preserves taste, texture, and freshness.

This subject is more relevant today than ever before. With growing demand for packaged food of high quality, rigorous food safety standards, and increasing focus on minimizing wastage, Thermoforming MAP technology is proving to be a game-changer for food manufacturers, retailers, and consumers.

What is Thermoforming MAP Technology?

Thermoforming MAP technology is a convergence of two dominant technologies: thermoforming and modified atmosphere packaging. It is a process that starts by heating a plastic film to the extent that it is pliable, then forming it into a thermoforming tray or pocket that contains the food item. After putting the product inside, the atmosphere is changed with a precisely formulated gas mixture, and the pack is closed to seal the freshness in.

The procedure depends on three main elements; Gas mixers, Barrier films and Sealing systems. These elements provide appropriate proportions of gas, prevent oxygen, moisture and impurities from entering and ensure tamper-proof packaging.

Nowadays, thermoforming MAP systems are automated and provide thermoforming vacuum packaging machines, high-speed conveyor belts, and advanced sealing stations. The machines, unlike simple vacuum packing food bags, not only evacuate air but also fill the place with a protective atmosphere.

How Thermoforming MAP Technology Works

The magic of modified atmosphere packaging food happens through the science of gases. Various products need various compositions of gases to remain fresh. For instance:

●       Nitrogen: Pushes out oxygen and prevents oxidation.

●       Carbon dioxide: Suppresses microbial growth.

●       Oxygen: Use in a controlled quantity to maintain the red meat colour.

The packaging process is usually composed of the following stages:

1. Thermoforming moulding: The plastic film is subjected to heat and moulded into trays or pockets.
2. Filling: The food item, whether cheese, meat, or bakery foods, is filled into the moulded cavity.
3. Gas flushing/vacuuming: Vacuuming or flushing the pack with gas is done. Devices such as commercial vacuum packaging machines or packing vacuum machines remove air effectively.
4. Sealing: The pack is sealed with a further film layer, guaranteeing an air-tight seal.

Automation makes this process seamless. Thermoforming machine manufacturers in India such as Nichrome create equipment with programmable parameters so that each pack is uniform. Whether it is sausage packaging, corn packing, or vacuum packing machine for grains, thermoforming MAP is tailored to different product requirements.

This combined action of vacuum and gas control helps the food products stay safe, fresh, and good-looking during storage and transportation.

Conventional Packaging vs Thermoforming MAP Technology

Benefit	Conventional Packaging	Thermoforming MAP Technology
Shelf Life	1–3 days	7–21 days (depending on product)
Spoilage	High	Significantly reduced
Appearance	Can deteriorate quickly	Maintains freshness and visual appeal
Transportation Loss	Moderate	Minimal
Compliance	Basic hygiene	Food safety and hygiene standards

Benefits of Thermoforming MAP Technology

The benefits of thermoforming MAP extend far beyond just shelf life:

●       Extended Shelf Life: Products stay fresh for much longer than with conventional packs. For example, meat and cheese can be kept fresh for weeks.

●       Less Food Waste: Longer-life products translate to fewer returns, less spoilage, and improved inventory control.

●       Improved Product Quality: Taste, texture, and appearance are not compromised. Unlike plain vacuum packaging machine processes, MAP prevents discoloration and moisture loss.

●       Cost Savings: There is less spoilage, so businesses save a lot on disposal costs for waste and replacement. Even the cost of the vacuum packing machine recovers easily through lesser losses.

●       Sustainability: Less food spoilage means fewer resources wasted during production, packaging, and transportation. Paired with reusable films, MAP also aids in environmentally friendly packaging.

This renders thermoforming MAP an excellent option for producers expanding operations with vacuum sealing machine industrial arrangements or combining vacuum packing machines with nitrogen flushing for further preservation.

Applications of Thermoforming MAP Technology

Thermoforming MAP is not a universal solution. It is customized for various food categories:

●       Meat and Poultry: Meat packs and sausage packs are commonly packaged using MAP. The controlled atmosphere preserves meat's red appearance and freshness, inhibiting microbial growth.

●       Dairy Products: Cheese, paneer, and butter are kept fresh for longer. In contrast to basic vacuum machines for packing, mould development is avoided and flavour loss prevented through MAP.

●       Ready-to-Eat Meals: MAP helps to increase the shelf life of packaged meals and snacks so that retailers can keep up with the escalating demand for convenience foods.

●       Bakery Products: Bread, cakes, and pastries gain from less staling and mould prevention.

●       Fresh/Cut Fruits and Vegetables: From corn packing to salads, MAP preserves crispness, colour, and nutrition.

 

 

Why Use Nichrome for Thermoforming MAP Technology

●       Established expertise: Years of leadership in automated packaging solutions.

●       Adaptable machines: Versatile formats, ranging from vacuum pack machines for food to thermoforming food packaging systems.

●       High precision & hygiene: Innovative sealing, uniform gas flushing, and adherence to global food safety standards.

●       Scalability: From a small unit to a massive production line, Nichrome provides thermoforming machine solutions that fit every budget and requirement.

Practical Tips for Implementation

●       Evaluate product requirements: Different products demand various gas blends and package designs.

●       Line and space integration: Make sure your facility has space to fit in the size of a thermoforming vacuum setup.

●       Operations & maintenance: Choose a good partner such as Nichrome, who not only supplies machines but also performs after-sales service and training.

●       Budget wisely: Compare the vacuum packing machine cost with projected savings in spoilage avoidance.

 

Conclusion

From increasing shelf life to saving money, thermoforming MAP technology is shaping the future of food packaging. By leveraging the strengths of vacuum packing machines and the science of gas-controlled environments, it provides unparalleled efficiency, cleanliness, and cost savings. For companies, it means lower losses, increased customer confidence, and a healthier bottom line.

With sustainability at the forefront of the food business, minimizing food loss is just as crucial as utilizing environmentally friendly materials. MAP technology speaks directly to this issue, and it is therefore a future-thinking solution for food manufacturers and retailers.

The future is bright: food companies that adopt innovation such as thermoforming MAP will lead in quality, profitability, and sustainability. Nichrome, with its expertise from thermoforming machine manufacturers in India, stands by to join forces with you on this journey.

FAQs

Q1. How does MAP prolong the shelf life of food products?

By substituting oxygen with gases such as nitrogen and carbon dioxide, MAP slows microbial growth and inhibits oxidation.

Q2. What types of foods benefit from MAP technology?

Meat, dairy, bakery products, fruits and vegetables, and even RTE meals. Vacuum packing machines for jars or vacuum sealing machines for glass bottles take this to specialized segments.

Q3. How do Thermoforming MAP machines automate the process?

These machines automatically form trays, fill them, flush gases, and seal, providing precision and hygiene.

Q4. What are the environmental benefits of MAP technology?

Less spoilage means reduced food waste, conserving resources and fostering sustainability.

Q5. How can businesses select the right MAP machine?

Consider product type, scale of production, available space, and compare offerings of credible thermoforming machine manufacturers like Nichrome.

 

QUALITY CONTROL IMPERATIVES IN MAP PROCESS

 

The hygiene and safety considerations while packaging of ready-to-eat foods is of paramount importance. Modified Atmosphere Packaging (MAP)is a means of ensuring that the safety and hygiene of the ready to eat food is preserved during transit and distribution.

The importance of maintaining food safety throughout the supply chain, including during packaging and distribution is evident. Packaging ready to eat foods helps extend their shelf life and protects them from contamination, vermin attacks, pilferage, rancidity, and many other forms of spoilage and taste loss. 

Packaging of ready to eatfoods also paves the way for protection of the packaged food during transportation. It is an excellent means of communicating to the customer of the goodness of the packaged ready to eat food inside by printing the product information on the outer cover. MAP also provides consumers with valuable information, such as nutritional information, origin, and safe handling instructions. 

Safety Imperatives 

The role of MAP in reducing the risk of foodborne illness and extending the shelf life of ready-to-eat foods is well known across the world. The need to follow food safety regulations and guidelines when using MAP, including labelling requirements and the use of approved packaging materials is an imperative. 

The potential for MAP technology to impact the sensory qualities of ready-to-eat foods, including taste, texture, and appearance, is bespoke. There is a dire need to carefully control the packaging process to preserve these qualities of the packaged food. With MAP technology there is also a reduced need for adding preservatives to the ready to eat food. 

Leak Testing 

Leak testing prevents needless returns, loss of prestige, legal consequences and worst case, loss of business. To optimise quality assurance, the user can choose between solutions for sample or in-line testing – based on CO₂ or a water bubble test. 

Package leak detection systems reliably detect even the smallest leakand are easy to operate. Furthermore, all tests can be digitally logged and documented for customers. 

System Maintenance 

Right from the point of mixing the gases and introducing them into the package, maximum care is required. A faulty mixture or a leaking packet can have serious effects. It can cause loss of nutrients, taste, colour or structure to a bad smell or infestation with micro-organisms. Health risks to the consumer can be eliminated by testing the MAP product.MAP therefore requires modern high-quality equipment and uncompromising standards of hygiene. 

So comprehensive quality assurance activities are essential. These can begin during the packaging process, using inline gas analysis, which constantly monitors the composition of the modified atmosphere. 

Tests 

After packaging, the packages must be tested for the correct gas mixture and for leaks. Only with this level of rigour can it be ensured that the full benefit of MAP is achieved, and that the customer receives a top-quality product. 

The importance of maintaining the cleanliness and sanitation of
modified atmosphere packaging equipment to prevent contamination of the packaged food cannot be undermined. The potential for MAP packaging to cause food waste if not properly handled and stored, and the need to consider this in the packaging process should not be neglected. 

Gas Monitoring 

Gas monitoring systems for ambient air protect employees and make the use of gases such as carbon dioxide safer. This is not toxic but accumulates unnoticed in closed rooms and replaces the oxygen in the air. A concentration of 0.3 percent carbon dioxide in ambient air can be a health hazard. The allowed maximum concentration in the workplace is 0.5 percent. 

At five percent, headaches and dizziness may occur; eight percent and more leads to unconsciousness or even death. The gas level warning unit permanently monitors the concentration of the respective gas in the ambient airand activates an acoustic and visual alarm when individually definable limits are exceeded. For food and vegetables, controlled atmospheres are not just used in packaging but also for the control of ripening control, in special ripening chambers with the help of ethylene. 

Consumer Education 

The role of consumer education in promoting the safe handling and storage of MAP ready-to-eat foods is a must. The consumer needs to be informed of the ingredients that the ready to eat food contains, nutrition facts, expiry date, to make a buying decision. All this information must be printed on the label. The label should also carry information on the possibility of causing allergies by eating the packaged product. 

Nichrome MAP Solutions 

If you are looking for a thali packing machine, tray sealing machine, container sealing machine, nitrogen packing machine, or a food tray sealing machine with MAP technology – a.k.a controlled atmosphere packaging – for your fresh food Nichrome is the ideal choice.Nichrome India is the final word in packaging machines, automatic filling machine manufacturers, filling and sealing machine manufacturers and providers of integrated packaging solutions.

With MAP tech, Nichrome puts India on World Map at WMNC 2022

 

Nichrome India Private Limited is counted among world’s leading makers of integrated & automated packaging solutions for a whole range of use cases including food processing, non-food packaging and pharmaceuticals packing.

At Nichrome, innovation is a part of our DNA. Since our pioneering beginning in 1977, we have been endlessly innovating and upgrading offerings to solve packaging industry challenges and deliver greater business value to our customers with our next gen integrated packaging solutions.

Our innovation is founded on Expertise, Partnership, Forward-thinking and Technology. Supported and strengthened by these four pillars, we are perfectly poised to cross new frontiers in performance, accuracy, and solution development.

Nichrome India leads the pack in the packaging industry with innovative packing, sealing, filling and cartoning systems. Nichrome has a plethora of systems for product handling, primary & secondary packing, end-of-the-line packing, warehousing, and track & trace.

MAP Technology in Action

Nichrome’s modified atmosphere packaging (MAP) for mithai and namkeen and food tray sealing machines are commendable. Nichrome is miles ahead of the competition in producing filling and sealing machines in India.

Thermoforming machines from Nichrome can also produce packaging with vacuum skins. The product is placed in a tray or a preformed packaging mould and is then sealed with skin film. This allows the safety of packaged products in a variety of shapes (as they were given a ‘second skin’). The product is untouched by human hands, and the MAP sealing process ensures longer shelf life.

Whether you use MAP technology for mithai & namkeen packaging or dairy products – the contents are assured of hygiene and freshness. For SMEs in the Indian mithai & namkeen segment, MAP technology from Nichrome is a godsend.

MAP is a pathbreaking packaging solution for convenience and presentation of mithai, dry fruits, namkeen and confectionery. It is highly valued when packed in elegant trays and beautifully decorated outer cartons.

WMNC Expo 2022

World Mithai-Namkeen Convention & Expo 2022 (WMNC-2022) which is being held in Chandigarh from December 19-21, is expected to host over 300+ exhibitors and draw 25000+ visitors and delegates from across the country & overseas.

WMNC is the singular event where one can find all solutions related to the mithai & namkeen industry under one roof. From packaging automation machinery to packing materials, raw materials for ingredients, WMNC-2022 is the hottest place to go this year.

WMNC 2022 is a unique show for the entire traditional sweets and namkeen industry. It represents the Indian sweets & snacks Industry which is worth Rs 100,000 crore. WMNC 2022 will host seminars & workshops and conclude with an award ceremony for different categories.

Mithai & Namkeen Segment

Mithai & namkeen segment is at the nascent stage of branding and its true potential is yet to be explored. Mithai & namkeen manufacturers are slowly but surely realizing the need for better quality packaging that protects their products and offers protection during transportation (secondary packing).

Even smaller mithai-walas with local clientele are considering modern snack packaging machines to ensure the hygiene and shelf-life of their products. As the preference of consumers is shifting from the unorganized sector to the organized, brand and quality consciousness has shot up tremendously.

Accordingly, brands need to focus on ensuring that their primary, secondary, and tertiary packaging authentically reflects the quality of their mithai and namkeen products.

This is more applicable to the food sector, where buying decisions are often impulse based. Food processing giants like ITC and Parle are already giving foreign companies like Pepsi Foods intense competition.

 

 

Nichrome’s MAP for Mithai & Namkeen

Modified Atmosphere Packaging (MAP) is a widely used technique for food preservation. MAP in tray sealing machines is gaining popularity as a method of preserving freshness and lengthening shelf life of fresh foods, fruits, vegetables, meat, and dairy products.

It is the preferred manner of preventing spoilage and extending the shelf life of mithai and namkeen products. MAP also helps shops sell Indian mithai and namkeen in stores located on highways where travellers stop for refreshments, and a multitude of other places within cities.

Nichrome’s MAP and food tray packaging solutions are products to reckon with. They are deemed ideal for tray sealing and packaging mithai and namkeen products.

Nichrome’s MAP food tray sealing packaging machine uses technology from Tecnovac, Italy and is the ideal choice for food tray and mithai and namkeen packaging.

This machine can seal, pack in a protective atmosphere (vacuum and gas) or with "skin effect". Due to its strong stainless-steel structure and easy maintenance, it is ideal packaging for SME use.

For marketers of cut fruits & vegetables, meat & fish, namkeen & sweets and even ready-to-eat meals like biryani, Nichrome’s MAP tech ensures that products are hygienic till they reach the consumer's table.

Conclusion

If you are looking for a thali packing machine, tray sealing machine, container sealing machine, nitrogen packing machine, or a food tray sealing machine with MAP technology – a.k.a controlled atmosphere packaging – for your fresh food and mithai and namkeen business, Nichrome is the ideal choice.

Nichrome India is the final word in packaging machines, automatic filling machine manufacturers, filling and sealing machine manufacturers and providers of integrated packaging solutions.