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:
- Thermoforming moulding: The plastic film is subjected to heat and moulded into trays or
pockets.
- Filling: The food item,
whether cheese, meat, or bakery foods, is filled into the moulded cavity.
- 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.
- 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
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.
