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.

MAP Technology and its Benefits for Your Packaging Operations

 

MAP or Modified Atmosphere Packaging is a widely used technique of preservation when it comes to food packaging. MAP technology like that in a tray sealing machine is gaining more and more popularity as a method of preserving freshness and lengthening the shelf life of fresh foods - fruits, vegetables, meat, dairy products and more. It is a notable method of preventing spoilage and extending the shelf life of various food products.

So what is MAP technology? 

Atmospheric air is a combination of 3 elements - N2 (79%), O2 (20.96%), CO2 (0.04%) and traces of inert gases and vapour. 

MAP packaging, sometimes known as controlled atmosphere packaging, is the method of modifying the makeup of the internal atmosphere of a package using a modified atmospherepackaging machine - usually food packages and medicines - in order to improve the shelf life of the packed products. 

This technology was developed to deal with the short shelf life of certain food products such as meat, fish, poultry and dairy in the presence of oxygen. The presence of oxygen in the packaging leads to the lipid oxidation of the food product. Oxygen contributes to the shortened shelf life of fresh produce because it leads to high respiration rates. Even microbiologically, Oxygen catalyses the growth of aerobic spoilage microorganisms.

 It is plainly obvious that a reduction in oxygen and its replacement with more suitable gases can deter or reduce oxidation reactions and microbiological spoilage.

 MAP food packaging using a MAP tray sealer generally involves the lowering of the amount of oxygen in the headspace within the package. Nitrogen - a comparatively inert gas - or carbon dioxide can be used to replace oxygen. 

The use of active techniques such as gas flushing and compensated vacuum, or passive ones like designing ‘breathable films’ can be used to achieve a stable atmosphere of gases inside the packaging. 

The different components of MAP Technology 

1.    Machine

2.    Gas mixer

3.    Gas analyser

4.    Trays

5.    Barrier film 

Why MAP Technology? 

●     Convenience

●     Quality

●     Safety

●     Availability

●     Brand image

●     Extended shelf life

●     Sensory aspects 

Advantages of MAP Technology 

●     Maintaining the quality throughout the manufacturing process (GMP) (GHP)

●     Maintaining protocols for food safety and HACCP

●     Consistent productivity with limited manpower

●     Can handle a variety of products and is capable of handling different SKU sizes 

Benefits of MAP Technology 

●     Shelf-life extension

●     Waste minimisation (profit maximisation)

●     Quality

●     Reduced need for artificial preservatives, maintaining the

●     Increased distribution possibilities 

Why maintain gas mixtures?

 

	Advantages/Benefits	Limitations	Effect on product
Carbon dioxide	•       Inhibits growth of most aerobic bacteria •       Extended shelf life	•       CO2 is readily absorbed by fats and water	•       Flavor tainting •       Drip loss
Nitrogen	•       Inert gas •       Used to exclude air/oxygen •       Used as balanced gas, maintain the %
Oxygen	•       Maintain fresh natural colour •       To maintain respiration •       To inhibit the growth of anaerobic bacteria	•       High O2 levels damage the vital cellular macromolecules, inhibiting microbial growth	•       Deterioration •       Reduced shelf life

 

How does MAP control micro-organisms?

MAP can control 4 types of micro-organisms:

•       Aerobic Microbes – require oxygen or air for respiration and growth    

•       Anaerobic Microbes - do not require oxygen or air to grow     

•       Microaerophilic Microbes – require a low level of oxygen for optimum growth

•       Facultative Anaerobic microbes - can respire and grow with/without the presence of oxygen 

MAP for shelf-life and food spoilage

•       Remain safe

•       Be certain to retain desired sensory, chemical, physical and microbiological characteristics

•       Comply with any label declaration of nutritional data when stored and handled under the recommended data 

Factors that influence shelf-life

●     Raw materials

●     Product formulation

●     Processing

●     Packaging atmosphere

●     Hygiene

●     Distribution

●     Storage

●     Consumer handling 

Nichrome’s MAP Tray Sealing Machines

●        Nichrome – Tecnovac Semiautomatic Tray sealing machine
 

●        Nichrome – Tecnovac Linear Machine model Athena

●        Nichrome – Tecnovac Dual Drive Machine model Athena

Conclusion

If you are looking for a thali packing machine , tray sealing machine, container sealing machine, nitrogen packing machine, or a food tray sealingmachine with MAP food packaging technology - aka controlled atmosphere packaging - for your fresh food business, connect with Nichrome.

Nichrome is among the leading packaging machine manufacturers, Automatic filling machine manufacturers, filling and sealing machine manufacturers and providers of integrated packaging solutions. Nichrome has an illustrious history and significant expertise in food packaging and offers the full range of VFFS (Vertical Form Fill Seal Machines), HFFS (Horizontal form fill seal machines) and automated packaging machines - including powder packaging machines, snack packaging machines, liquid packaging machines, pharmaceutical packaging machines and ready-to-eat packaging machines.

Nichrome proactively works in conjunction with its clients, helping them plan and implement the most cost-effective and dependable MAP solution for their needs. 

Visit www.nichrome.com to learn more!

ADVANTAGES OF MAP FOOD PACKAGING

 

MAP or Modified Atmosphere Packaging is a widely used technique of preservation when it comes to food packaging. It is a notable method of preventing spoilage and extending the shelf life of various food products. 

Modified Atmosphere Packaging and food tray sealing machines became especially essential during the COVID-19 pandemic as customers were instructed to leave their homes only when necessary, so many people began stocking up on food products with longer shelf lives. This resulted in an extensive increase in demand for packaged food products that were packed using MAP technology. 

What is MAP exactly? 

Modified Atmosphere Packaging includes either actively or passively modifying the atmosphere surrounding the product in the interior of a package made of various types and/or combinations of films. 

Modified atmosphere packaging machines India come in two kinds: Passive and Active. An active modified atmosphere packaging is the process in which the displacement of gases in the package is done and is then replaced with a desired mixture of gases. A passive modified atmosphere packaging is when the product is packaged using a selected film type and the required atmosphere develops on its own as a consequence of the products’ respiration and diffusion of gases through the film. Another approach is to use an automatic packing machine or a tray sealer machine india to create a vacuum in the packaging hence not allowing the food to spoil.

One of the major active MAP technologies in Packaging solutions in India for food and beverage products is gas flushing. A gas flush is used for the following purposes: 

●     Displacement of oxygen inside the package to delay oxidation

●     Decreasing the development of aerobic spoilage organisms

●     Acting as a filler for maintaining package conformity 

During the gas flush procedure, a harmless gas - usually nitrogen or carbon dioxide or both - is dynamically pumped into the bag before it is sealed in order to displace ambient oxygen. The reason for this is to decrease the amount of oxygen since it is the most damaging to the freshness of the material. 

The role of nitrogen and carbon dioxide 

Nitrogen, being an inert gas, is frequently used in nitrogen packing machines and nitrogen filling machines for food packaging to displace oxygen for products which are prone to oxidation. It also acts as a filler gas to prevent the pack from collapsing. Many snack products like potato wafers rely on nitrogen flushing to ensure longer shelf life, decrease rancidity and maintain the quality of the snacks. 

Carbon dioxide is generally inserted to act as an anti-microbial agent. A minimum amount of 20% carbon dioxide is mixed with nitrogen to form anaerobic environments that inhibit the growth of aerobic microorganisms. Most commonly, raw and cooked meats, fish, ready meals, combination products and bakery goods are packed with a proportion of carbon dioxide. Carbon dioxide is usually used at levels between 25-40% but can be used up to 100% in packaging bakery goods and some cheeses to provide a longer mould-free shelf life. 

How does modified atmosphere packaging protect food items? 

The primary way in which modified atmosphere packaging by a food tray packing machine protects fresh food is by decreasing its exposure to oxygen. The presence of oxygen leads to oxidation, which causes discolouration, spoilage, and change in flavour and texture. Decreasing or regulating the amount of oxygen present in a package can ensure that the food product remains fresh longer, thereby extending its shelf life and ensuring the consistency of the food products. 

Nichrome’s MAP Offerings 

One of Nichrome’s MAP offerings in Packaging Machines India is the Athena Thermoforming Tray Sealing Machine from Tecnovac, Italy. The Athena machine is able to seal and pack in a protective atmosphere of vacuum and gas all types of trays and jars. Its strong stainless steel structure and easy maintenance make the Athena ideal for use in small and medium-sized companies. 

The Athena horizontal packaging machine ensures that the marketers of cut fruits & vegetables, meat & fish, namkeen & sweets, and ready to eat meals like biryani are able to ensure that their products stay safe and hygienic till they arrive at the consumer’s table. 

The modified atmosphere packaging machine works by extracting oxygen & carbon dioxide from the air of the trays, while synchronously filling them with nitrogen or mixed air to ensure that the food does not deteriorate, after which, the tray is sealed well. 

Conclusion

With ‘snackification’ being all the rage and the growing demand for packed foods with longer shelf lives, it is imperative that manufacturers and packagers invest in reliable MAP technology for their packaging process. MAP allows food producers to maximize convenience to consumers while still offering the fresh, preservative-free food products they desire.

We recommend that you connect with Nichrome, one of the leading packaging machine manufacturers, Automatic filling machine manufacturers, filling and sealing machine manufacturers and providers of integrated packaging solutions. Nichrome has a storied history and considerable expertise in food packaging and offers the full gamut of VFFS (Vertical Form Fill Seal Machines), HFFS (Horizontal form fill seal machines) and automated packaging machines - including powder packaging machines, snack packaging machines, liquid packaging machines, pharmaceutical packaging machines and ready-to-eat packaging machines.

Nichrome proactively works with its clients, helping them to plan and implement the most cost-effective and dependable MAP solution for their needs. 

Visit www.nichrome.com to learn more!