A New MAP for Natural Products Packaging

Consumer demand for more organic, natural, fresh and locally manufactured food continues to drive a new revolution in food and food-related packaging, modified atmosphere packaging (MAP).

MAP, the process of modifying the composition of the internal atmosphere of a sealed package in order to improve the product’s shelf life, is by no means new. In fact, it has been in practice for decades primarily in the food industry. The concept is relatively simple: reduce the amount of oxygen in the package, replacing it with an inert gas such as carbon dioxide or nitrogen, and the product inside will be less susceptible to ill-effects, such as causing fresh-baked products going stale or fresh-cut fruit changing color. An oxygen-rich environment is a breeding ground for various molds and bacteria that can quickly multiply and cause food products to spoil. MAP is a proven method to inhibit oxidization, bacteria and mold growth and can increase a products shelf life from a few days to years depending on the nature of the product, the mixture of gas and the properties of the packaging materials.

MAP is finally breaking through into mainstream food packaging thanks to advancements in both the materials and the technology used to apply it. More food manufacturers are using lightweight rigid trays or cups to pack food products. These trays and cups are inexpensive to manufacture, are very often recyclable and can be engineered for the right barrier and protective properties for the food products they contain.

MAP equipment is also advancing favorably. Specifically, a new advancement by the Israeli company Hefestus LTD called SLB™ (Shelf Life Booster™) is able to achieve an oxygen residual of less than 0.5 percent using a unique and patented gas flush method. This new technology is in wide use already by food manufacturers throughout Israel, Europe, Asia and Africa who recognize the unique ability to pack absolutely any food product in a modified atmosphere, thereby having great effect on that product’s longevity.

To date, there are three primary methods of applying MAP. Vacuum, vacuum-gas and gas flush. While these methods are very effective in applying the modified atmosphere they are also the reason that MAP is not more widely used in today’s market place. The vacuum and vacuum gas methods employ a high-powered vacuum system to remove the entire atmosphere in a package and then either seal or back flush with inert gas and seal the package. Gas flush simply puts the product into a gas-rich environment and then seals the package. Each method, while highly effective, has its flaws.

The pressure the vacuum process has on the product is a major short coming. The vacuum force necessary to keep up with today’s production environments is so strong that very few products are actually good candidates. The vacuum will actually destroy the texture and appearance of a product not to mention that particles such as crumbs, powder and liquids can be sucked up into the equipment causing costly damage and contamination.

Similarly limited is gas flush, with which it is very difficult and costly to achieve oxygen residuals of less than 4 percent. Gas flush systems are gentler on the product compared to a vacuum process; however, the apparatus required to effectively remove the oxygen content is large, costly to operate and at times requires special filtration to protect machine operators from the carbon dioxide that is very common in MAP.

The economic and social benefits of the new shelf life-extending MAP technology are just starting to hit the U.S. market. Extended shelf-life means the odds that product sells every day it is allowed to remain on the shelf increases exponentially. In addition, the entire supply chain can be leaner and more cost effective as MAP will allow food processors to streamline their labor and distribution operations. Consumer needs are also met as food processors now have the ability to reduce the amount of preservative ingredients in any given product and still preserve valuable shelf life.

This shelf-life extending MAP also allows products that have never traditionally been MAP candidates to be packed in light weight, eco-friendly materials. For instance, a vacuum will absolutely destroy a fresh-cut fruit product. The juice is extracted and the texture of the fruit is destroyed. With the new MAP, a specific mix of inert gases can be introduced to a sealed cup or tray with absolutely no vacuum effect. Furthermore, the shelf-life in most cases can be almost doubled compared to fresh-cut fruit that is not packed in MAP. This represents a significant boost in saleable product and savings in labor and distribution.

In addition to fresh fruit, the possibilities for MAP now appear endless. If you can put it into a tray or a cup, it can be MAPed. In addition to fresh fruit and vegetables, products such as nuts, soup mixes and fresh soups, spreads, dips, sauces, dressings, spices, cheeses, creams, liquors, ready meals, baked goods, airline meals, fresh fish, fresh meats and many more are being packed using the new MAP technology. In addition to food products, MAP is slowly branching out into other industries such as pharmaceuticals, nutraceuticals and even electronics.

Greg Levy is director of marketing and distributor development at ARPAC-Hefestus USA, a wholly owned subsidiary of ARPAC LP, a premium manufacturer of end of line packaging equipment located in Schiller Park, Ill., and Hefestus USA, as subsidiary of Hefestus Ltd. of Israel and originators of SLBTM technology. For more information please visit www.arpachefestus.com.