What is Modified Atmosphere Packaging (MAP)?

Modified atmosphere packaging, also known as modified air packaging or MAP packaging, is a type of packaging solution that’s sealed so the air inside it can be manipulated to preserve perishable contents. In this article, we’ll look at how modified atmosphere packaging works, various available types, common uses for MAP and its pros and cons.

How Does Modified Atmosphere Packaging Work?

Oxidation is the process that causes food products to turn brown and spoil. As the name suggests, oxygen is the key catalyst, reacting with food components when they come into contact. Modified atmosphere packaging prevents oxidation by modifying the chemical contents of the air surrounding what’s inside, creating an atmosphere that maintains freshness and prevents spoilage.

Types of Modified Atmosphere Packaging?

There are two main types of modified atmosphere packaging: active and passive. Active MAP actively replaces the gases present inside a package with a different, more optimal blend of gases. Passive MAP uses packaging films and other passive methods to diffuse or absorb the gases in the atmosphere naturally, creating the right environment to maintain freshness. These are some of the most common types of active and passive MAP:

• Gas Flushing
• Barrier Films
• Scavenger & Desiccant Packs
• One-Way Package Valves

Gas Flushing

Gas flushing is a process that quickly and completely removes oxygen from the atmosphere of a package by injecting, removing and reinjecting inert gases like nitrogen or carbon dioxide. This is the most common type of active MAP, actively flushing out the oxygen to create the right atmosphere.

Barrier Films

Barrier films are a type of passive MAP used to control the atmosphere from the inside by blocking out oxygen, water and other elements that can change the composition of a package’s contents. Barrier films can be made from various materials, including polyester (PET), nylon (PA) and ethylene vinyl alcohol (EVOH). They can also be made into different forms like pouches, vacuum packaging and flat bottom bags.

Scavenger & Desiccant Packs

Oxygen scavengers or oxygen absorbers are sachets containing iron powder, which actively removes oxygen from the air. Desiccant packs commonly contain silica gel or activated carbon, which passively modifies the environment by removing moisture from the air. You’ve probably seen these included in the packaging for a variety of products, from food items to electronics.

One-Way Package Valves

One-way packaging valves extend shelf-life by releasing excess carbon dioxide out of the packaging without letting oxygen in. One-way valves are often used to preserve the flavor and aroma of fresh coffee beans.

Industries That Use Modified Atmosphere Packaging

Modified air packaging is primarily used by the food and beverage industry, but it’s also being adopted by other industries whose products require a specific environment to stay fresh.

• Food and Beverages
• Cannabis
• Coffee
• Pharmaceuticals

Food and Beverages

Modified atmosphere food packaging is used to maintain freshness for a variety of perishable food and beverage products, including fresh fruits and vegetables, meat and seafood, and dairy goods like cheese and butter. MAP packaging can also maintain freshness for baked goods and ready-made meals.

Cannabis

The cannabis industry is growing nationwide, and so is the use of MAP packaging by growers, distributors and dispensaries. Cannabis can deteriorate quickly after it’s harvested if exposed to heat, light and oxygen. Modified air packaging maintains the quality, aroma and potency of cannabis by controlling this exposure. MAP use supports larger distribution areas for cannabis and allows dispensaries to keep products on the shelf longer, without affecting quality.

Coffee

Is there anything better than the smell of fresh coffee beans? It’s no wonder modified atmosphere packaging is widely used to preserve the aroma, freshness and flavor of coffee during shipment and on the shelf.

Coffee bags often feature a small one-way degassing valve, which makes it possible to package coffee beans soon after they’re roasted and capture that fresh-roasted flavor. Barrier films, oxygen scavengers and desiccant bags are also frequently used in coffee packaging to maintain freshness.

Pharmaceuticals

Certain types of pharmaceutical products, including medications and medical devices, require a controlled atmosphere to preserve quality and effectiveness. MAP packaging is used to maintain the right balance of oxygen and carbon dioxide to prevent microorganism growth and ensure drugs are still effective when they reach their destination. Barrier films, gas flushing and scavenger packs are most commonly used in the pharmaceutical industry.

Is Modified Atmosphere Packaging Safe?

Generally speaking, modified atmosphere packaging is very safe. No harmful chemicals are used to modify the environment, only harmless gases like oxygen and nitrogen. And just like any type of food packaging, the materials it’s made from have to meet stringent health and safety regulations.

However, environments that suppress the growth of microorganisms can potentially support the growth of pathogens, including some that can survive with low oxygen, like salmonella, listeria and E. Coli. Food and beverage companies should take steps to minimize this risk by reducing pH levels and moisture, and maintaining temperatures below three degrees Celsius if possible.

The Advantages of Modified Atmosphere Packaging

Modified atmosphere packaging offers a number of benefits for businesses and customers.

• Extended Shelf-Life of Product(s)
• Enhanced Product Appeal
• No Chemical Preservatives
• Sustained Nutritional Value, Flavor, and Potency
• Less Waste

Extended Shelf-Life of Products

By slowing the process of oxidation and the growth of harmful microorganisms, MAP can significantly extend the shelf-life of food and pharmaceutical products. This means businesses can ship their products in larger quantities across a wider distribution area, because they’ll stay fresh during transit and after arrival. For customers, this means more choice plus extended value for purchased goods.

Enhanced Product Appeal

Packaging can tell potential customers a lot about the product inside. By signaling freshness and safety, modified atmosphere packaging can help boost your brand reputation and make your product more appealing on the shelf.

Absence of Chemical Preservatives

Modified air packaging is good for your health, because it eliminates the need to add preservatives and other chemicals to the product itself to maintain freshness and safety. Adding “No preservatives” to your food packaging appeals to health-conscious shoppers, especially those with kids, and can give your brand a boost.

Sustained Nutritional Value, Flavor, and Potency

When you keep food and other perishable products fresh for longer periods of time, you’re also retaining all the goodness of the product longer. For food products, that means sustained nutritional value and flavor. For cannabis products, it means retaining potency, flavor and aroma. And for pharmaceutical products, extending the shelf life preserves efficacy.

Less Waste

Literally millions of tons of food waste are produced each year in the US alone. Modified atmosphere packaging for food can help reduce waste by keeping food products fresh longer, preventing spoilage and making it less likely to end up in the trash. An extended shelf life also means companies can make less frequent deliveries, which helps to reduce the carbon footprint.

The Disadvantages of Modified Atmosphere Packaging

While modified atmosphere packaging offers many benefits, there are a few drawbacks to consider, too.

• Cost and Difficulty
• Anaerobic and Psychrotrophic Pathogens
• Packaging Film and Temperature Issues

Cost and Difficulty

The equipment, processes and materials required for producing modified atmosphere packaging are complex and, in some cases, costly. Machinery that seals packaging environments and modifies the gases inside can be expensive and requires regular maintenance, which also drives up costs. Identifying and monitoring the right mix of gases for different products is also tricky, and this type of packaging requires a higher level of quality assurance than simpler options. All of these factors can lead to production and quality issues.

Anaerobic and Psychrotrophic Pathogens

Modified air packaging prevents the oxidation that signals food isn’t safe to be eaten, but may allow the growth of some types of microorganisms. Anaerobic pathogens are a type of bacteria that can thrive in low-oxygen or oxygen-free environments. Examples include clostridium, which causes infections like tetanus and botulism, and bacteroides, which can cause abscesses and infections. Psychrotrophic pathogens are bacteria that can grow at refrigeration temperatures of seven degrees Celsius or below. Listeria is one example that poses a serious safety risk.

Packaging Film and Temperature Issues

Temperature control is another potential issue with MAP packaging. Some types of film become more permeable in higher temperatures, which can allow gasses to escape, altering the carefully modified environment designed to prevent spoilage. To maintain a steady state, modified atmosphere packaging should ideally be shipped and stored in a temperature-controlled environment.

How Ernest Can Help with Modified Atmosphere Packaging Design

If your company sells fresh food and beverage products, including produce, meat and seafood, dairy products or anything else that needs to be kept fresh, Ernest’s team of packaging design experts can help. We understand the need to preserve freshness for all kinds of products during shipment, and have an extensive network of suppliers and vendors to help us land on the perfect solution for your unique needs.

To find out if modified atmosphere packaging is right for your products, drop us a line today.