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Opening Up a Rotten Package to Find a Rotten Product is Just that; Rotten. June 2, 2016

A biological explanation of why food rots and how you can use MAP to prevent it.

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Why Products Rot…

Food decomposition is dependent on three factors:

1. Decomposers: “Decomposers” are microscopic bacteria that are about 1/3 the width of your hair. They are airborne and are perpetually surround us [i]. The decomposers found in and on food are commonly aerobes, which mean they need oxygen/air to grow.

Decomposers land on food or other products such as wood, and immediately start breaking down the organic matter by feeding on it. As the decomposers germinate, strands form that release spores. These strands are what we commonly perceive as mould.

2. Light: In a process called photodegredation, light causes the compounds in food to break down, causing a loss of colour, vitamins, and proteins.

3. Temperature: Temperature increases ultimately cause a further decomposition of organic matter as it is a maj PLEX-PACK-PRODUCTS-10-200x300 or accelerant of chemical reactions [ii]. It works as a catalyst for photodegredation but can also encourage the germination of decomposers.

How Can Manufacturers Prevent Product Decay? By using Modified Atmosphere Packaging (MAP).
MAP is a popular form of packaging for food and beverage industry buyers. It commonly works in two ways to aid in the prevention of product decay:

By flushing the package with a gas, such as Nitrogen and/or Carbon dioxide, producers can modify the atmosphere within the package and making it more difficult for aerobic bacteria to grow.
By vacuuming the air out of the package, producers remove a great deal of oxygen, also making it difficult for aerobic bacteria to grow [iii].
Many manufacturers use a combination of these two tactics to prevent product decay.

How Plexpack Helps to Prevent Product Decay: the MPS7103-VGF & VacPack

The Emplex MPS 7103 is a high speed, continuous band sealer equipped with a vacuum and nitrogen gas flush system for creating high quality moisture proof, oxygen free packages. It is ideal for customers that require higher capacity output than our impulse vacuum sealers. Typically, customers requiring more than 15 bags a minute find a greater return on investment by choosing a continuous band vacuum sealer. Our satisfied customers include producers of coffee, snacks, pre-baked goods, electronics, medical products, and fresh or dried food, produce and meat.

Plexpack’s VacPack Series are robust, stainless steel food grade sealers that create vacuum and gas flushed sealed bags for a wide range of package sizes, including extra wide and heavy products. VacPack vacuum sealers employ an ejector style vacuum pump and produce hermetically sealed packages on any heat sealable bag up to 12 mil/300 micron in thickness (6 mil/150 micron maximum when gusseted). The VacPack Series includes the VP2400, VP3000, and VP3600 floor stand models Tabletop models – VP2440, VP3040 and VP3640 are also available. All models include the same washdown, vacuum, gas flush capabilities.

The vacuum and nitrogen gas flush system removes oxygen and creates a moisture-free package, resulting in longer shelf life, product integrity, and protection against discolouration. For snack products a gas flush only system can create a cushion-like buffer against damage.

So… What Other Preventative Measures Can Manufacturers Take?

By using foil packaging, food and beverage manufacturers can prevent light from photodegrading their products. It is also important to consider that different kinds of packaging that may actually encourage bacterial growth and product spoilage. [iv]

With that in mind, we encourage readers to contact one of our industry specialists for a customized packaging consultation. We offer bag sealers, wrappers, bundlers as well as manufacturing automation on a case-to-case basis.

Should you have any questions, please contact me for information on product offerings and solutions.

Thanks for reading!

Jackie Irvine and the Plexpack Team

[i] https://www.youtube.com/watch?v=JyqOE2Z-MdU

[ii] http://wonderopolis.org/wonder/why-does-food-rot/

[iii] http://modifiedatmospherepackaging.com/

[iv]http://www.foodpackages.net/freepress/en/download.php?act=323e17b3d34ae5abe1a3682ed8d3c10d&file=Rm9vZFBhY2thZ2VzRnJlZVByZXNzMDkucGRm&adv=FF09&title=Packages%20and%20beverages&board=FREEPRESS_DOWNLOAD

How Gas Flush and Traditional Vacuum Sealing Differ

While both methods preserve food by removing air from storage bags, their processes and the environments they create are different:

5 Advantages of Gas Flushing

Understanding the benefits of a sealing method is vital when choosing one for your packaging. This method offers several advantages, making it a popular choice for food manufacturers and retailers looking to boost the presentation and longevity of their products.

1. Extended Shelf Life

Nitrogen allows you to create an ideal atmosphere for products, removing all traces of oxygen. Secondly, vacuum sealing creates durable packaging that protects your products from the elements and any external contaminants, increasing product longevity and quality and keeping perishables fresh for longer.

Extending your products' shelf life reduces product losses, which is excellent for your consumers and bottom line.

2. Elevated Food Safety

Packaging your products with gas flush systems eliminates the need for chemical preservatives, reducing the risk and making your products more appealing to consumers. Nitrogen is the most abundant gas in the atmosphere, and we breathe it every day, making it safe for use in preserving and packaging food products.

3. Enhanced Product Appearance

The gas flush process prevents products from coloring, keeping food looking fresher for longer. Oxygen interacts with the natural pigments in many foods, particularly meat products, which can cause them to appear discolored. Nitrogen and other nonreactive gases prevent this discoloration from happening. Their nonreactivity allows food products to retain a fresh appearance, making them more appealing to buyers.

4. Protected Product Integrity

You can flush products with extra nitrogen, depending on your needs. This process provides extra cushioning for fragile products so they don't break and retain their freshness during transport, storage and packing. More robust products also benefit from this additional protection to maintain the product's structure. For medical and pharmaceutical products, gas flush vacuum sealing puts products in more ideal storage conditions so they maintain their effectiveness.

This packaging method also seals in flavors, allowing consumers a better user experience.

5. Ease of Use

Gas flush systems are quick, efficient and user-friendly. The machine is easy to install, maintain and operate. You can automate the process and customize the settings for various products. Automating your equipment frees your team to focus on other critical tasks, reduces labor costs and increases output speed.

How to Choose the Right Gas Flush Vacuum Packaging Machine

Businesses have differing packaging needs, and choosing the right high-efficiency vacuum sealing machine can be challenging. Choosing the right equipment for gas flush vacuum sealing is crucial to help your business maximize packaged products' quality and shelf life. Keep the following tips in mind to ensure you make the best decision for your business:

Production Requirements

Consider the volume of products requiring packaging throughout your operation. Explain your output requirements to your product provider so they can help you determine which type of machine is best suited to our needs. Look into the machine's operational speed, temperature range, sealing band and height adjustment capabilities to start with.

Consider your future requirements. If you expect considerable business growth, purchasing equipment that quickly becomes obsolete could cause unnecessary hassle. You can discuss the option of add-on equipment like trimmers, conveyors, embossers and printers that can complement your operations.

Packaging Environment

Depending on your product, you may have stringent safety and hygiene regulations to consider. Your chosen equipment should be designed for easy cleaning to maintain compliance in your workspace.

Package Quality and Appearance

Packaging affects whether consumers purchase your products. Your packaging should be attractive and functional to build trust in your brand and demonstrate the quality of the product inside. Consider how your packages are displayed and how consumers use your products. The right packaging equipment should provide a visually appealing result that represents your products and encourages purchases.

Maintenance and Ease of Operation

Consider how easy it will be to set up, use and maintain your machine. These factors can affect your costs, efficiency and downtime. Your device should be easy to work with so you can integrate it into your existing workflow and start enjoying the results.

Supplier Partnership

Having a solid partnership with your supplier is essential. They should take the time to understand your needs and plan business growth. As you'll use your equipment as part of your operations, ask your supplier about their support level and their experience with your industry.

Machine Quality and Efficiency

Selecting a machine also depends on your budget, and it's essential to balance the initial cost of your machine with maintenance and operation costs. A return on investment (ROI) is critical to your profitability, and a quality machine can set you up for the future by increasing your output speed and elevating your presentation. Consider investing in equipment that can grow with your business.

Take Your Packaging to the Next Level With Plexpack

Integrating new equipment into your operations requires careful consideration to ensure you choose the right products. While both traditional and gas flush vacuum sealing offer food and medical products enhanced shelf life and protection, a gas flush is a more effective solution for a broader range of perishable products. Gas flush packaging has considerable benefits for many procedures, including food and beverage applications. You need a reliable and experienced supplier partnership for the best results.

Plexpack has helped thousands of companies worldwide find the best product packaging option. We pride ourselves on providing customers with reliable, high-quality, North American-made packaging equipment. We also understand that working with a supplier requires a solid partnership, so our trained technicians are here to support you throughout your operations. Our gas flush vacuum seal machines are efficient and high quality. They may speed up your packaging processes and serve your organization for many years to come.

Contact us to learn more about our innovative products. We will walk you through the best product choices for your budget and application.

Take Your Packaging to the Next Level With Plexpack

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