Case Study: How nexAir Helped a Food Packaging Plant Extend Product Shelf Life

A regional food processor was losing money on returned products at their packaging facility. Their premium deli meats looked fresh when packaged, but customers complained about discoloration and off-flavors appearing days before the printed expiration dates. The plant manager knew something was wrong with their modified atmosphere packaging, but pinpointing the exact problem proved difficult.

Shelf life problems cost food processors in multiple ways. Retailers demand longer dating to reduce their own waste, while consumers expect products to stay fresh until the package says they expire. When products fail early, everyone loses money and confidence.

The Investigation Process

Our food industry specialists visited the facility to observe their packaging operations firsthand. The plant used standard modified atmosphere packaging with nitrogen and CO2, but gas delivery timing and mixture accuracy varied throughout shifts. Some packages received proper gas ratios, while others got inconsistent blends that failed to protect the meat adequately.

Gas purity testing revealed contamination issues in their supply lines. Food-grade gases require strict purity standards, and even small amounts of oxygen contamination can drastically reduce shelf life for sensitive products like sliced deli meats. The facility’s aging gas distribution system allowed minute amounts of air infiltration that accumulated over time.

Temperature fluctuations in the packaging area also affected gas performance. Modified atmosphere packaging works best under consistent conditions, but the plant’s HVAC system struggled to maintain stable temperatures during peak production hours. These variations changed how gases behaved during the packaging process.

The Solution Implementation

We redesigned their gas delivery system with dedicated food-grade lines and improved purity monitoring. New regulators maintained consistent pressure and flow rates regardless of production demand fluctuations. Gas mixture accuracy improved from acceptable ranges to precise ratios that optimized shelf life extension.

Bulk gas storage replaced their previous cylinder system, eliminating contamination risks from frequent connections and disconnections. The bulk system included automatic switchover capabilities that maintained uninterrupted supply during peak production periods while ensuring consistent gas quality throughout each shift.

Staff training covered proper handling procedures for food-grade gases and troubleshooting techniques for identifying problems before they affected product quality. Production workers learned to recognize early warning signs of gas system problems and when to contact technical support rather than attempting temporary fixes.

Measurable Results

Product shelf life increased by an average of four days across their deli meat product lines. Customer complaints about premature spoilage dropped by 78% within six months of implementation. Return rates decreased significantly, improving relationships with retail customers who had been frustrated by previous quality inconsistencies.

Cost savings exceeded expectations when reduced waste and improved customer satisfaction were factored into the analysis. The plant recovered their investment in gas system improvements within eight months while building a foundation for long-term quality improvements that support business growth.

nexAir’s expert KnowHow includes understanding the specific requirements of food packaging applications and how gas management affects product quality and shelf life. Our technical team works with food processors to identify optimization opportunities that improve both product performance and operational efficiency.

Ready to optimize your food packaging gas systems for better shelf life performance? Contact nexAir to discuss modified atmosphere packaging solutions that help your operation Forge Forward with improved product quality and customer satisfaction.