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  • How Does Modified Atmosphere Packaging Protect Food Products?

    How Does Modified Atmosphere Packaging Protect Food Products?

    Modified atmosphere packaging (MAP) is known to prolong the shelf life of food and enhance product safety by limiting the oxygen exposure of fresh and processed food alike. It offers added protection against spoilage, therefore more food industry companies are using MAP to maintain quality and match the increasing demand for packaged food.

    If you’re in the food industry, MAP could certainly help you optimally meet the rising consumer demand for well-packed and ready-to-eat food products.

     

    What is Modified Atmosphere Packaging (MAP)?

    Modified atmosphere packaging (MAP) is a tried-and-tested packaging solution that controls the air in and around a container or a package, so the food inside stays fresh for an extended period. Which also means the food is safe for consumption for an extended period. 

    MAP does this by limiting the amount of oxygen, nitrogen, carbon dioxide, and water vapor inside sealed packages. These elements are generally responsible for discoloration and the change in flavor and texture. Through MAP, oxidation is less likely to occur.

    MAP is perfect for fresh fruits, vegetables, and other consumable food products, keeping them fresh for longer and minimizing spoilage.  Coffee beans are another common example of MAP packaged goods. Roasted beans release carbon dioxide; MAP regulates the carbon dioxide buildup to prevent the packaging from bursting open and to keep the roasted coffee beans safely stored.

     

    How Does MAP Affect Food Products?

    Modified atmosphere packaging essentially prevents oxidation, preserves food quality, extends shelf life, and minimizes the need for food preservatives. Let’s dig deeper into the ways MAP protects food products and other perishable and consumable items.

    MAP Removes Oxygen and Prevents Oxidation

    Gas flushing, or the process of increasing the nitrogen level in a package while reducing the oxygen level, is one of the most common ways to prevent oxidation and delay the growth of harmful microorganisms that lead to spoilage. A conservative amount of carbon dioxide is needed inside the package in order to regulate the moisture level.

    MAP Protects Food with the Help of Barrier Films

    Barrier films serve as an added protection for food products in modified atmosphere packaging. These are plastic films and foils that seal the package and prevent outside gasses from disrupting its carefully balanced level of oxygen, nitrogen, and carbon dioxide. The right type of barrier film can effectively preserve food quality for longer.

    MAP Reduces the Need for Food Preservatives

    More and more consumers are interested in organic food and food products that are made without GMOs and preservatives. MAP is an ideal packaging type for these food products because it doesn’t use preservatives to limit oxidation and maintain freshness. As such, both consumers and manufacturers understand the appeal of using MAP.

     

    Use MAP as a Cost-Effective Food Packaging Option

    Modified atmosphere packaging is a cost-effective type of packaging for consumables and perishables. It contributes to longer shelf life and minimizes food wastage, so less labor is required for product restocking.

    To know more about how MAP can help your food business, reach out to us. nexAir prides itself on its KnowHow which enables it to be more than just a product supplier. We believe in providing complete solutions and technical knowledge to truly help you Forge Forward. Contact us today for enquiries. 

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    Manufacturing downtime costs American companies billions annually. When production lines halt due to gas supply issues, every minute translates to lost revenue, missed deadlines, and frustrated customers. At nexAir, we've spent decades developing solutions that keep manufacturing operations running smoothly.

    The Hidden Costs of Gas-Related Downtime

    When manufacturers calculate downtime costs, they typically focus on labor and lost production. However, gas supply disruptions create cascading effects that multiply these losses:

    • Production rescheduling that disrupts carefully optimized sequences
    • Rush shipping fees to meet customer deadlines despite delays
    • Quality inconsistencies when processes restart after interruptions
    • Overtime costs to catch up after unplanned stoppages
    • Reputation damage when delivery commitments are missed

    For a typical mid-sized manufacturer, each hour of downtime represents $5,000-$10,000 in direct and indirect costs. Our analysis shows that gas-related issues cause 7-12% of total manufacturing downtime - a substantial opportunity for improvement.

    From Reactive to Proactive: The Supply Continuum

    Most facilities follow a predictable pattern in their gas management evolution:

    Stage 1: Reactive Management At this stage, facilities order gas when they notice supplies running low or, worse, after running out. Emergencies are common, and disruptions are accepted as "part of doing business." One automotive parts supplier operating this way experienced 14 production interruptions in a single quarter.

    Stage 2: Calendar-Based Management Facilities advance to scheduled deliveries based on estimated usage. While better than the reactive approach, this method still results in either excess inventory (tying up capital and space) or shortages when usage spikes occur. A plastics manufacturer following this model maintained 40% more cylinder inventory than necessary while still experiencing occasional stockouts.

    Stage 3: Consumption-Based Management Our telemetry systems monitor actual gas consumption, automatically triggering orders based on usage patterns rather than calendar dates. This approach virtually eliminates both stockouts and excess inventory. 

    Stage 4: Integrated Supply Management The most advanced approach connects gas management directly to production planning systems. Upcoming production requirements automatically adjust supply parameters, ensuring resources are precisely aligned with needs. A medical device manufacturer using this approach reports zero gas-related downtime for 27 consecutive months while operating with minimal inventory buffers.

    Our expert KnowHow™ in industrial gas applications allows us to guide customers through this evolution at a pace that makes sense for their operations.

    Customizing Solutions for Maximum Uptime

    Manufacturing environments vary dramatically in their gas requirements and operational constraints. We've developed flexible approaches that address these differences:

    • For high-volume, consistent usage operations, our bulk systems eliminate the cylinder handling that frequently causes supply disruptions. Bulk installations include telemetry monitoring and automated ordering to prevent outages.
    • For variable-demand environments, our microbulk delivery systems provide the benefits of bulk supply with lower volume commitments. These systems reduce handling requirements while maintaining the flexibility needed for changing production schedules.
    • For specialized applications requiring multiple gas types, our gas management programs combine cylinder tracking, usage monitoring, and automated replenishment. This comprehensive approach ensures that specialty gases are always available when needed, regardless of how infrequently they might be used.
    • For multi-site operations, our enterprise supply programs coordinate deliveries and optimize inventory across locations. By treating the organization's gas requirements holistically, we minimize both stockouts and excess inventory across the network.

    This consultative approach ensures that manufacturers receive solutions aligned with their specific operational patterns rather than generic "one-size-fits-all" systems.

    Beyond Traditional Supply: Integrated Services for Total Reliability

    Maximum uptime requires more than just reliable gas delivery. Our integrated services address the full spectrum of gas-related reliability factors:

    Equipment maintenance programs that prevent system failures before they impact production Technical gas specialists who resolve application issues that could otherwise cause production problems Safety training that prevents accidents leading to downtime events Emergency response capabilities that minimize impacts when unexpected events occur Supply chain redundancy that ensures continuity despite regional disruptions

    These services complement our supply solutions to form a comprehensive reliability strategy. By addressing both everyday operations and exceptional circumstances, we help manufacturers Forge Forward with confidence that gas-related disruptions won't derail their production targets.

    Measuring Success: The Results That Matter

    The ultimate measure of any downtime reduction strategy is its impact on production metrics. Our manufacturing customers consistently report significant improvements after implementing our comprehensive gas management solutions:

    Downtime reductions of 85-95% for gas-related issues Inventory cost decreases of 20-30% through optimized supply management Administrative time savings of 5-10 hours weekly through automated ordering and tracking Production schedule adherence improvements of 3-7% due to improved supply reliability

    These performance gains translate directly to bottom-line benefits that typically deliver ROI within months rather than years. More importantly, they allow manufacturers to confidently make delivery commitments, knowing that gas supply issues won't compromise their ability to perform.

    Don't let gas supply issues impact your productivity. Contact us today to explore our tailored solutions.

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    Industry Knowledge and Expertise

    Find out how nexAir KnowHow has impacted businesses all over the Southeast

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    Our expertise makes us more than a valuable partner, it makes us headlines

    nexAir is always open!