MODIFIED ATMOSPHERE

PACKAGING (MAP)
 INTRODUCTION

According to the recent FAO report,

50% of agricultural products are
destroyed because of the absence of
packaging. The causes of this loss are
bad weather, physical, chemical and
microbiological deteriorations.
Progress in the packaging of foodstuffs
will prove crucial over the next few
years mainly because of new consumer
patterns, demand creation and world
population growth which is estimated
to reach 15 billion by 2025.
 GENERAL OVERWIEV
FOOD PACKAGING TECHNIQUES

In the last decade, the most important additional function of the

packaging method is to prolong the shelf-life of the food product.
Vacuum packaging
Active packaging
Modified atmosphere packaging
Aseptic packaging
Edible coatings
 Introduction

-The steady growth in retail sales of fresh

fruits
 Everyone knows that food does not stay
fresh forever. Milk turns sour, bread goes
mouldy, meat develops a brown colour and
an ‘off’ smell. A number of factors cause
food spoilage.
 Oxygen in the air can cause a process of
decay called oxidation. For example fats and
oils in food can oxidise to make the food
turn rancid. One of the main causes of the
spoilage of food is the growth of microbes
such as bacteria, yeasts and mould.

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 The appearance of food can also change
over time when exposed to air. Fresh meat
turns brown after a while because of
interactions between oxygen and pigments
in the tissue.

There are a number of ways to slow down

these processes of spoilage and to keep food
attractive and edible for as long as possible.
These include: refrigeration, pickling,
curing with salt or by adding artificial
preservatives.

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 However, to keep food fresh for as long as
possible without additives is a challenge, and one
key technology for achieving this goal is to seal
the food product in a package which contains a
mixture of natural gases in carefully controlled
proportions that significantly slow down the
process of decay by inhibiting processes of
oxidation and the growth of microbes.
 This is the essence of modified atmosphere
packaging: the atmosphere in which the food is
packaged is modified so that spoilage is
markedly reduced and the shelf life of the
product is increased.

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MODIFIED ATMOSPHERE PACKAGING
MAP - an atmosphere with a gas composition different
from that of air is created in the package. The gases mainly
used are the following:
CO2 – antimicrobial effect;
O2 – a reduced oxygen concentration in the head-space of
a package below 1-2 %, even to 0.2 % by replacing oxygen
with nitrogen and /or carbon dioxide;
- a high oxygen concentration, even 80 % or above is
used in order to inhibit microbial growth through oxygen
shock;
N2 – inert gas (equilibrium of atmospheric pressure).

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Historical developments
"Controlled atmosphere" and "modified atmosphere" are terms implying the
addition or removal of gases from storage rooms, transportation containers
or packages in order to manipulate the levels of gases such as oxygen,
carbon dioxide, nitrogen, ethylene etc., and achieve an atmospheric
composition different to that of normal air around the food (Floros, 1990).

In the case of controlled atmosphere, the gas composition around the

product (usually in storage rooms or transportation containers) is
continuously monitored and controlled. Modified atmosphere indicates that
the composition of the storage atmosphere is not closely controlled.
Historical developments……..cont

Consumers were looking for convenient food products due to

their busy lifestyles. Health concerns resulted in an elevated
interest in the quality rather than the quantity of food. The
demand for "fresh" and "natural" products without the addition
of "dangerous" chemicals increased dramatically.

MAP seemed to be the ideal method of preservation of many

foods, because it could extend the shelf life of the product
significantly, without affecting its "fresh" or fresh-like
characteristics.
 MAP was first recorded in 1927 as an
extension of shelf life of apples by
reducing oxygen and increased carbon
dioxide
 In 1930s it was used to transport fruits on
ships
 In UK, Mark and Spenser used MAP for
meat in 1979

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DEFINITION
 Modified atmosphere is a condition of atmosphere (normally in a
package of commodity) around the commodity that is different from that
of air (78.08% N2, 20.95% O2, and 0.03% CO2).
 Usually this involves reduction of O2 and/or elevation of CO2
concentrations.
 Modified atmosphere packaging (MAP) involves the exposure of
produce to the atmosphere generated in a package by the interaction of
produce, the package and the external atmosphere.
 Different additives that may affect the atmosphere may be introduced
into the package before it is sealed.
 The main feature distinguishing MAP from controlled atmosphere (CA)
is that , in the case of MAP, active human involvement stops at the
moment of sealing.
 MAP is a multidisciplinary technology of maintaining freshness that
utilises basic principles of chemistry, physics, plant physiology and
pathology, microbiology, food science, engineering, polymer chemistry.
MODIFIED ATMOSPHERE PACKAGING
 MAP of non-respiring foods, a high
CO2 content (>20%) is used in most cases together
with a low O2 content (<0.5%) and a recommended
storage temperature < 5oC for the most foodstuffs.

 MAP of respiring foods i.e. fresh fruits

and vegetables, once the atmosphere has been
changed to the desired level, the respiration rate of
the produce should equal the diffusion of gases
across the packaging material in order to achieve an
equilibrium atmosphere in the package.

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Product % O2 %CO2 %N2

Red meat 60-85 15-40 -

Cured meat - 20-35 65-80

Poultry - 25 75

Fish (oily) - 60 40

Hard cheese - 100 -

Soft cheese - 30 70

Bread - 30-40 60-70

Fruits & vegetables 3-5 3-5 65-95

Dried/ Roasted nuts - - 100

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MODIFIED ATMOSPHERE PACKAGING
Packaging materials
 Concept of food packaging - the entire dynamic interaction between food,
packaging material and ambient atmosphere has to be considered.
 Design and manufacture of packaging materials:
- a multistep process
- involve careful and numerous considerations to successfully engineer the
final package with all the required properties.
 Properties to be considered in relation to food distribution may include gas
or water vapour permeability, mechanical properties, sealing
capability, thermoforming properties, resistance (towards water, grease,
acid, UV, light, etc.), machinability (on the packaging line),
transparency, antifogging capacity, printability,
availability and, of course cost.

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 Packaging materials requirements
Particularly with regard to gas packaging, the important factors
are the following:
 Gas barrier properties
In most gas packaging applications, excluding
vegetables and fruits, it is desirable to maintain the
atmosphere initially injected into the package for as
long a period as possible. Some of the polymers
currently used include PE, PETP, metallised PETP,
PP, PS, PVC, PVDC, PA, EVA, and EVOH.
These polymers are normally used as laminated or co-
extruded multilayer materials in order to have the
barrier properties required. The inner layer is
usually polyethylene or its co-polymer which forms
the food contact and heat seal medium;
polyethylene or ethylene vinyl acetate alone are not
suitable for gas packaging because of their high gas
permeability.
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 Packaging materials requirements
As a rule, packaging materials with oxygen permeability lower than
100 cm3/m2 24 h 101.3 kPa are used in gas packaging. In the
literature, on the other hand, very few reported investigations are
available on the significance of oxygen permeability between 0-
100 cm3/m2 24h 101.3 kPa for quality gas-packed products.
Vegetables and fruits differ from other foodstuffs in that they
continue to respire even when placed in a modified atmosphere.
Due to the respiration, there is a danger that CO2 will increase to
levels injurious to the packed commodities. On the other hand,
respiration consumes oxygen and there is a danger of
anaerobiosis. A number of special packaging materials intended
for vegetables and fruits have been developed such as smart films,
microporous film and micro-perforated films.
 Mechanical strength
In choosing packaging materials for food one has also pay attention
to how resistant to mechanical stresses (e.g. puncture), humidity
and temperature (frozen or chilled) the material needs to be. If a
material is of poor mechanical strength, the mechanical stresses,
humidity and low temperature during storage transport and 17
handling can damage the package and cause leakage.
 Packaging materials requirements
 Integrity of sealing
The adequate integrity of the seal is important in order to
maintain the correct atmosphere in the package.
 Type of package
The type of package to be used, rigid or semi-rigid, lidded tray
or flexible film pouch has to be taken into consideration when
choosing packaging materials.
 Fogging
In order to improve the appearance of the packages in retail
outlets, the polyethylene in the packaging laminates can be
specially treated to prevent condensation of water, which fogs
the package and prevents the consumer examining the product.
 Microwaveability of packaging materials is a
factor that should also be considered in gas packaging,
particularly in the case of ready-to-eat food products. For
instance, the low melting point of PVC makes the PVC-LDPE-
laminate or coextrusion film much used as a base web material
in deep - draw machines unsuitable for microwave oven 18
heating.
 Packaging materials requirements
 Biodegradability and recyclability
These factors are new trends in packaging business.
A major challenge for the materials manufacture is the natural
hydrophilic behaviour of many biobased polymers as a lot of
food applications demand materials that are resistant to moist
conditions.
 Thermal and mechanical properties
Most biobased polymer materials perform in a similar fashion
to conventional polymers.
The mechanical properties in terms of modulus and stiffness
are not very different compared to conventional polymers.

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 Packaging materials requirements
In general, the oxygen permeability and the permeability of
other gases of a specific material are closely interrelated. This
relation is also observed for biobased materials. However, for
some biobased materials, e.g. PLA and starch, the
permeability of carbon dioxide compared to oxygen is much
higher than for conventional plastics.

As many of these biobased materials are hydrophilic, their gas

barrier properties are very much dependent on the humidity
conditions for the measurements and the gas permeability of
hydrophilic biobased materials may increase considerably at
increased humidity levels. This phenomenon is also seen with
conventional polymers. The gas permeability of high gas
barrier materials, such as nylon and ethylvinyl alcohol, is
likewise affected by increasing humidity. Gas barriers based
on PLA and PHA are not expected to be dependent on
humidity.

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 Physiological Considerations
Respiration
C6H12O6 + O2 ------- CO2 +H20+ Energy + Water

Carbon Dioxide
e

Energy Rich
OXYGEN
ATP

Air
 Changes in harvested produce

∙ Respiratory metabolism ∙ Ethylene biosynthesis and action

∙ Compositional changes ∙ Growth and development
∙ Physical injuries ∙ Water loss
∙ Physiological disorders ∙ Pathological breakdown
 Effects of MAP

• Gas exchanging

O2
Gas composition
O2
20 %

O2
O2
CO2
0%
H2O CO2 Time

H2O CO2
 Effects of MAP

• Considerable factors
- Oxygen and carbon dioxide concentration
- Duration of exposure
- Commodity
- Temperature
- Physiological maturity

• Influenced factors
- Respiration
- Ethylene
- Pathogen
- Humidity
 The MAP System
Plastic Film
Area
Volume
Permeability
O2
Permeability CO2i CO2e
CO2
thcikness

Produce O2i O2e

Weight
Oxygen
uptake
CO2
Production
 Principles of MAP
The objectives of MAP are to extend the shelf life of food products and to
prevent (or at least retard) any undesirable changes in the wholesomeness,
safety, sensory characteristics, and nutritive value of foods.

MAP achieves the above objectives based on three principles:

1. It reduces undesirable physiological, chemical/biochemical and physical
changes in foods
2. It controls microbial growth
3. Just like any other packaging technique, it prevents product contamination.

The three main gases used in MAP are nitrogen (N2), oxygen (O2), and carbon
dioxide (CO2).
 Principles of MAP (1)
At sea level, the approximate composition of atmospheric air is
78.1% N2,
20.9% O2, and 0.03% CO2.

The role and the importance of each gas in MAP are related to
its properties.

Nitrogen is an inert and tasteless gas, without any antimicrobial

activity.
It is not very soluble in water, and it is primarily used to
displace oxygen and prevent
package collapse.
 Principles of MAP (2)
Oxygen inhibits the growth of anaerobic micro-organisms, but promotes the growth of
aerobic microbes.

Additionally, oxygen is responsible for several undesirable reactions in foods,

including oxidation and rancidity of fats and oils; rapid ripening and senescence of
fruits and vegetables; staling of bakery products; color changes; and spoilage due to
microbial growth.

Due to oxygen's negative effects on the preservation of the food quality, it is generally
avoided in the MAP of many products. However, its presence in small quantities is at
times necessary for some products.

For example, a minimum oxygen concentration is required by many fruits and

vegetables in order to sustain their basic process of aerobic respiration.

In other cases, such as red meats, high oxygen concentration is used to initiate
"bloom" and preserve the bright red color of fresh meats.
 Principles of MAP (2)
Carbon dioxide is soluble in both water and lipids, and its
solubility increases with decreasing temperatures. The
dissolution of CO2 in the product can result in package collapse.
Carbon dioxide has a bacteriostatic effect, and it slows down the
respiration of many products.

All three gases are common and readily available, safe,

economical, and are not considered to be chemical additives.
However, the optimum level of each gas for each food product
must be determined and used in order to maximize the positive
and minimize the negative effects.
PRINCIPLES OF MAP
 MAP is a dynamic system during which respiration and permeation occur
simultaneously.
 Factor affecting both respiration and permeation must be considered when
designing a package.
 Commodity mass, temperature, O2, CO2, and C2H4 partial pressure and stage
of maturity are known to influence respiration in a package.
 Type, thickness, intended holes, and surface area of packaging film, as well
as temperature, RH, and gradient of O2 and CO2 partial pressures across the
film, are known determinant of permeation.
 Package equilibrium or steady state is defined as the point at which the
commodity CO2 production and O2 consumption rates are equal to the
permeation rates of the respective gases through a package at a given
temperature.
 Poorly designed package will become anaerobic or develop unacceptable
levels of CO2 before equilibrium is achieved.
 MAP Technique
Two basic techniques are employed to replace air in MAP :
GA S FLUSHING & COMPENSATED VACUUM

1. Gas flushing : Air is replaced by passing a stream of gas. The air gets
diluted & the pack is sealed. Air dilution can be continuous and hence
the packaging system is very fast. Gas flushing is normally
accomplished with the use of vertical or horizontal form-fill-seal
machines. The oxygen levels in gas –flushed packs may be upto 2-5% .
Nitrogen flushing is common in our country for readytoeat snacks &
fried items.
2. Compensated Vacuum : Here, vacuum is first applied to remove the air
& then the desired gas or gas mixture is incorporated. Since it
involves an extra step, this process is slower. It has its own advantage,
because , the residual oxygen is much less and can be used to pack
oxygen sensitive foods.
 MAP Technique
The atmosphere inside a package can be modified by either passive or active
means). In the first case, the rate of change and the final gas composition in
the package depend largely on both the packaged product and the permeability
of the packaging material.

It is well known that most foods come from living entities and continue to
live after harvesting.

Fruits and vegetables, for example, consume the oxygen of the surrounding
environment and release carbon dioxide via the respiration process.
Similarly, the natural microflora of many products also consume oxygen.
Besides the biochemical and physiological processes that utilize the
available gases, oxidative reactions also take place during the storage
period of foods, resulting in a reduced oxygen concentration over time.
 MAP Technique (1)
If the above phenomena occur in a sealed package, impermeable or permeable to
gases, the gas composition inside the package will change. If the container is
impermeable to gases (e.g. glass jars, rigid metal cans, barrier plastic films), the
rate of gas production and/or consumption will dictate the gas composition at
any time.

However, if the container is permeable to gases (e.g. flexible non-barrier plastic

package), the gas exchange with the environment will also take place through the
package (Figure 10.1).

As a result, the gas composition inside the package will be further modified and
the final gas composition will be different in the two containers.

The main disadvantage of the passive atmosphere modification method is that

the desired atmosphere is achieved very slowly (Figure 10.2a). This can
sometimes result in uncontrolled levels of oxygen, carbon dioxide or ethylene,
with a detrimental effect on the quality of the product.
MAP Technique (2)
 MAP Technique
The process of applying a vacuum can be considered a method of active atmosphere
modification . It is commonly used in packaging techniques such as canning or bottling in
glass containers.

The main purpose of such vacuum application is to reduce the residual oxygen in the
headspace of a package, which eventually retards oxidative chemical reactions and
aerobic microbial growth. When a vacuum is used with flexible packages, the packaging
material collapses around the product and practically
eliminates the existence of the headspace.

A vacuum is also often applied to storage rooms and transportation containers, a

technique called hypobaric or low-pressure storage. In this method, a slight vacuum is
maintained in the storage room or container, which reduces the partial pressure of oxygen
and continuously removes undesirable gases such as ethylene. As a consequence,
oxidative and physiological reactions are retarded.
Finally, relatively recent technological innovations allow for in-package control of
a specific gas (oxygen, carbon dioxide or ethylene).
 MAP Technique
Such "active" packaging systems are designed to remove or add
certain gases selectively. This is usually achieved by using a
substance that can bind (scavenger) or release (emitter) certain
molecules as a result of chemical or enzymatic reactions.
The "active" substance can be placed in the package (e.g. in a
sachet), or in more sophisticated systems it can be incorporated
into the packaging material itself The method is referred to as
active packaging.
An example of this technique is the addition of small sachets in
cans of coffee. The sachets contain a mixture of iron oxide and
calcium hydroxide that binds oxygen and enables the control of the
package environment without gas-flushing or the application of a
vacuum
Different Modified Atmospheres
 High oxygen atmosphere packaging : Here, the gas
composition may be upto 70% oxygen, 30% carbon
dioxide & 0-20% nitrogen. This system is mainly used
for red meats. Without oxygen, undesirable brown
colouration is developed. This packaging is used in both
individual display packs or display packs in aggregated
master packs that are opened before meat is displayed.
 Low Oxygen atmosphere packaging : The air from a pack
is replaced with carbon dioxide or carbon dioxide-
nitrogen mixture. Plain gas flushing would allow a
residual oxygen level about 10%, while compensated
vaccum , a level 1% can be achieved.
Different Modified Atmospheres
This modified atmosphere is used for both display & bulk
packs of meats. It cannot be used for red meats & other
susceptible to oxidative deterioration.
 Vaccuum packaging : This is a simple technology. The
product to be packed is placed in a pouch of suitable
material, air is drawn out from the pack & the pack is
sealed. The packaging film is applied closely to all surfaces
of the product. This packing is not suited for soft food
products, whereby shape & other physical modifications of
the product takes place. Generally, in india, this packaging
is carried out for nuts, which withstand any modifications in
shape, for tea where flavour retention is necessary for
extended periods.
 Potential benefits Potential harmful effects

• Retardation of senescence • Initiation or aggravation of

• Reduction of fruit certain physiological
sensitivity to ethylene action disorders
• Alleviation of certain • Irregular ripening of fruits
physiologiical disorders • Off-flavor and off-odors
• Directly and indirectly • Susceptibility to decay may
affect postharvest pathogens increase
• Useful tool for insect • Sprouting and retardation of
control in some periderm development are
commodities stimulated in some root and
tuber vegetables, such as
potatoes.
 Advantages Disadvantages

• Reduction of weight loss, desiccation • Requirement of additional investment

and shriveling in machinery and labor in the package
• Delay of ripening line
• Alleviation of chilling injury • Risk of spoiled produce due to
• Semicentralised manufacturing option improper packaging of temperature
• Expanded radius of distribution system abuse
• Reduction of labor and waste at the • Possible occurrence of new risk of
retailer level microbiological safety due to possible
• Quality advantages such as colour, development of anaerobic pathogenis
moisture, flavour and maturity retention flora
• Excellent branding option • Plastic film may be environmentally
• Reduction of handling and distribution undesirable unless effective recling is
of unwanted or low grade produce installed
• Quality advantages transferred to the • MAP technology is still unavailable
consumer for most produce
 Advantages & disadvantages
MAP offers many advantages to consumers and food producers. To the consumer, it
offers convenient, high-quality food products with an extended shelf life. It also reduces
and sometimes eliminates the need for chemical preservatives, leading to more "natural"
and "healthy" products. At the same time, producers also enjoy the benefits of increased
shelf life. By using MAP many products can be packaged centrally, and their
distribution cost is reduced because fewer deliveries over longer distances become
possible. Moreover, because of the extended shelf life, MAP allows transportation
of foods to remote destinations and increases product markets.

MAP also has several disadvantages. Usually, each MAP product needs a different gas
formulation. This requires the use of specialized and expensive equipment. At the same
time, production staff must receive special training. For most products, storage
temperature control is required and product safety must be established.
Furthermore, MAP causes larger package volumes, which leads to increased
transportation and retail display space needs. All the above add a noticeable cost, which
must be paid by the consumers. Finally, another disadvantage of MAP is that it loses all
its benefits once the consumer opens the package.
Effects MAP
on Shelf Life
 Effects MAP on Shelf Life
Meat
Atmospheres high in carbon dioxide should be used to suppress microbes and extend shelf
life. Consequently, MAP of meat in a gas mixture with high amounts of both oxygen and
carbon dioxide is ideal for preserving the product's quality and extending its shelf life.

Bakery products
Because of its bacteriostatic and fungistatic properties, and its inhibitory effect on insect
growth, high carbon dioxide MAP can be used with bakery products to eliminate growth
of molds and subsequently to extend the product shelf life.

Fruit and vegetables

Reduced levels of oxygen and increased levels of carbon dioxide in the atmosphere
around fresh produce appear to have several positive effects. Among others, they
preserve product quality because they slow down respiration, decrease softening rates,
and improve chlorophyll and other pigment retention. In addition, as in other products,
elevated levels of carbon dioxide reduce the rate of microbial growth and spoilage.
 Effects MAP on Safety
The antimicrobial effect of carbon dioxide occurs at or near a 10% level, and
increases with higher concentrations. Using 20% carbon dioxide can control the
growth of several aerobes, including Pseudomonas, Acenatobacter and Momxella,
but higher concentrations in the ranges of 20% usually give better results.

However, very high concentrations of carbon dioxide may stimulate the growth of the
anaerobe Clostridium botulinum. Although the mechanism of carbon dioxide's
antimicrobial activity is not fully understood, it appears that CO2 extends the lag
phase in the microbial growth (Ray, 2001) in many ways: it penetrates the microbial
cell wall and alters the cell permeability; it solubilizes inside the cells and produces
carbonic acid (H2CO3), which reduces the pH of the cell; and finally, it interferes
with several enzymatic and biochemical pathways inside the microbial cells, and thus
reduces their growth rate.

The effect of MAP on each micro-organism and its rate of growth also depend on the
food itself, the amount of oxygen dissolved or entrapped in the product, the available
nutrients, and the presence of reducing components.
Combination of MAP
1. Refrigeration
2. Freezing
3. Irradiation
4. Hurdle technology
5. Edible coating
6. Biological Control
 Summary

• MAP is cheap and easy tool.

• MAP can reduce respiration rate, ethylene synthesis,
bacterial growth rate and increase relative humidity.
• MAP has beneficial effects on preservation of commodity.
• Not all plant material benefit from MAP. Those that do may differ
in
their responses to atmospheres generated.
• Much more research is needed to find optimal gas composition of
various product.