Modified Atmosphere Packaging (MAP) Overview

MAP provides food manufacturers with a way to extend shelf life while maintaining the freshness and appearance consumers expect from perishable products.

Extended Shelf Life
By controlling oxygen levels and the atmosphere surrounding the product, MAP can slow the processes responsible for food deterioration.

Reduced Microbial Growth
The controlled atmosphere creates conditions that are less favorable for many bacteria, molds, yeasts, and other microorganisms associated with food spoilage.

Reduced Oxidation
Limiting oxygen exposure helps protect against oxidation that can cause discoloration, undesirable flavors and aromas, and degradation of certain nutrients.

Less Food Waste & Spoilage
Longer-lasting products can reduce the amount of inventory lost to spoilage throughout production, distribution, retail, and consumer storage.

Improved Product Presentation
Preserving color, texture, and overall product quality helps create a more attractive package on the shelf.

Flexible Packaging Systems
MAP can be incorporated into equipment ranging from compact tabletop machines to fully automated packaging lines.

MAP technology can be used across a wide range of applications, including:

• Fresh fruits and vegetables
• Pre-cut produce
• Raw and cooked meats
• Dairy products
• Ready-to-eat meals
• Bakery products
• Other fresh and perishable foods

Both Vacuum Skin Packaging (VSP) and Modified Atmosphere Packaging (MAP) can help preserve food and extend shelf life, but they accomplish this in different ways.

MAP removes the existing atmosphere surrounding the food and replaces it with a controlled gas mixture containing lower levels of oxygen. This modified atmosphere helps limit oxidation and microbial growth while maintaining an environment appropriate for the packaged product.

MAP is commonly used for:

• Bakery products
• Dairy products
• Produce
• Ready-to-eat meals

VSP removes the ambient air surrounding the product without replacing it with another gas mixture. A flexible barrier film then conforms closely around the product and seals it to the tray or board.

Because VSP tightly secures the product while significantly reducing oxygen exposure, it is particularly well suited for:

• Meat
• Poultry
• Seafood
• Ready-to-eat meals

The right technology depends on the product, desired shelf life, presentation requirements, and production environment.

MAP systems carefully control the atmosphere within each package while maintaining the appropriate pressure and volume to protect both the package and its contents.

While individual equipment configurations vary, the basic MAP process typically includes:

1. Load the Product
Products may be manually placed into the sealing chamber or automatically transported into the system using conveyors and integrated production equipment.

2. Remove the Existing Atmosphere
A vacuum system removes most of the ambient atmosphere surrounding the food inside the package.

3. Introduce the Gas Mixture
The removed atmosphere is replaced with a controlled gas mixture, typically containing carbon dioxide and nitrogen. The exact gas composition depends on the food product and application.

4. Seal the Package
A barrier film is heat-sealed to the tray, creating an airtight package that maintains the modified atmosphere.

5. Trim & Release
The film is cut to the appropriate dimensions and the completed package is released for the next stage of production.

Point Five Packaging offers MAP-capable equipment ranging from compact systems for startups, laboratories, and smaller producers to fully automated packaging lines capable of high-volume production.

Maintaining a controlled atmosphere requires more than the packaging machine itself. Trays, films, and other components must work together to prevent oxygen and moisture from entering the package after sealing.

Plastic Food Trays
MAP trays need to withstand sealing, storage, transportation, and retail handling without compromising the package.

Depending on the application, trays may offer:

• Durable materials such as CPET and PP
• Leak- and spill-resistant construction
• High-barrier properties
• Microwave- or oven-safe performance
• Strength for shipping, storage, and display

High-Barrier Packaging Films
Barrier films help prevent oxygen and moisture transmission after the package has been sealed. Many high-barrier films use multilayer structures that combine materials to achieve the required performance.

Common materials include:

• Low-Density Polyethylene (LDPE)
• Polypropylene (PP)
• Polyvinyl Chloride (PVC)
• APET/PET

Film selection depends on the food product, tray material, desired shelf life, storage conditions, and barrier requirements.

Scavenger & Desiccant Packs
For applications where residual oxygen or moisture requires additional control, specialized sachets can absorb moisture or oxygen within the package.

On-Package Valves
One-way valves allow gases produced by certain products to escape after sealing without allowing outside oxygen to enter. This can help manage internal pressure during storage and transportation.

Point Five Packaging offers MAP-capable systems for operations ranging from entry-level production to fully automated, high-volume packaging lines. Many systems can perform tray and cup sealing, MAP, vacuum-gas packaging, and Vacuum Skin Packaging (VSP) on the same platform.

Since 2010, Point Five Packaging has provided food manufacturers with packaging equipment, materials, and technologies designed around their specific production requirements.

From compact tabletop equipment to fully automated packaging lines, our MAP systems can accommodate businesses at different stages of growth while providing access to tray sealing, vacuum-gas MAP, VSP, and other packaging capabilities.

Our team can help determine the appropriate machine, tray, barrier film, gas-flushing configuration, and supporting equipment based on your product, desired shelf life, production volume, and packaging requirements.