How Does MAP Tray for Meat Work?

The different terminology for different types of trays and tray sealing processes for the food industry can be confusing.

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Here’s a brief explanation of the differences between CPET & MAP trays.

CPET Trays

CPET refers to the predominant plastic used in this type of tray.

CPET is a plastic commonly used for trays in the food industry, as it can be heated, and is therefore perfect for packing ready meals or similar.

However, plastic trays for food packaging can also be made out or Polypropylene (PP), Polyethylene terephthalate (PET), or Bioplastics; just to name a few options.

Every type of plastic has its own unique qualities, so choosing what type of plastic tray to use depends on your specific needs.

MAP Trays

Some may often refer to ‘MAP Trays’, MAP is actually not a type of tray.

MAP stands for Modified Atmosphere Packaging, which is a type of tray sealing process.

This process means that once the product is placed in a tray, the oxygen is then sucked out of the package, and a combination of food gas is pumped in to replace it.

The lidding film is then sealed over the tray, creating a modified atmosphere inside the package.

This gas mixture is specifically designed to increase a product’s shelf life, prevent the growth of bacteria, and retain freshness.

MAP is often used with fresh foods such as red meat, seafood or ready meals – and trays from various types of plastic can be used in this process.

Do you want to improve your packaging, or are you looking for a better packaging option? Either reason, you should choose modified atmosphere packaging.

This is the best packaging solution as it can keep the food’s freshness, color, and taste for days to months. For this, it only uses different gases for certain products. 

To learn details about MAP, let’s dive into the below-

What Is Modified Atmosphere Packaging?  

If you want to keep fresh fish, meat, vegetables, etc, and increase their shelf life, modified atmosphere packaging (MAP) is your only option. This is a revolutionary method of packaging for perishable food. 

Basically, MAP removes the oxygen and includes carbon dioxide and other gases during the packaging process. Therefore, it slows down the growth of bacteria and maintains the color and texture of the food products. 

Material Used In Modified Atmosphere Packaging  

Let’s take a look at the use of several materials in a modified atmosphere packaging here-

1. Polyethylene terephthalate (PET): It is widely used for packaging food items. PET provides a high degree of protection from moisture and oxygen. Also, as it has a clear and transparent body, the consumer can see the products and their conditions. 

2. Polyamide: This nylon material is often combined with polyethylene to offer an ideal heat seal obstacle. It is best at resisting puncture and abrasion as well as oxygen. Therefore, you can use polyamide(PA) to pack raw meat in vacuum pouches. 

3. Polyethylene: Often, polyethylene (PE) is mixed with other surfaces, like aluminum, to be used in modified atmosphere packaging. It is not great at preventing gas; however, it’s best at protecting food against water. Different types of PE are available for various applications; check them out-

4. Polypropylene (PP): It is one of the materials used for flexible modified atmosphere packaging. You can use PP for rigid packaging. Although it is best for barriers water, not gases. Hence, PP can be microwaved with low-fat food items. However, it’s best to avoid microwave PP when it stores fatty foods. 
5. Polyvinyl chloride: Polyvinyl chloride (PVC) is the best material for thermoformed packaging due to its sound processing and low softening features. It also has moderate gas and water barriers and excellent oil resistance. It’s commonly used in modified atmosphere packaging base trays mixed with PE for heat sealing.
6. Expanded polystyrene (PVC): This material of MAP does not provide full protection against gas for food items. But when you combine ethylene vinyl alcohol (EVOH) and PVC, you can use it in trays like a layer of structure. 

Types Of Modified Atmosphere Packaging?   

Typically, modified atmosphere packaging has two types, however, each one has other kinds with unique features. I have described all of them in the below section; read them thoroughly-

Active Modified Atmosphere Packaging

It involves actively altering the gas composition inside a package to extend product shelf life. This technique replaces the natural atmosphere with a mix of gases, such as nitrogen or carbon dioxide. This way, active modified packaging slows down spoilage and maintains freshness in food products. 

Scavenger or desiccant packs

These scavenger or desiccant packs contain a combination of iron, carbon, and acid. When placed in bags or containers, they can absorb oxygen.

Therefore, you can use these MAPs for various of industry for packing items, for instance-

• 3-side seal pouches
• Doy packs
• Flexible vacuum packaging
• Kraft paper pouches

Gas flushing

This is a type of MAP where the air inside a package is replaced with a specific gas mix, usually nitrogen or carbon dioxide. The process slows down oxidation, microbial growth, and spoilage. So, it is ideal for perishable goods.

Let’s see a few packages you can use gas flushing-

• Cheese packaging
• Flat bags
• Meat or vegetable trays with lidding films
• Centre seal pouches made from rewind

On-package valves

Another popular MAP option is on-package or one-way packaging valves. These valves can release gases inside the package and prevent air from entering from outside. The coffee and tea industries usually use this method more often.

For some of the bag options, you can use the valves- 

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• Vacuum pouches
• Custom meat and seafood bags
• Quad Seal pouches
• Flat Bottom Bags

Passive Modified Atmosphere Packaging

If you use breathable films in the packaging, they can diffuse gases. For this, you have to select the best packaging films that can absorb the moisture of the products. 

Vacuum skin packaging

Vacuum skin packaging (VSP) is a MAP method where the product is tightly sealed in a skin-tight film with most of the air removed. This process preserves the product’s freshness by reducing oxygen exposure and preventing spoilage.

You can use vacuum skin packaging in these pouches-

• Frozen meat and poultry bags
• Seafood pouches
• Cheese wraps
• Processed food trays

Barrier films

This is another passive method in MAP. Barrier films are used in controlled atmosphere packaging on the inside of the bags to block oxygen, water, and other properties. Therefore, the products can increase shelf life. 

It is a flexible process and can match these items-

• Center seal pouches
• Clear flat pouches
• Flat Bottom Bags
• Flexible vacuum packaging
• Stand Up Pouches
• Carton meat and seafood pouches inside boxes

How Does Modified Atmosphere Packaging Work?  

Modified Atmosphere Packaging works by controlling the atmosphere surrounding a product inside its packaging to extend its shelf life. The process involves replacing the air in the package with a specific blend of gases, usually carbon dioxide, nitrogen, and even oxygen. You should adjust the gases depending on the product’s needs. 

This gas mixture helps slow down the growth of bacteria and mold. Also, it can reduces oxidation, and maintain the product’s freshness, flavor, and texture. MAP is commonly used in the food industry for perishable items.

Here, let’s see how MAP controls the atmosphere of the food inside the packaging-

Applications Of Modified Atmosphere Packaging  

• Meat: MAP can prevent spoilage of meat by slowing down the growth of aerobic bacteria and oxidation. It maintains the red color and freshness.
• Seafood: Storing seafood in modified atmosphere packaging minimizes the growth of bacteria. Also, MAP can maintain the texture and flavor by controlling oxygen levels.
• Bakery Products: You can use MAP to package baking cakes or biscuits. It delays staling and mold growth and extends shelf life.
• Ready-to-Eat Meals: MAP ensures that ready-to-eat meals like instant noodles retain their original color, freshness, and taste.
• Snacks: As you know, snacks like chips need to be crunchy, and MAP can provide that by reducing moisture.
• Cheese: MAP inhibits mold growth and delays spoilage of the cheese while maintaining texture.
• Coffee and Tea: The MAP is the best option for protecting the aroma and flavor of coffee and tea. It prevents oxidation and moisture absorption.
• Fruits: Modified atmosphere packaging for fruits and vegetables slows down ripening and spoilage by controlling oxygen and carbon dioxide levels.
• Fresh pasta: MAP extends freshness and prevents discoloration of pasta by minimizing oxygen exposure.

Benefits Of Modified Atmosphere Packaging 

• Improved Quality: With MAP, you can ensure product quality. This is because the packaging can keep the product fresh by maintaining the food flavors and nutritional value. 

• Extended Shelf Life: MAP does not allow moisture to attack the products as it can remove oxygen from the package. Usually, this packaging can extend meat shelf life from 4-22 and pasta from 4-61 days. Also, it can keep the cheese fresh for 6-181 days. 

• Reduced Waste: The MAP can increase the shelf life of food, reducing food waste and spoilage. So, you can transport food items to faraway places and boost sales. 

Drawbacks Of Modified Atmosphere Packaging  

• It can be expensive to set the MAP in the first place.
• When the gas is mismatched, that can spoil the food. 

Machines For Modified Atmosphere Packaging  

You can use different automated machines for modified atmosphere packaging based on your production types and requirements. 

1. Thermoforming MAP Packaging Equipment

A Thermoforming modified atmosphere packaging machine utilizes thermoforming technology to shape plastic film into packages, which are then filled with products. This is an automatic machine that can work at a high speed.

If you have a specific requirement, you can customize the thermoforming machine according to product size. The machine offers precise control over temperature and atmosphere, ensuring the quality of various food items.

2. Vacuum Packaging Equipment

This combines vacuum sealing with modified atmosphere techniques to protect food from spoilage and oxidation. The machine removes air from the packaging and replaces it with nitrogen gas or carbon dioxide. 

Therefore, you can use this vacuum MAP machine to preserve the quality of meats, cheeses, and ready-to-eat meals. This MAP machine will ensure the food remains safe and flavorful over time.

3. Form Fill Seal Machine

With this MAP machine, you can form pouches or other bags and then fill them with products. Before sealing, this machine inputs gas to maintain the quality of the food. Whether you have the pharmaceutical, food, and beverages industry, you can use this machine. However, this machine can be two types, such as-

• Vertical Form Fill Seal (VFFS): These machines form the package from a roll of film, fill it with product, and seal it vertically. They are ideal for high-speed, small to medium-sized packages.
• Horizontal Form Fill Seal (HFFS):  HFFS machines use a horizontal film roll to form, fill, and seal packages. These are suitable for larger and more rigid products, such as frozen foods, prepared meals, and medical supplies.

Other Types Of Modifies Atmosphere Machines

MAP Tray Packaging Equipment: This machine seals the tray and injects gas to prevent mold, keeping the product fresh for many days. It can also print information on the package. 

MAP Fin Seal Flow Wrap Equipment: It can offer a customized option for your specific packaging choice. This machine can also print film that is ideal for single food content, like a tray with meat pieces. 

MAP Band Sealing Equipment: Typically, this sealing machine puts gas inside the package and seals it. 

Conclusion

Now you are expert and know everything about modified atmosphere packaging (MAP), from its definitions, applications, benefits, and cons. So, if you want to keep your food tasting as fresh as organic and maintain quality for months, use MAP in your industry.  

But if you need professional help choosing the best packaging machine, you can contact us. Our professional R&D team will assist you.

FAQs

What are the gases used in modified atmosphere packaging?

Gases like nitrogen, carbon dioxide, and even oxygen are commonly used in modified atmosphere packaging. Therefore, nitrogen helps displace oxygen and reduce food spoilage. At the same time, carbon dioxide inhibits microbial growth and slows down the ripening process. Also, by controlling oxygen levels, you can maintain food items’ freshness and quality.

What temperature is modified atmosphere packaging stored at?

Typically, modified atmosphere packaging is stored at 0-5°C. This temperature helps to slow down microbial growth and preserve the product’s quality. Often, the ideal storage temperature can vary depending on the specific product and its packaging.  

Is modified atmosphere packaging safe?

Yes, modified atmosphere packaging is safe and sustainable as it only uses gases to protect the food from bacteria. This way, it can reduce food waste. However, nonrecyclable plastic can impact environmental pollution. So, try to choose materials that are reusable and recyclable. 

Are you interested in learning more about MAP Tray for Meat? Contact us today to secure an expert consultation!