Gas Packaging in the food industry

What is gas packaging

Gas packaging is the process in which the composition of atmospheric air inside a package is modified to improve the preservative properties of food products. By selecting the correct gas composition, spoilage mechanisms can be slowed down and product quality can be maintained for a longer period.

This technique is also known as Modified Atmosphere Packaging, or MAP. In practice, it is not only about the packaging method itself, but about controlling oxidation, moisture and microbiological activity throughout the entire production process.

Why food deteriorates

Food begins to degrade as soon as it is produced or harvested. This affects appearance, smell, taste, texture and food safety.  

Three processes play a central role:

• Oxidation caused by contact with oxygen
• Moisture absorption or moisture loss
• Growth of micro-organisms

By controlling the atmosphere surrounding the product, greater control over shelf life and product quality is achieved.

Protection against oxidation with nitrogen

When food components come into contact with oxygen, oxidative reactions may occur. This leads to discoloration, off-flavours and quality loss.

By displacing oxygen in the package and replacing it with nitrogen, oxidation is significantly reduced or completely prevented. Nitrogen is inert and does not react with the product. As a result, flavour, aroma and texture are preserved.

Moisture control in packaging

Atmospheric air contains water vapour. For dry or hygroscopic products, this can result in moisture absorption and quality loss.

By using extremely dry nitrogen, the moisture level inside the package can be controlled. This prevents structural degradation and extends shelf life. Nitrogen is also applied during storage and transport of powders to ensure stability.

Modified Atmosphere Packaging (MAP)

Modified Atmosphere Packaging is a method in which the natural air composition is adjusted by introducing nitrogen, CO2 and, if required, oxygen in a controlled ratio.

By reducing oxygen levels and strategically applying CO2, the growth of specific micro-organisms can be inhibited. This makes it possible to extend shelf life without the use of additional preservatives.

The effectiveness of MAP depends on several factors, including temperature control, hygiene standards, raw material quality and the barrier properties of the packaging. MAP is therefore part of an integrated quality management approach.

Why nitrogen is used in the food industry

Nitrogen is the most widely used gas in gas packaging and MAP applications. This is due to the following functional benefits:

• Displaces oxygen from the packaging
• Prevents oxidation of sensitive components
• Preserves flavour, aroma and texture
• Stabilises packaging through pressure control
• Is inert and does not react with the product

In addition to gas packaging, nitrogen is used for storage, silo blanketing and process support within the food industry.

Food grade nitrogen and regulations (E941)

When nitrogen comes into direct contact with food, it must comply with applicable regulations. Within Europe, nitrogen is classified as E941 when used as a packaging gas.

This means the gas must meet established contaminant specifications and its purity must be verifiable. For producers, this is essential from a quality, food safety and compliance perspective.

A reliable gas supply is therefore important for process reliability.

On-site nitrogen production versus traditional gas supply

With an on-site nitrogen generator, you produce nitrogen gas yourself, directly at your location. You continuously have access to the required flow and purity. 

The advantages of on-site nitrogen production:

• Continuous availability without supplier dependency
• Consistent quality and purity
• No storage of high-pressure cylinders
• Reduced logistical burden
• Structural reduction of operational costs

This increases process reliability and gives you full control over your gas supply.

Nitrogen solutions for your application

Avilo supplies food grade gas generation systems for a wide range of applications within the food and beverage industry.

Would you like to understand what gas packaging and on-site nitrogen production can mean for your process?
Contact us for a technical analysis of your situation.