MAP technology (Modified Atmosphere Packaging) is an effective method to significantly extend the shelf life of meat. By modifying the composition of gases in the packaging, the growth of spoilage-causing microorganisms is slowed down. Nitrogen plays an essential role as an inert gas that displaces oxygen and prevents oxidation. A professional MAP system with the right gas composition can extend the shelf life of fresh meat by 50-400%, depending on the type of meat and the initial quality.
What is MAP technology and how does it extend the shelf life of meat?
MAP technology or Modified Atmosphere Packaging is a preservation method where the normal air composition in a food package is replaced by a carefully composed gas mixture. For meat products, this significantly delays natural aging and spoilage.
The working principle behind MAP is relatively simple but very effective. By modifying the atmosphere in the packaging, two important processes that cause spoilage are inhibited:
- Microbial growth: MAP mixtures with an elevated CO₂ content inhibit the growth of aerobic bacteria that spoil meat.
- Oxidation: By reducing the oxygen content, oxidation of fats and pigments is slowed down, preventing discoloration and rancidity.
The modified gas composition creates an environment in which spoilage processes are inhibited, while quality characteristics such as color, flavor, and texture are preserved. This keeps the meat fresh longer, which not only extends shelf life but also reduces food waste and improves food safety.
With MAP technology, it’s crucial that the packaging is sealed airtight so the protective gas atmosphere is maintained throughout the entire storage period. Modern MAP systems can very precisely regulate and monitor the gas composition to guarantee optimal results.
Which gases are used in MAP packaging for meat?
In MAP packaging for meat, primarily three main gases are used, each with a specific function in the preservation process. The exact composition varies depending on the type of meat and the desired properties.
The most important gases in MAP packaging are:
- Nitrogen (N₂): Functions as an inert filler gas that displaces oxygen. It has no direct antimicrobial effect but helps maintain the packaging shape and prevents the package from collapsing.
- Carbon dioxide (CO₂): Has a strong antimicrobial effect and inhibits the growth of aerobic bacteria and molds. It partially dissolves in the meat tissue, which has a slight preservative effect.
- Oxygen (O₂): In specific cases, a certain amount of oxygen is maintained, especially for red meat, to preserve the red color. For most other types of meat, oxygen is minimized.
| Meat type | Optimal gas composition | Intended effect |
|---|---|---|
| Red meat | 70-80% O₂, 20-30% CO₂, 0-10% N₂ | Preservation of red color, inhibition of bacterial growth |
| Poultry | 25-30% CO₂, 70-75% N₂ | Maximum inhibition of bacterial growth |
| Processed meat | 30-40% CO₂, 60-70% N₂ | Prevention of oxidation, extension of shelf life |
Choosing the right gas composition is important for optimal results. Too much CO₂, for example, can lead to acidification or discoloration, while too little reduces the antimicrobial effect. Professional nitrogen generators provide the required gases in the right proportions and purity.
What are the benefits of nitrogen in MAP packaging?
Nitrogen is an essential gas in MAP packaging for meat with various important benefits. As an inert gas, it plays a crucial role in extending shelf life and maintaining the quality of meat products.
The main benefits of nitrogen in MAP systems are:
- Oxygen displacement: Nitrogen effectively displaces oxygen from the packaging, which slows down oxidation processes. This prevents discoloration and rancidity of fats.
- Bacterial growth inhibition: By creating a low-oxygen environment, aerobic bacteria are inhibited in their growth, which delays spoilage.
- Preservation of structure: As a filler gas, nitrogen prevents the collapse of packaging when CO₂ is absorbed by the product.
- Neutral for taste and smell: Nitrogen is odorless, tasteless, and does not react with food components, thus preserving the original sensory properties.
- Safe to use: Nitrogen is non-toxic, non-flammable, and chemically inert, making it a safe gas for food applications.
For meat processors, having their own nitrogen generator offers important operational advantages. You are no longer dependent on external gas suppliers, leading to lower operational costs, fewer logistical challenges, and a constant gas supply. The continuous availability of freshly produced nitrogen ensures consistent quality in your MAP packaging.
How do you implement an effective MAP system in your meat processing company?
Implementing an effective MAP system in your meat processing company requires a systematic approach and the right equipment. A well-implemented system not only improves the shelf life of your products but also increases the efficiency of your production process.
Follow these steps for successful implementation:
- Needs analysis: Determine which meat products you want to package and what shelf life you want to achieve. Different products require different gas mixtures.
- Selection of equipment: Invest in quality components:
- Nitrogen generator with sufficient capacity
- Gas mixing station for precise composition
- Packaging machines suitable for MAP
- Quality control systems for gas composition
- Integration into production line: Ensure seamless integration of the MAP system into your existing production process. This includes proper placement of equipment and alignment of production speeds.
- Staff training: Train your employees in correctly operating the equipment, the importance of hygiene, and recognizing deviations in the process.
- Testing phase: Conduct tests with different gas mixtures and packaging materials to determine the optimal configuration for your products.
- Quality control system: Implement regular checks of gas composition, packaging integrity, and product shelf life.
Regular maintenance of your MAP system is essential for optimal performance. This includes calibration of gas mixers, checking the nitrogen generator, and preventive maintenance of packaging machines. A well-maintained system guarantees consistent results and prevents costly production interruptions.
What are the key considerations when using MAP for meat?
For optimal results with MAP technology, several critical factors are of great importance. These considerations largely determine the effectiveness of your MAP system and thus the ultimate shelf life of your meat products.
Pay attention to the following important aspects:
- Initial product quality: MAP can extend shelf life but does not improve the quality of the meat. Always start with fresh, high-quality meat processed under hygienic conditions.
- Packaging integrity: Even the smallest leak can nullify the protective gas mixture. Use high-quality packaging materials with good barrier properties and ensure perfect sealing.
- Temperature control: MAP works best in combination with refrigeration. Maintain the cold chain for maximum effectiveness. Even with MAP, meat will spoil faster at higher temperatures.
- Consistent gas composition: Ensure a reliable nitrogen source with constant purity. Fluctuations in gas quality can lead to inconsistent results.
- Hygiene during packaging: Prevent recontamination during the packaging process through strict hygiene measures and regular cleaning of equipment.
- Monitoring and validation: Regularly check the gas composition in packages and validate shelf life through microbiological tests.
An often overlooked aspect is the impact of product variation. Different types of meat, fat contents, and pH values respond differently to MAP. It may be necessary to adjust your gas mixtures for specific product categories to achieve optimal results.
By systematically addressing these considerations, you maximize the effectiveness of your MAP system and create a reliable process that guarantees consistent quality and shelf life.
Important conclusions about MAP technology for meat shelf life
MAP technology offers meat processors a proven method to extend the shelf life of their products without compromising quality or food safety. By properly implementing this technology, you can expand your market reach, reduce food waste, and improve your business profitability.
The key to successful application of MAP lies in the combination of the right equipment, optimal gas mixtures, and consistent process control. Nitrogen plays a central role due to its unique properties as an inert filler gas that prevents oxidation and ensures packaging integrity.
At Presscon, we understand the challenges faced by meat processors in the food industry. Our customized nitrogen generators offer a reliable and cost-effective solution for your MAP needs. We not only provide the equipment but also support you in integrating it into your existing processes and ensuring optimal performance.
By choosing your own nitrogen supply, you make your company independent from external gas suppliers. This results in lower operational costs, improved flexibility, and consistent gas quality that directly contributes to the shelf life and quality of your products.
With the right knowledge, equipment, and support, you can optimally utilize MAP technology to strengthen your competitive position and meet the increasing market pressure for fresher products with longer shelf life. For personalized advice on your specific needs, contact our MAP technology specialists.