How much can I save by switching from CO2 to nitrogen in MAP?

When switching from CO2 to nitrogen in Modified Atmosphere Packaging (MAP), you can save 30-50% on your gas costs. This saving comes from lower purchase costs for the gas itself, the elimination of transport and storage costs, and the ability to produce nitrogen on-site with your own generator. For most companies, the investment in a nitrogen generator is recovered within 1-3 years. In addition to the financial benefits, nitrogen also offers better product protection and is more environmentally friendly than CO2.

Why Switch from CO2 to Nitrogen in MAP Packaging?

Switching from CO2 to nitrogen in MAP packaging offers various advantages for food producers and packaging companies. Nitrogen is an inert gas that effectively slows oxidation and microbial growth, similar to CO2, but often at lower costs.

You can produce nitrogen on-site with a generator, eliminating dependency on external suppliers. This removes the logistical challenges often associated with CO2 deliveries, such as transport delays or stock shortages.

Additionally, nitrogen is more environmentally friendly. CO2 is a greenhouse gas, while nitrogen is a natural component of our atmosphere (78%). By using nitrogen, you reduce your company’s ecological footprint, which is increasingly important for consumers and regulatory compliance.

For many products, nitrogen also provides better protection against moisture and helps preserve aromas, resulting in longer shelf life and better product quality. This reduces waste and increases customer satisfaction.

What Are the Direct Cost Savings When Switching to Nitrogen?

The direct cost savings when switching from CO2 to nitrogen are substantial and manifest in several ways. The purchase price of nitrogen is typically lower than that of CO2, especially when you invest in your own nitrogen generator.

With delivered CO2, you pay not only for the gas itself but also for transportation, cylinder or tank rental, and sometimes delivery surcharges. With your own nitrogen generator, you produce the gas on-site, eliminating these extra costs.

Another significant advantage is that the price of self-produced nitrogen remains stable, regardless of market fluctuations. You mainly pay for electricity and maintenance, costs that are predictable and increase gradually compared to the volatile CO2 market.

For businesses with high gas consumption, savings can amount to thousands of euros per month. Moreover, the need for storage space for gas cylinders or tanks is reduced, freeing up additional room for other business activities.

How Does Nitrogen Affect Product Shelf Life?

Nitrogen has a positive influence on the shelf life of products in MAP packaging by creating an oxygen-poor environment. This slows oxidation processes and inhibits the growth of aerobic microorganisms that cause spoilage.

For products such as meat and fish, nitrogen helps maintain natural color and prevents rancidity. In bakery products, it prevents mold growth and preserves texture. For snacks and dry products, nitrogen maintains crispness and prevents moisture.

Compared to CO2, nitrogen offers some specific advantages. While CO2 can dissolve in moist products and sometimes cause acid formation, nitrogen remains inert. This makes nitrogen particularly suitable for products with high moisture content or products sensitive to acid formation.

Additionally, nitrogen does not cause volume changes in the packaging over time, while CO2 can sometimes be absorbed by the product, leading to collapsed packaging. This gives products packaged with nitrogen a more consistent and attractive appearance on the shelf.

What Is the Return on Investment Period for a Nitrogen Generator?

The return on investment period for a nitrogen generator typically varies between 1 and 3 years, depending on various factors. The gas consumption volume is the most determining factor – the more gas you use, the faster the investment is recovered.

The initial investment for a nitrogen generator depends on the desired capacity and purity. Systems for smaller companies start at a few thousand euros, while larger industrial installations can cost significantly more.

Your current CO2 expenditures form the reference point for your potential savings. If you currently have high costs for CO2 purchases, transport, and storage, your payback period will be shorter than for companies with lower gas costs.

Operational factors also play a role. The energy costs for running the generator, as well as maintenance costs, must be included in the calculation. Modern nitrogen generators are becoming increasingly energy-efficient, contributing to a faster return on investment.

For most food producers and packaging companies with average to high gas consumption, the investment is recovered within 18-24 months, after which you benefit from substantial cost savings for years to come.

How Do You Begin the Switch from CO2 to Nitrogen?

The transition from CO2 to nitrogen in MAP packaging begins with a needs analysis. Map your current gas consumption, along with production patterns and peak moments. This helps determine the right capacity for your nitrogen generator.

Next, it’s important to determine the specific purity level you need for your products. Different foods require different nitrogen purities, usually between 95% and 99.999%.

Test the new nitrogen application on a small scale before fully switching over. You can do this by creating test packages and monitoring shelf life and product quality. This allows you to make any adjustments to your packaging process or gas mixture.

For implementation, you may need to adapt or upgrade your current packaging machines to work optimally with nitrogen. Often these adjustments are minimal, as most MAP equipment is suitable for both gases.

Finally, consider a gradual transition by starting with one production line or specific products. This phased approach minimizes risks and ensures a smooth transition. Would you like to know more about the possibilities for your specific situation? Then contact us at Presscon for consultation.