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Protective gas in food packaging
Keep food fresh for longer with the help of Becker vacuum pumps!
1. Why protective gas packaging is indispensable
Whether fresh meat, cheese, baked goods or snacks: the shelf life and freshness of food are crucial for sales success and customer satisfaction. Modified Atmosphere Packaging (MAP) is now one of the most important methods for keeping food fresh for longer without the use of additional preservatives. As a manufacturer of vacuum pumps, central vacuum systems and compressors, this article explains how modified atmosphere packaging works, which gases are used, which specifications and guidelines must be followed, and how vacuum solutions from Becker play a key role in all of this.
2. What is Modified Atmosphere Packaging (MAP)?
In modified atmosphere packaging, the natural air in a food package is replaced by a defined gas or gas mixture to extend shelf life. Instead of "normal air" with approx. 21% oxygen, the packaging then contains an optimised gas atmosphere, usually with reduced oxygen or, depending on the area of application, even completely oxygen-free.
Advantages of MAP technology in the food industry:
- Extended shelf life without chemical additives
- Preservation of taste, consistency and colour
- Protection against oxidation and microbiological spoilage
- Attractive product appearance
3. Typical protective gases and their effects
The choice of the right gas for food packaging depends largely on the type of food. Here are a few examples of applications:
| Gas | E number | Effect |
| Nitrogen (N₂) | E 941 | Inert gas, displaces oxygen, prevents oxidation |
| Carbon dioxide (CO₂) | E 290 | Inhibits bacterial and mould growth |
| Oxygen (O₂) | E 948 | Preserves the red colour of meat, inhibits anaerobic bacteria |
Gas mixtures are often used, e.g. 70% N₂ / 30% CO₂ for cheese or 80% O₂ / 20% CO₂ for red meat, depending on the specific requirements of the food. In most cases, a gas or gas mixture can be used that is optimally suited to the food in question.
4. How the protective gas packaging process works
Modified atmosphere packaging processes usually follow the same procedure.
In the first step, the natural ambient air is completely or partially removed from the packaging. A vacuum pump ensures that oxygen, moisture and any airborne microorganisms are reduced. Depending on the product, a partial vacuum or a near-complete vacuum can be created.
- The aim is to minimise oxidation, delay microbial growth and extend shelf life.
- Suitable products: Oil-lubricated or oil-sealed rotary vane vacuum pumps from Becker offer advantages here, as they ensure high process consistency and are permanently reliable even at high cycle rates.
- Special cases: For sensitive products (such as soft baked goods), the vacuum is adjusted so that the packaging is not deformed.
In the second step, after the air has been removed, the packaging is filled with a predefined protective gas or gas mixture. This step is usually carried out immediately after the vacuum phase in order to keep the oxygen content inside the packaging as low as possible.
- Gas types: Examples include nitrogen (E 941) as an inert gas, carbon dioxide (E 290) to inhibit bacterial and mould growth, and oxygen (E 948) for meat products to preserve colour.
- Requirements: The protective gas must be pure in accordance with food law (in accordance with EU Regulation (EC) No. 1333/2008 and the relevant HACCP requirements).
- Technical implementation: The gas is supplied via precise dosing and mixing systems, which are often integrated into the packaging machine. The interaction of vacuum technology and gas supply is a decisive factor in determining shelf life and quality at this point.
In the final step, the packaging is sealed airtight to ensure that the gas mixture remains intact throughout the entire storage period. The following parameters must be observed here:
- Sealing techniques: Sealing with films, heat sealing or mechanical closure for containers and cans.
- Quality control: Modern MAP systems perform internal leak tests to ensure that no gases escape.
- Long-term safety: A stable seal not only protects against gas loss, but also against the ingress of moisture, germs or odours.
5. Role of vacuum pumps and systems in the MAP process
Vacuum pumps play a central role in the efficiency and quality of modified atmosphere packaging. They ensure that air is removed quickly and reliably during the packaging process, which significantly reduces cycle times in production. Rapid evacuation means that more packaging units can be processed in less time, which significantly increases productivity. Consistent process quality is equally important: uniform and stable negative pressure ensures that every package meets the same high standard and that the protective gas is used in the correct concentration. For particularly hygiene-sensitive applications, such as in food or pharmaceutical production, oil-free vacuum pump designs are advantageous as they eliminate the risk of contamination.
In addition, there are combined pressure/vacuum pumps that not only generate the necessary vacuum, but can also supply compressed air. This compressed air can be used, for example, for control tasks or for handling products within the packaging system, which further optimises the overall process.
A central vacuum system with a variable number and performance of pumps can be the next step in production efficiency. Production and vacuum pumps are separated from each other, the system is automatically controlled according to production requirements and the energy required for air conditioning the production facility is reduced. Advantages of a central vacuum system:
- Higher yield
A central vacuum system shortens evacuation times and increases the performance of production machines. - Clean production
The elimination of decentralised individual pumps reduces noise, heat and oil mist – for better working and production conditions. - Greater operational reliability
Reliable backup pumps minimise downtime, increase production efficiency and reduce operating costs.
6. Industries and foods that benefit from protective gas
The food industry in particular benefits from protective gas packaging, which extends the shelf life of food and ensures an appetising appearance. Product examples where protective gas packaging is frequently used include:
- Meat & sausage: oxygen-containing gas mixtures for red colour
- Cheese & dairy products: nitrogen/CO₂ mixture to prevent mould growth
- Baked goods: nitrogen to protect against oxidation
- Snacks & nuts: nitrogen against rancidity
- Ready meals: gas mixtures for long shelf life with consistent taste
7. Hygiene and legal requirements
The food industry is subject to strict hygiene and safety regulations to protect consumer health and ensure consistently high product quality. These are based, among other things, on EU Regulation (EC) No. 1333/2008, which regulates the approval and use of food additives – including protective gases – and international standards such as ISO 22000 and HACCP, which prescribe comprehensive food safety management. In addition, the EHEDG guidelines (European Hygienic Engineering & Design Group) provide specific requirements for the hygienic design of machines and systems in order to minimise contamination risks and enable simple, thorough cleaning. Becker vacuum pumps can be seamlessly integrated into hygienically designed MAP (Modified Atmosphere Packaging) systems, ensuring that the entire packaging process complies with applicable standards, both technically and hygienically. This not only ensures compliance with legal requirements, but also supports the safety and quality of the packaged food in the long term.
8. Common mistakes and how to avoid them
Various errors can occur during the packaging process with protective gas, which can significantly impair the shelf life and quality of the products. One of the most common is excessive contact with oxygen prior to packaging. If the food is exposed to ambient air for too long before sealing, this can accelerate oxidation, which has a negative effect on taste, colour and nutrients.
Another critical issue is insufficient vacuum: if not enough air is removed during evacuation, oxygen residues remain in the packaging, which promote the spoilage process and shorten the shelf life.
Becker offers high-performance vacuum pumps for optimum results. An incorrect gas mixture that is not optimally matched to the product in question is equally problematic. This can affect colour, consistency or taste. Finally, leaks in the packaging pose a considerable risk: if the protective gas escapes through leaks, the desired effect is lost and the food spoils more quickly. These errors can be reliably avoided through careful process control, the use of suitable gases from and regular inspection of the systems.
9. Conclusion – Freshness that lasts longer
Today, protective gas packaging has established itself as the recognised state of the art when it comes to presenting food in a fresh, safe and visually appealing way. Not only does it enable longer shelf life, it also helps to preserve the taste, colour and consistency of products over a longer period of time. Vacuum pumps play a central role in this process, acting as the heart of the system. They remove the air from the packaging quickly and efficiently, create the necessary vacuum and then enable precise filling with the optimally balanced gas mixture. This ensures that every product is packaged under ideal conditions and that quality is maintained from the first to the last day of storage.
As an experienced manufacturer of vacuum pumps, Becker is proud to provide professional support to the food industry in the field of modified atmosphere packaging.
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