www.wittgas.

com
TECHNOLOGY FOR GASES

Does your process involve modified

atmosphere packaging (MAP)?
[ Friedrich hillebrand: regional SaleS Manager WiT T gaSeTechniK ]

Our MAP solutions

guarantee certified safety for
your packaging process.
Keyword: HACCP

ISO 22000 approval for food safety

THE RIGHT MODIFIED ATMOSPHERE FOR EVERY PRODUCT

PROTECTIVE GASES
Oxygen (O2) essentially causes food to
spoil due to oxidation and forms the ideal
preconditions for aerobic microorganisms
to grow. as a result, oxygen is frequently
excluded from modified atmosphere
packaging. in some cases typically red
meat processing is deliberately carried
out with high oxygen concentrations, in
order to prevent the red colour from becoming 'pale' and inhibit the growth of
anaerobic organisms.
Carbon dioxide (CO2) is colourless, odourless and tasteless. it has an oxidation-inhibiting and growth-inhibiting effect on
most aerobic bacteria and moulds. The gas
is frequently used to increase the shelf life
of food. The shelf life of packaged or stored
food is normally longer, the higher the co2
content. nevertheless, many products can
become sour if the dosage is too high. in
addition, the gas can diffuse out of the
packaging or be absorbed by the product the packaging collapses. The use of
supporting or filling gases can slow down
this effect.
Nitrogen (N2) is an inert gas and exhibits a
high degree of purity, depending on the
production. it is usually used for displacing
air, especially atmospheric oxygen, in food
packaging. This prevents the oxidation of
food and inhibits the growth of aerobic
microorganisms. it is frequently used as a
supporting or filling gas, as it diffuses very
slowly through plastic films and hence remains longer in the packaging.
Carbon monoxide (CO) is colourless, odourless and tasteless. Similar to oxygen, carbon monoxide is sometimes used to retain
the red colour of, for the most part, meat.
The required concentrations are very low.
in some countries, including the eU, the
use of carbon monoxide for modified atmospheres is nevertheless prohibited in
foods.

MEAT AND SAUSAGE PRODUCTS

Product
raw red meat
raw entrails
raw poultry with skin
raw poultry without skin
cooked meat and sausage products

o2
70
80
0
70
0

co2
2030
20
30
2030
2030

n2
010
0
70
010
7080

examples of gas mixture compositions in %

Meat and sausage products, above all raw meat, are very prone
to spoiling due to microbial growth on account of their high
moisture and nutrient content. no matter whether beef, pork our
poultry spoilage begins from the moment of slaughter and
especially all butchering. besides high hygiene standards and permanent cooling, modified atmospheres can significantly extend
the shelf life of meat and sausage products. co2 is the most
important among the protective gases. at concentrations above
20 %, co2 can considerably reduce microbial growth.
in the case of red meat, there is also the risk of oxidation of
the red colour pigments. The meat will lose its red colour, becoming grey and unappetising in appearance. This oxidation is
especially prominent with beef. a high oxygen content in protective gas packaging can prevent oxidation. a low carbon
monoxide content (approx. 1 %) can also help to retain the red
colour of meat. however, the use of gas is not allowed in the eU,
for example.
Poultry is especially sensitive to rapid spoilage and is therefore subject to higher requirements for permanent cooling. here
too, a modified atmosphere with co2 content will extend the
shelf life. a high oxygen content is also used for poultry without
skin so as to retain the colour of the meat. The co2 can partly be
absorbed by the foods. To prevent the packaging from collapsing,
nitrogen is used as a supporting gas.
Sausage and meat products, e.g. marinated or smoked meat
pieces, react very differently depending on the preparation. The
longer shelf life from the start can also be influenced positively
with protective gases. The co2 content should not be too high
with these products, in order to prevent a sour taste.

MILK PRODUCTS

FISH AND SEAFOOD PRODUCTS

Product
raw low-fat fish
raw high-fat fish
Shellfish and crustaceans
cooked/Smoked fish

o2
20-30
0
30
0

co2
40-60
40
40
30-60

n2
20-40
60
30
40-70

examples of gas mixture compositions in %

Product
hard cheese
Soft cheese
Sliced cheese
cream cheese
Yoghurt
Milk powder

o2
0
0
0
0
0
0

co2
30-100
10-40
30-40
100
0-30
020

n2
0-70
60-90
60-70
0
70-100
80100

examples of gas mixture compositions in %

Fish and seafood are some of the most sensitive foods. They are
at risk of rapidly declining in quality and spoiling even shortly
after the catch. The reason for this lies in the neutral Ph value
as an ideal precondition for microorganisms as well as special
enzymes that negatively affect taste and odour. Fish, which is rich
in fatty acids, also becomes rancid quickly.
The most important element for a longer shelf life is cooling
close to 0 celsius. Modified atmospheres with minimum 20 %
co2 also retard the growth of bacteria. co2 components around
50 % are frequently used. higher co2 concentrations can lead to
undesirable side effects such as liquid loss or a sour taste.
in the case of low-fat fish and shellfish, o2 is also used in the
packaging. This prevents a fading or loss of the colour, while
serving as a growth inhibitor for some types of bacteria at the
same time.
When dealing with shellfish and crustaceans, special attention
should be paid to ensuring a co2 content that is not too high. This
can be discerned most clearly by a sour taste, while these products absorb co2 the most, as a result of which the packaging
can collapse. nitrogen as an inert supporting gas prevents this
effect.

cheese is predominantly spoiled by microbial growth or rancidness. a continuous cooling chain essentially extends the shelf life
of products. With hard cheese, there is a risk of mould formation
upon contact with oxygen. as a result, vacuum packaging was
frequently used in the past, even though these are awkward to
open and can leave unattractive marks behind on the product at
the same time. co2 effectively prevents mould formation, but
does not otherwise affect the maturation of the cheese.
Soft cheese can quickly become rancid. This problem can also
be tackled with co2 modified atmospheres. however, as soft
cheese absorbs co2 to a significantly higher extent, there is a risk
of the packaging collapsing. a correspondingly lower co2 content should therefore be chosen.
in the case of milk products such as yoghurt or cream, there
is a risk of the products absorbing too much co2 and becoming
sour. a lower co2 content should therefore be chosen.
Milk powder, above all for use in baby food, is a highly sensitive product. it is especially important to ensure that oxygen
is displaced from the packaging in order to extend the shelf life.
in practice, packaging is carried out in pure nitrogen with as low
a residual oxygen content as possible.

ISO 22000 approval for food safety

FRUIT AND VEGETABLES

Product
Fresh fruit and vegetables
cooked vegetables

o2
3-10
0

co2
3-10
30

n2
80-90
70

examples of gas mixture compositions in %

BREAD AND CAKE

Product
crispy breads
cakes, biscuits

o2
0
0

co2
50-100
50

n2
0-50
50

examples of gas mixture compositions in %

With bread, cake and biscuits, the shelf life is primarily affected
by potential mould formation. a high standard of hygiene during
production and packaging can significantly minimise this risk.
Packaging involving a modified atmosphere with co2 and without oxygen extensively prevents the products from becoming
mouldy and extends the shelf life. To prevent the packaging from
collapsing owing to co2 absorption by the products, nitrogen is
used as a supporting gas in many cases.

Modified atmospheres in packaging make it possible to offer consumers fresh and untreated products in other words succulently
fresh fruit and vegetables with a long shelf life. at the same time,
fruit and vegetables are subject to very special requirements in
regard to the nature of the packaging and atmosphere. This is because in contrast to other food fruit and vegetables continue
breathing after the harvest and consequently require an oxygen
content in the packaging. Furthermore, the packaging film does
not have to be fully tight. by taking the product's breathing and
the permeability of the film, typically via micro-perforation, into
account, the composition of carbon dioxide, nitrogen and low
amounts of oxygen ideal for the product can be maintained. The
term used here is an eMa (equilibrium modified atmosphere). The
gas composition is individually adapted to the corresponding
product.
Thorough cleaning along with hygienic processing are the
fundamental preconditions for long-lasting freshness. Modified
atmospheres, in conjunction with corresponding cooling, can be
used to extend the shelf life of fresh produce, while achieving an
attractive packaging design at the point of sale.

SNACKS AND NUTS

PASTA AND READY-MADE MEALS

Product
ready-made meals
Pasta/Pizza
Sandwiches

o2
0
0
0

co2
30-60
30-60
30

n2
40-70
40-70
70

Product
Snacks/crisps/Peanuts

o2
0

co2
0

n2
100

example of gas mixture compositions in %

examples of gas mixture compositions in %

The nature and composition of fresh pasta and, in particular,

ready-made meals are very different. above all, multi-component
products such as ready-made pizzas or sandwiches contain many
different foods with differing shelf lives and spoilage properties.
in the majority of cases, modified atmospheres can significantly
extend the shelf life without using oxygen. Mixtures of co2 and
nitrogen are used here. The concentration of the gases is oriented
to the content of the product. if, for example, there is a risk
that large volumes of co2 will be absorbed by the product, the
nitrogen content should be chosen higher to prevent the packaging from collapsing.

Snack products, for example potato crisps or peanuts, primarily

involve problems associated with the fat content of the food.
There is a risk of oxidation, whereby the products can quickly become rancid if the packaging is not optimal. To extend the shelf
life, it is therefore important to minimise the contact with oxygen.
Modified atmospheres with 100 % nitrogen are frequently used.
in this way, a premature spoilage can be prevented, while these
atmospheres also provide protection from mechanical damage
to sensitive products, e.g. potato crisps in conventional packets.

VIN

COFFEE

Product
White wine / ros
White wine / ros
red wine

o2
0
0
0

co2
20
20
0

n2
80
0
100

ar
0
80
0

Product
coffee

o2
0

co2
0

n2
100

example of gas mixture compositions in %

examples of gas mixture compositions in %

gases or gas mixtures are often used to protect wine in the different
phases of its production process and to retain the quaility of the
product. They are mainly used to avoid contact with oxygen and
prevent microbial deterioration. The tank headspace is replaced
with an inert gas or a gas mixture, for example of co2, n2 or ar. The
composition of the gases is chosen according to the type of wine.

as a dried product, coffee is relatively insensitive to spoilage by

microorganisms. however, the risk of the fatty acids it contains
oxidising and making the product rancid is greater. To prevent
this, coffee is packaged with the exclusion of oxygen. instead, a
modified atmosphere comprising pure nitrogen is frequently
used in coffee sachets or capsules.

ISO 22000 approval for food safety

CONTROLLED QUALITY
OFFERS PEACE OF MIND
This security for your packaging process is provided with WiTT
MaP-solutions certified according to iSo 22000 food safety
standard.
as the market leader with decades of experience, WiTT offers
you gas Mixing and Metering systems, gas analysers, leak
Testing equipment for packages as well as ambient air Monitors
from a single source.
rely on german Quality and local contacts worldwide.
WITT THE NO. 1 IN MAP

10

The illustration of the packaging process on the right shows where

WITT products provide quality and security.
GAS MIXER AND GAS FLOW CONTROL SYSTEMS

KM-Series

Mg-Series

Kd 500-1a

1
GAS ANALYSERS

oXYbabY o2/co2

Pa o2/co2

MaPY o2/co2/co/n2o/he/c2h4

LEAK DETECTION SYSTEMS

leaK-MaSTer eaSY

leaK-MaSTer

9A leaK-MaSTer MaPMaX (Leak detection for single packages)

9B leaK-MaSTer MaPMaX
(secondary packaging, e.g. cartons, E2-boxes)
GAS MONITORING

10 rooM air MoniToring

Please find the explanation to each product and also the corresponding technical features and benefits in the chart on the
following pages.

FloW PacK Machine

vacUUM PacKaging Machine

LEAK DETECTION SINGLE PACKAGES

GAS SUPPLY

LABORATORY / SAMPLE CHECK

2
6
SAMPLE- AND PERMANENT CONTROL

7
8

5
A

4
5

3
LEAK DETECTION SECONDARY PACKAGING

9B

9A

ISO 22000 approval for food safety

PRODUCT OVERVIEW
GAS MIXER AND GAS FLOW CONTROL SYSTEMS
PRODUCT

KM-Series

Mg-Series

Kd 500-1a

APPLICATION

FEATURES

gas mixing systems for 2 or

3 dened gases, designed for
a variety of applications,
particularly for all areas with
constant or varying mixed gas
ow demands.

electronic ow control system

for modied atmosphere
packaging (MaP) to suit ow pack
machines in the food industry and
for room atmospheres e.g. for the
storage of fruit and vegetables.
Total control of the o2 residual in
the pack.

APPLICATION

FEATURES

innitely variable mixture settings

Proportional mixing valve for two gases with %-scale
individual mixing valves for three gases with %-scale
gas mixture withdrawal from zero to max ow capacity
integrated pressure equalization system
Splash-proof, robust stainless steel housing

integrated o2 analysis
electronic control of gas ow to sensor
Threshold limit control with alarm relay contacts
integrated pressure control
Splash-proof and robust stainless steel housing
interfaces for documentation and remote transfer
of settings and measured values

GAS ANALYSERS
PRODUCT

oXYbabY o2/co2

cordless hand held gas analyser

for checking modied
atmosphere packs (MaP).
The ideal instrument for portable,
faster and accurate sample tests
at the packaging machine, in
stores or in laboratories.

Minimum sample gas requirement (approx. 2 ml)

Fast measurement
ergonomic design
large illuminated graphic-text-display
integrated needle cover
integrated data logger
Specic product names
Flow control with alarm function
USb port
Multilingual menu guide

Pa o2/co2

compact gas analyser for

checking and/or monitoring
modied atmosphere packs/
packaging (MaP). For continuous
analysis (in-line) and also
intermittent sampling via a
needle at the packaging machine,
in stores or in laboratories.

Minimum sample gas requirement

Threshold limit control with alarm relay contacts
large illuminated graphic-text-display
Zirconia sensor for o2 measurement possible
integrated data logger
Specic product names
USb port
continuous analysis or sample testing
Separate Pc-software
Multilingual menu guide

MaPY
o2/co2/co/n2o/he/c2h4

Premium Multifunctional gas

analyser for checking and/or
monitoring modied atmosphere
packs/packaging (MaP). For
continuous analysis (in-line) and
also intermittent sampling via a
needle at the packaging machine,
in stores or in laboratories.

Features see PA, plus:

large, clear colour touch screen
User management for up to 60 users
administration of up to 1000 products
auto run of the sample hold measurement
data transfer via USb-stick or ethernet connection
Flow control with alarm function
automatic checking
Pressure compensation
electrochemical, Zirconia or Paramagnetic sensor for o2

Product features may differ according to version

YOUR BENEFITS

OPTIONS

always the correct gas mixture

easy mixture adjustment without any complicated calculation

all-purpose for large and small packages

Protection against pressure uctuations in the gas supply
easy to clean and hygienic

reliability by permanent control of the o2 concentration

optimal process reliability by self-control
direct alarm reaction avoids defective goods (by stopping the packaging machine)
Protection against pressure uctuations in the gas supply
easy to clean and hygienic
customer-oriented quality documentation

gas supply monitoring

integrated analysis
Mixer mounted on a buer tank
For ammable gases available
as eex-version with separate control
cabinet
remote control

gaS conTrol cenTre Software

for data processing
integrated printer for
data documentation
Separate printer for data documentation
Zirconia sensor for
o2 measurement

YOUR BENEFITS

OPTIONS

ideal instrument for all pack sizes

result after max. 6 seconds
genuine one hand operation, plug and play
easy to read. all information at a glance
User protection
Storage of the last 500 measurements
Practical classication of the measured values
Prevention of incorrect results
comfortable connection to Pc
d, UK, F, i, nl, S, Fin, e, Pl, rUS, JP, cn, h, Tr

ideal instrument for all pack sizes

direct alarm reaction avoids defective goods (by stopping the packaging machine)
easy to read. all information at a glance
Fast, precise measurement
Storage of the last 500 measurements
Practical classication of the measured values
comfortable connection to Pc
Flexible usage
For documentation of the measured values
d, UK, F, i, nl, S, Fin, e, Pl, rUS, JP, cn, h, Tr

Benefits see PA, plus:

optimal information and easy to operate
Personalisation of measurements
individual classication of results and limits
For productivity and comfort
customer-oriented quality documentation
high measuring accuracy
high process safety
reliable steady measuring results
The best measuring principle to suit the application

integrated barcode-reader
bluetooth
obcc Software
for data processing
Separate printer via bluetooth
for result documentation
device for headspace analysis
in cans/bottles
P version (for pressurised sample gas)

vertical or inclined display

obcc Software for
data processing
Separate printer for result documentation
connection plugs
dierent versions available:
continuous analysis, sample testing and
P version (for pressurised sample gas)

gaS conTrol cenTre Software for

data processing
integrated printer for result documentation
dierent versions available:
continuous analysis, sample testing and
P version (for pressurised sample gas)
barcode reader
Fully automatic calibration
Special version for higher inlet pressures
as 19-rack version

ISO 22000 approval for food safety

PRODUCT OVERVIEW
LEAK DETECTION SYSTEMS
PRODUCT

APPLICATION

FEATURES

leaK-MaSTer eaSY

leak detection systems for

packages. The leaK-MaSTer
eaSY features the detection of
the smallest of leaks without the
need for trace gases.

no trace gas required in package

no electrical connections, operation using compressed air
visual test
Testing of vacuum packages possible
easy to use
low maintenance
Perspex housing

leaK-MaSTer

leak detection system for

packages containing co2.
leaK-MaSTer features
non-destructive testing of the
smallest of leaks without the
need for costly helium.

non-destructive testing
large and clearly arranged touch screen
User administration
data storage for over 6,000 measurements
data transmission via ethernet or Wlan
co2-based
Stainless steel housing
various chamber sizes
barcode reader (optional)
Multilingual menu control
Separate Pc software

leaK-MaSTer MaPMaX
(Single packages)

in-line micro-leak detection

system for packages containing
co2. MaPMaX features
non-destructive detection of the
smallest of leaks without the
need for costly helium directly
from the packaging line.

Features see LEAK-MASTER, plus:

Fully automatic leak detection
various chamber sizes
high operating speed (max 15 cycles/min)
100 % automatic control of all packages

APPLICATION

FEATURES

gas monitoring system for the

depletion of oxygen (o2)
and/or detection of carbon
dioxide (co2)

9A
9B

leaK-MaSTer MaPMaX
(Secondary packaging)

GAS MONITORING
PRODUCT

10

gaS MoniTor

Product features may differ according to version

3 alarm limits adjustable within the measuring range

Triple-digit display
connections for alarm easily accessible on front
continuous self monitoring
Separate control panel and transmitter
4 channel control panel also available

YOUR BENEFITS

OPTIONS

Usable without modied atmosphere (MaP)

easy installation and operation
localisation of leak
one system for all kinds of packages
no special skills required
Time and cost eective
easy to clean

dierent chamber sizes

available for vacuum packages
available for altitude simulation test

Products remain undamaged and dry for further processing

optimal information and easy handling, no special skills required
Personalisation of measurements
For high measurement frequencies
customer orientated quality documentation
no costly helium required
robust and easy to clean
Testing of single packages, cartons or e2 boxes possible
avoiding operator errors and enhancing productivity
ger, UK, F, e, Fin, i
For documentation of test results

various chamber sizes

documentation software
gaS conTrol cenTre
barcode reader
barcode reader iP 65
W-lan (WiFi)

Benefits see LEAK-MASTER, plus:

avoiding operating errors
Testing of single packages, cartons or e2 boxes possible
high productivity of packaging line
no leaking packages are delivered to the customer no costly returns

various chamber sizes

reject system
documentation software
gaS conTrol cenTre
barcode reader
barcode reader iP 65
W-lan (WiFi)

YOUR BENEFITS

OPTIONS

individually adjustable alarm limits

Permanent visual control
easily accessible, for easy installation
high process safety
Flexible installation for highest safety
Monitoring of large areas

Flashing beacon and sounder

Flow adapter for sensor
check and calibration
other gases on request

WITT THE NO. 1 IN MAP.

ISO 22000 approval for food safety

www.wittgas.com
TECHNOLOGY FOR GASES

OUR PRODUCT RANGE

Gas Control Equipment

Gas Safety Equipment

Flashback arrestors
non-return valves / check valves
Quick couplers
Safety relief valves
Stainless steel devices
gas filters
Pressure regulators
outlet points
lance holders
ball valves
automatic hose reels
Test equipment
accessories
customised safety equipment

v _ 10 / 2014

gas mixing systems

gas metering systems
gas analysers
leak detection systems
gas pressure vessels
engineering of customised
systems

WITT-Gasetechnik GmbH & Co KG

Salinger Feld 48 58454 Witten
Pob 2550 58415 Witten
germany
Tel. +49 (0)2302 8901-0
Fax +49 (0)2302 8901- 3
www.wittgas.com [email protected]

WITT Gas Techniques Ltd.

212, europa boulevard Westbrook
Warrington, Wa5 7Tn
great britain
Tel. +44 (0)1925 234466
Fax +44 (0)1925 230055
[email protected]

WITT FRANCE S.A.R.L.

131 voie de compigne
91390 Morsang sur orge
France
Tel. +33 (0)160 151779
Fax +33 (0)160 154782
[email protected]

WITT Tecnologa de Gas, S.L.

c/Simn cabarga n 2a bajo
39005 Santander
espaa
Tel. +34 942 835142
Fax +34 942 835143
[email protected]

WITT Gas Controls LP

380 Winkler dr., Suite 200
alpharetta, ga 30004
USa
Tel. +1 888 948 8427
Fax +1 877 948 8427
[email protected]

WITT POLSKA Sp. z o. o.

ul. legnicka 55/Ua5
54-203 Wrocaw
Polska
Tel. +48 (0)7135 22856
Fax +48 (0)7135 13113
[email protected]

WITT ITALIA Srl.

via giovanni XXiii, 18
24030 Solza (bg)
italia
Tel. +39 035 4933273
Fax +39 035 4948098
[email protected]

GUSTUS & PARTNER GmbH

installation Service Wartung
alt Salbke 610, geb. 59
39122 Magdeburg
germany
Tel. +49 (0)391 4015246
Fax +49 (0)391 4013296
[email protected]

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