Presentation

On
Controlled Atmosphere Packaging
&
Modified Atmosphere Packaging
Introduction
Controlled and Modified atmospheric packaging can be
used to the maintenance of optimum temperature and
relative humidity for preserving quality and reducing
postharvest losses of tropical fruits & vegetables during
transport and storage. CAP/MAP reduce respiration
rate ,ethylene production , to delay fruit ripening
,composition changes associated with ripening and
incidence of some physiological disorders.

A reduction in concentration of oxygen and an increase

in carbon dioxide concentration of storage atmosphere
surrounding a food reduces the rate of respiration of
fresh fruits and vegetables and also inhibits microbial
 History
In 1930s and 1940s fresh apples and pear were placed in enclosed warehouses the
shelf life of Apples extend as long as six months after the original harvest about
double the normal cold storage shelf life.

In 1950s and 1960s scientist from Whirlpool Corporation developed a method to

control the atmosphere surrounding meat, fruit, and vegetable products under
refrigerated conditions.

The concept called TECTROL (Total Environmental Control) employing a gas burner to
reduce the oxygen, evolving air to the exterior to prevent oxygen extinction and
permit the use of filters and scrubbers to remove excess carbon dioxide.

IN the mid to late 1960s hundreds of apple and pear warehouses throughout the
world were equipped with TECTROL system to extend the shelf life of the fruits.

The TECTROL system was applied in transportation system of fruits and vegetables .
CONTROLLED ATMOSPHERE
PACKAGING
Controlled Atmosphere packaging is a storage technique whereby the level of
oxygen (O2) is reduced and(CO2) is increased. Quality and the freshness of fruit
and vegetables are retained under Controlled Atmosphere conditions without
the use of any chemicals.

Controlled Atmosphere Packaging refers to system whose objective is to extend

the shelf life of food product by altering the gaseous environment in and around
the food

Controlled atmosphere (CA) storage involves maintaining an atmospheric

composition that is different from air composition generally, O2 below 8% and
CO2 above 1% are used.
Under CA conditions, many products can be stored for 2 to 4 times longer
than usual
Purpose of Controlled Atmosphere Packaging

Increasing the shelf life of food products .

Maintaining the quality & freshness of food products.

Inhibition of pathogens growth in food products & Control of

the spoilage of food.

Long time storage of food without using of harmful chemicals.

For Controlling biochemical and enzymatic changes in food

products
Principle of (CAP)
Reduce the rate of respiration, reduce microbial growth, and
retard enzymatic spoilage by changing the gaseous environment
surrounding the food product.
Gaseous environment is achieved by reducing the concentration
of oxygen (O2), which is required in respiration, or by adding an
inhibitory gas such as carbon dioxide (CO 2) or carbon monoxide
(CO). The balance between O2and CO2is critical, and an optimal
ratio is required for each specific product.

The gas concentration ranges encountered in CA storages are 1

to 10% O2, 0 to 30% CO2, and the balance is nitrogen (N 2).
 ub bers
c r Ethylene converters
CO 2-s

Gas contr
oller

Temp. controller

Nitrog Humidity controller

en
gener
ator
 General Functioning of the Controlled
Atmosphere System
Generally fruit will be kept in CA Chamber and desired controlled atmosphere i.e. O2 less than 5% ,
CO2 less than 1%, C2H4 less than 1 ppm & CA chamber will be closed. Now once the fruit will
generate CO2 from O2 via respiration, this will increase the CO2 level and decrease O2 level inside
the container.
When the CO2 level reaches above the CO2 set point the scrubber blower will activate and evacuate
CO2 with the selective scrubber bed.
. In case the O2 level goes below the O2 set point the fresh air valve will open and let in compressed
oxygen.

In case the C2H4 level goes high the C2H4 set point the scrubber blower will activate and evacuate
C2H4 with the selective scrubber bed.
In case O2 level increases above the set point then N2 dosing will start in CA chamber till O2 comes
below 3%.
Scrubber: The unit consists of an activated carbon filter chamber, a low pressure ventilator, an
air-transport system, a control unit, and a buffer or lung system.
Scrubbers use advanced electronic control and a panel mounted Carbon Dioxide Analyzer to
constantly monitor the status of the carbon beds..
Equipment used in controlled atmospheric storage

CO2-scrubbers
O2 scrubbers
Ethylene converters
Gas analyzer
Humidifier
Over and under pressure valve
Gas-tight doors
1. CO2-scrubbers

When the CO2 level reaches above the CO2 set point
the scrubber blower will activate and
evacuate CO2 with the selective
scrubber bed.
A CO2scrubber removes the carbon dioxide from your
storage cells in order
to prevent concentrations getting too
high and causing damage to your fruit. CO -
2
scrubbers
CO2scrubber determine which situation is suitable for
your specific food items.
2 .O2-scrubbers

It uses oxygen (O2) and produces carbon dioxide (CO2).

An O2 -scrubber reduces the oxygen level in the storage

area after the moment of storage or after the interim
opening of the cell, in order to inhibit respiration and
extend the storage period.

O2 scrubber is suitable for situation preferred storage

conditions.

When O2 level goes below the O2 set point the fresh air
valve will open and let in compressed oxygen.
 3. Ethylene converters

When the C2H4 level goes high the C2H4 set point the
scrubber blower will activate and evacuate C2H4 with
the selective scrubber bed.

Fruit varieties
that are sensitive to ethylene (under CA conditions),
such as kiwis, require an ethylene converter.

The ethylene converter uses oxygen to convert

ethylene into CO2 and water, both inert substances.
4. Gas analyzer

Analyzing gases such as O2 and CO2 by meters. Meters are fitted into our
operating systems.

In-built meters offer 3 types of oxygen measurement methods;

galvanic cell ;(electro-chemical measurement cell); suitable for

measuring low CO2 levels. Often used for hard fruit
and kiwi storage.
Zirconium cell; suitable for measuring higher CO2 values but
not suitable for measuring high ethylene concentrations .Often
used for berry storage.
Paramagnetic cell ;Can measure very accurately. Often used within
laboratories.
Humidifier
Water management
Most fruit varieties are stored under high relative
humidity, above 95%. Moisture loss can limit the storage
quality of fruit in a cool cell.

Measuring moisture loss (RH meters)

Fruit that is stored in a CA loses moisture. This moisture
loss reduces if RH levels (relative humidity) are kept
above 90-95. You can thus maintain an overview of
moisture loss within a storage cell.
Over and under pressure valves
. In this case, an over/under pressure valve will take up the pressure
difference in your storage area in order to prevent damage from
occurring. Every cool cell used for CA storage needs at least one under
and one over pressure valve. Numerous valves will be used for larger
cells.

When the O2 level goes below the O2 set point the fresh air valve
will open and let in compressed oxygen.

Scrubbers are connected to the cool cells via PVC pipes.

Gas-tight doors

The doors of CA cool cells are a crucial

element of storage under low oxygen
concentrations; a small leak means that
percentages of less than 3% oxygen will not
be achieved.

gas-tight doors guarantee oxygen values of

less than 0.5% as a result of using a special
rubber, inflatable profile. Small deformities in
the wall and the floor no longer present a
problem.
.
The gas-tight doors can be supplied in a
horizontal or vertical format
 .
Max. level of CO2 & min level of O 2 for
storage of fruits & vegetables
food CO2% O2%
apple 2 2
avocado 5 3
banana 5 -
cabbage 5 1
cauliflower 5 3
Citrus fruits - 5
onion 10 1
potato 10 10
Strawberry 20 2
Sweet corn 20 -
tomato 20 3
How to affect Controlled
atmosphere
Commoditie Temp. in 0 Reduced Increased Benefits
s C O2 CO2%
name in %
Banana 12 - 16 2-5 2-7 delayed repining
,injurious level reduced
>7%
avocado 5 - 13 2-5 3 - 10 Delayed softening
,reduced chilling injury
Mango 10 - 15 5-7 5 - 10 Delayed ripening ,
firmness retention
papaya 10 - 15 2-5 5-8 Degrading & softening ,
delayed repining ,
firmness retention
Pine apple 8 - 13 2-5 5 - 10 Reduced chilling injury >
10%
Tolerance to Low Oxygen

Min. % O2 Commodities
0.5 Tree nuts, dried fruit & vegetables
1 Some cultivars of apples & pears, broccoli, most
fresh cut F&V, mushrooms

Most cultivars of apples and pears, kiwifruit,

peach, strawberry, cantaloupe, lettuce, cabbage
2
3 Avocado, persimmon, tomato, pepper,
cucumber
5 Citrus, asparagus, potato, sweet potato
Tolerance to Low Corban di
oxide
Min.CO2 commodities
%
1 Some cultivars of apples (Fuji, Pink Lady,)
2 Some apples & pears, apricot, pear, grape,
tomato, lettuce, celery, artichoke

Some apples and pears, kiwifruit, peach, plum,

orange, grapefruit, lemon , lime, avocado ,
banana, cauliflower
5
 Benefits of controlled
atmospheric packaging
Reduction in chlorophyll breakdown, with resulting higher color stability.
Reduction in enzymatic browning in cut produce, whenever low levels of O 2 are used.

Improvement in texture caused by the action of CO 2 on enzymes acting on cellular membranes.

Reduction in some physiological disorders ,chilling injury of citrus fruits, avocado, chili pepper.
Reduction in microbial activity especially molds.
The marketing and distribution advantages of CA technologies include:
Reduction in fresh food spoilage and quality loss through the distribution at the retail level.
Expanded radius of distribution systems and market area.
Improved branding options and product differentiation.
Potential for increased profitability in all fresh or chilled food operations .
Low O2 Retards Ripening of Partially Ripe
Tomato Fruit

Low O2
Level of CO2 increase the shelf life products
Level of CO2 increase the shelf
life products
Reducing Chilling Injury of
Avocado with CA
Disadvantages of cap
The high initial cost of air-tight storage .

The high cost of the generation and transportation of the gas.

Requirements of special types of equipment .

The interaction of CA gases with the storage structure can cause

some practical problems.

More risk as compare to map packaging.

What is MAP?
Alteration the gas atmosphere surrounding a particular food
product to retard:

chemical and metabolic processes

that are detrimental to product
quality (Oxidative Reactions &
enzyme activity)

or to inhibit the growth of

undesirable microbial populations

27
Plastic Film
The MAP
Area
Volume System
Permeability
O2
Permeability
CO2 CO2i CO2e
thcikness

Produce O2i O2 e
Weight
Oxygen
uptake
CO2
Production
 The Advantage of MAP

increased shelf life

reduction in retail waste
improved presentation-clear view of product and all round visibility
hygienic stackable pack, sealed and free from product drip and odor
little or no need of chemical preservatives
increased distribution area and reduced transport costs due to less
frequent deliveries
reduction in production and storage costs due to better utilization of
labor, space and equipment.

30
The Disadvantages of MAP

capital cost of gas packaging machinery

cost of gases and packaging materials
cost of analytical equipment to ensure that correct gas mixtures
are used
cost of quality assurance systems to prevent distribution of
leakers
increase of pack volume which will adversely affect transport
costs and retail display space
benefits of MAP are lost once the pack is opened or leaks

31
 Purpose of MAP

Reducing respiration rate

Extending shelf life

Maintenance of freshness

32
 Principle of MAP
Modification of gas composition

Reducing oxygen concentration

Increasing CO concentration

Decrease ethylene level

Adding CO

33
 Gases used in MAP
Oxygen
The reduction of surrounding oxygen can control the oxidative and
browning reactions.
Oxidative reactions occur in meat and fish i.e. lipid rancidity.
Browning reactions are presented on the surface of fruits and
vegetables.
Low level of O is preferred to avoid both fermentation and growth of
aerobic spoilage microorganisms.
Some microorganisms such as Cl. botulinum can grow in complete
absence of O. This microbial hazard could be eliminated, if
completely O absence is avoided.

34
Carbon dioxide (CO)

It has important bacteriostatic and fungistatic properties.

It is water solute and creates carbonic acid, causing pH reduction and

increasing solution acidity, which has further preservative effect.

When temperature is increased gas solubility also increases. Therefore,

in low temperatures, the antimicrobial activity of CO increases as a
result of the increased concentration.

The high solubility of CO can result in pack collapse due to reduction

of headspace volume.

35
 When O2
CO2
Respiration is slower
Growth of microorganism is retarded
Fruit ripening is inhibited
Lower the risk of chilling injury
Condition: the temperature of storage
the lower the better

4/25/17 YHA_ITP 36
 Example : with 20% CO2

Storage life: 2 times in room

temperature
4 times in refrigerated
4/25/17 temperature YHA_ITP 37
Nitrogen

It has low solubility in water (0.018 g/Kg at 20C), and it aims to prevent pack collapse.

Nitrogen indirectly affects the microorganism growth in foods, which is achieved with

the avoidance of aerobic bacteria growth .

Carbon monoxide
CO has been studied in MAP of meat.

The MAP effect on myoglobin was indicated, which leads to the formation of
carboxymyoglobin, a bright red pigment.

The commercial use of CO is still under consideration because of its high toxicity and
flammability.

38
Sulfur dioxide
It is antimicrobial in its non-ionized molecular form. This is achieved in low pH
environments(p<4).
Its fungicidal and bacteriostatic properties affect Gram(+) rods (e.g., E. coli,
Pseudomonas) and Gram (+) rods (e.g., lactobacilli).
In many food packages, such as fruits, sausages, juices, wines and shrimps packages,
sulfur dioxide is used.
Noble gases
He, Ne, Ar and Xe are members of this group.
Ar can replace nitrogen to fill in wine bottle neck before corking.
Noble gases can extend the shelf life of fruits and vegetables.
The main gas that is used in modified atmosphere packages is Ar.
Ar has ability to prevent growth of m.o. in foodstuffs such as broccoli and lettuce.

39
 In meat, CO2 affect the pH

CO2 entering meat tissues producing acid

carbonate

Resulting the lowering pH

As a result the development of
microorganism is retarded or inhibited
When temperature is decreased the CO2
solubility in tissues is increased

4/25/17 YHA_ITP 40
Recommended conditions of MAP/CAP
Product Temperature O2 (%) CO2 (%) N2 (%)
(oC)
Meat 02 30 30 40
Fish 02 30 40 30
Poultry 02 0 30 70
Cheese 02 0 0 100
Pasta 05 0 60 40
Bread 2 22 0 100 0
Apple 05 23 12 Rest
Broccoli 05 12 57 Rest
Tomato 8 12 35 0 Rest
Banana 12 15 25 25 Rest

4/25/17 YHA_ITP 41
Packaging Material
Six Main characteristics while selecting MAP.
1) Resistance to puncture
2) Sealing reliability
3) Antifogging properties
4) Carbon dioxide permeability
5) Oxygen permeability
6) Water transmission rate
 Method of atmosphere modification in package foods
Vacuum packaging

Gas flushing

Gas packaging

Mechanical air replacement (i) gas flushing; and (ii) compensated vacuum.

Passive atmosphere modification.

Active packaging that can be classified as oxygen absorbents, carbon dioxide

absorbents/emitters, ethanol emitters and ethylene absorbents.

44
 Passive atmosphere modification

The produce is sealed within the pack with pack flushed with
required gas mix or no modification to atmosphere.

Subsequent respiration of produce and gas permeability of

packaging allow an equilibrium modified atmosphere to be
reached.

So it is also called as Equilibrium modified atmospheric

packaging .

45
 Passive MAP

Lower O concentration To reduce respiration rate

Increase CO concentration To prevent microbial

growth

Maintain high RH To avoid dehydration

46
 Active MAP
When packaging performs an additional role, other
than just exhibiting itself as an inert barrier to
external influences.
The concept of active packaging has been
developed to correct deficiencies in passive MAP.

47
 Active MAP
Oxygen scavengers
- extends shelf life
- Reduce need for extremely low O in MAP

Oxygen
scavenger
pouch

Oxygen scavenger
in crown cap

48
 Active MAP
CO scavengers
- Reagents : Ca(OH)
- To avoid packaging destruction
- Applications: coffee
- Ca(OH)+CO CaCO + HO
CO emitters
- reagents: ascorbic acid
- To avoid food deterioration
- Applications: meat, poultry, fish, cheese

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 Active MAP
Moisture absorber
Reagents silica gel, activated carbon, zeolite,
cellulose and derivatives
To control excess moisture in packaged food
To reduce water activity on surface of food in order to
prevent growth of moulds, yeast and spoilage bacteria.
Applications meat, fish, bakery products, fruits and
vegetables.

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 Active MAP
Ethylene scavengers
Reagents potassium permanganate, activated
carbon

to prevent too fast ripening and softening.

Applications banana, apple, tomato, avocado,
carrots

51
 Active MAP
Gas flux
- Reagents - N
To reduce O level
Applications cut salads
This system is expensive and needs high barrier film.

52
Vegetables

53
Fruits

54
Influence of packaging conditions on
greening and browning on endive after 7
days of storage at 20C

55
Examples

56
Thermo fill seal
Gas replacement by evacuation within
the vacuum chamber.
Typical products- meat, fish, cooked
meat, pizza
Manufacturers- multivac, macaplastic
etc.

57
58
 Machinery used in MAP
Modified atmosphere packaging (MAP) equipment is divided into
two main categories:
Pillow wrap and
chamber
Pillow wrap can be divided into two further categories:
horizontal
Vertical processing machines.
Chamber machines can use two different techniques.
thermoforming technique.
In second technique, ready containers can be used for the packaging of
products (Preformed Container Machines)

59
Difference between cap and map
C A STORAGE MA STORAGE

High degree of control over gas low degree

concentration

longer storage life less

More expensive technology less

atmosphere is modified by adding gas it is created by either addition or removal of

gas

Specific temperature should maintain may or may not be maintained

 Conclusion
Cap /Map both are storage techniques of food and its
use for the extend the shelf life of food products by
creating the gaseous environment surrounding the food.
Cap / Map are also preservation techniques used for
food preservation for longer time.
REFERENCES
FOOD PROCESSING TECHNOLOGY (Principles and Practice) Second
Edition BY P. Fellows

ANON. (Undated) Care with cryogenics. BOC gases, Worsley, Manchester M28
2UT, UK.

ANON. (1979) Recommendations for Chilled Storage of Perishable Produce.

International Institute for Refrideration, Paris.

ANON. (1994) Britons report successful use of an oxygen-removing label. Food

Engineering.

BLAKISTONE, B. A. (1998a) Meats and poultry. In: B. A. Blakistone (ed.) Principles

and Applications of
Modified Atmosphere Packaging of Foods, 2nd edn. Blackie Academic and
Professional, London,
THANK YOU