PACKAGING SOLUTIONS
Gas analysers offer quality control solution on MAP lines.
isn’t simply a plug-and-play technology – she warned that it is easy to underestimate what it takes to make this packaging solution perform reliably. Her advice is to always start with the product, not the packaging. “The first question that should always be asked is what are you trying to protect?” she said. Baked goods vary significantly in their
BY REPLACING THE NATURAL ATMOSPHERE INSIDE THE PACKAGING WITH AN
APPROPRIATE PROTECTIVE GAS MIXTURE, IT IS
POSSIBLE TO SIGNIFICANTLY SLOW DOWN SPOILAGE
MECHANISMS, WITHOUT THE NEED FOR PRESERVATIVES
moisture content, fat levels, water activity, and microbial risk profile. A pre-baked ciabatta, a sliced wholegrain loaf, and a butter-rich pastry all spoil differently. For most ambient bakery MAP applications, oxygen will be the primary concern because it drives mould growth and oxidation. But depending on the product, moisture migration or carbon dioxide sensitivity can be just as important. “Getting the gas mix wrong for your specific product can accelerate spoilage rather than slow it,” warned Joanna. “For this reason, it is not a decision that can be made based on generic guidance. It requires proper product testing.” Once the most suitable gas mix for a
particular application has been defined, the next step is to ensure that the film is able to maintain that atmosphere throughout the product’s entire shelf life and distribution journey – not just at the point of packing. For extended shelf-life applications,
EVOH-based thermoforming films are the benchmark. The oxygen barrier performance achievable with EVOH layers is in a completely different category to standard OPP or PE formats. “adapa’s thermoforming films incorporate EVOH technology to ensure that the barrier specification is able to match the shelf-life target, and not the other way around,” said Joanna. Flowpack laminates and lidding films
are increasingly relevant for portioned products like toast, pita, and pre-baked items, particularly where distribution chains are longer, and retailer shelf-life expectations have grown. Here, barrier performance and seal integrity become critical. A film that loses its gas atmosphere during chilled distribution isn’t delivering on its specification, regardless of what was flushed into the pack at the line.
The challenges are real Seal integrity is one of the most common operational difficulties encountered in bakery MAP. Crumbs, seeds, and irregular product shapes regularly contaminate the seal area. A film that is not able to maintain a reliable seal under real production conditions will lose the atmosphere, and the shelf-life benefit along with it. That’s not just a film specification issue – it’s a line setup and process discipline issue too.
APRIL/MAY 2026 • KENNEDY’S BAKERY PRODUCTION • 35
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