PACKAGING SOLUTIONS


some bakery goods it can be used at levels of up to 100% to increase the mould-free shelf-life. When reducing the level of carbon


dioxide in MAP gas mixes, it is important to ensure that food safety and shelf-life are not impacted. This can be determined by shelf-life studies – including product packed without any carbon dioxide into your shelf-life studies are a good way to understand the impact ahead of being affected by a carbon dioxide shortage.


Quality control solutions Because the spoilage risk in baked goods is so high, effective quality assurance is also essential for MAP packaging lines. A MAP solution will only work if both the gas composition and the integrity of the packaging are correct. Even the most carefully selected gas mixture will not work properly when the gas flushing process is not correct. For this reason, the core focus of quality assurance must be on postpackaging gas analysis, according to WITT-Gasetechnik, a manufacturer of gas- related equipment. Mobile gas analysers are now widely


used to provide fast and precise measurement of residual oxygen levels directly at the packaging line. Only a minimal sample volume is


required – so the solution is suitable even for packages with a very small headspace. Within seconds, operators can have useful data that can also be digitally stored for traceability and compliance requirements. This is important, because products such as crusty bread and pastries can have sharp edges or can have crusts or crumbs that can easily damage the film or interfere with the sealing process. Even small imperfections in the seal can lead to significant loss of shelf life, as ambient air will quickly replace the protective atmosphere. For this reason, final leak detection is an important element of quality control on a MAP packaging line. WITT can offer several solutions for


this. For sample testing, its LeakMaster Easy uses the waterbath method which sees the package placed in a waterfilled chamber, which is then evacuated. If the packaging is leaking, air or protective gas escapes visibly as rising bubbles. The key advantage of this method is that operators can immediately identify exactly where a leak is located. For users seeking a


more


operatorindependent method, CObased detection systems such as the LeakMaster Pro 2 can provide automated results. These systems detect escaping CO under vacuum conditions and document the results digitally, offering a fast and nondestructive test.


At the top of the


Carbon dioxide is normally included as an antimicrobial agent. A minimum of 20% carbon dioxide is often suggested to have an effect, but there is little scientific data to back this. It is often used in combination with nitrogen to form an anaerobic environment to inhibit aerobic microorganisms. The concentration o f dissolved carbon dioxide in the water phase of food helps to inhibit some microorganisms (for example, gram- negative microorganisms, such as Psuedomonas). Bakery goods are usually packed with


a proportion of carbon dioxide. Inclusion levels of 25-40% are common, but in


qualityassurance pyramid are inline leak detection systems. Integrated


Image


courtesy adapta.


directly into the packaging line, these systems are able to inspect the entire production output using CO sensors. WITT offers a solution with testing speeds of up to 15 cycles per minute.


MOBILE GAS ANALYSERS ARE NOW WIDELY USED TO PROVIDE FAST AND PRECISE MEASUREMENT OF RESIDUAL OXYGEN LEVELS DIRECTLY AT THE PACKAGING LIN


In conclusion MAP works well in bakery packaging applications, but it is important that the whole system is properly specified. The product characteristics, gas mix, film structure, sealing parameters, and distribution conditions all interact, and all have an important role to play in successful projects. The bakery manufacturers who will get the best returns from an investment in MAP technology are those who treat it as a technical project from the start – and not simply as a procurement decision.


APRIL/MAY 2026 • KENNEDY’S BAKERY PRODUCTION • 39


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