Modified Atmosphere Packaging (MAP) technology has significantly impacted the food packaging industry, particularly in sweets and namkeen sectors. It addresses product issues, ensures product life, and improves aesthetic appeal.
Researchers and packaging experts collaborate to fine-tune parameters like gas composition, materials, and sealing techniques to preserve distinct flavours and textures, while enhancing the visual appeal of these treats.
Overwhelmed with the tantalizing symphony of flavours and aromas, Mithai & Namkeen Times embarked on a journey to delve into the domain of MAP Technology. With an insatiable curiosity, the publication meticulously gathered a diverse array of insightful replies from experts in the field. The anticipation now builds as we unveil the enlightening sequence of events that ensued.
Specifically Tailored MAP Tech
Our discourse commences with insights shared by Bharat Patel of Message Fusion Services, a prominent figure in this domain.
“Message Fusion Services has developed the patented Automap technology, a revolutionary solution for MAP technology.
Automap allows mithai and namkeen makers to use its potential without relying on specialized machinery, thereby reshaping the industry. Its adaptability allows it to operate in full view of consumers within stores, thereby building consumer trust and redefining engagement.
Automap’s success in preserving Bengali sweets, where traditional MAP methods often fail, demonstrates its efficacy in this challenging arena. Its versatility extends beyond rigid containers, functioning seamlessly in any airtight environment and introducing a new dimension to packaging possibilities, Bharat gave a precise reply.
Bharat’s insights highlight the profound potential of Automap to revolutionize food preservation and packaging, signalling a new era in packaging technology. The future implications of Automap call for reimagining food preservation methods and the broader boundaries of innovation.
In a resounding endorsement of MAP technology, Keyur Thakkar, the CEO of Maxon Food Services LLP, has illuminated the transformative potential of this innovation in the terrain of sweet distribution. Thakkar expressed his enthusiasm for the technology, affirming that it dismantles the formidable barriers that had previously constrained the distribution of perishable sweets with limited shelf lives.
Thakkar highlighted the significant role of MAP technology in the sweet’s distribution landscape, enabling the seamless delivery of regional flavours and culinary heritage across geographical boundaries. This technology has revolutionized the consumer experience, allowing sweets to be purchased from distant destinations in a visually appealing and delectable form, overcoming the constraints of time-sensitive shelf lives.
Thakkar emphasized, “In bygone days, individuals were inclined to procure sweets from their surroundings. In the present landscape, patrons can savour confections from any corner of India, assured of impeccable quality and tailor-made choices—gratitude owed to the marvel of MAP Technology.” He also stressed the credibility of MAP technology over conventional absorbers and sachets in extending shelf life.
He argued that MAP technology is a proven solution, earning trust from the sweets industry over decades. Esteemed brands have embraced this innovation, reaping its numerous benefits, unlike absorbers and sachets that offer marginal shelf-life extension.
Furthermore, Thakkar expounded the strategic benefits of MAP technology, especially for entrepreneurs managing multiple sweet stores. It offers bulk packing and preservation capabilities, enabling proactive storage of sweets, facilitating meticulous production planning and paving the way for a new era of operational efficiency.
Vivek Adinath Chougule eloquently articulates his perspective on the subject, shedding light on Eka Global’s extensive journey spanning four decades in the area of high barrier rigid packaging, encompassing a diverse spectrum of product applications. This enduring legacy has been characterized by a relentless pursuit of technological advancement, tailor-made to harmonize seamlessly with the unique demands of each application.
In the annals of packaging innovation, Eka Global’s pioneering role stands undeniable. A watershed moment was etched in 2012 when Eka Global, previously known as Printpack, unfurled the pioneering canvas of MAP technology on Indian soil. This moment marked not only a remarkable milestone for the industry but also unveiled a trajectory of relentless evolution.
Eka Global’s innovative architecture features specialized barrier structures made of EVOH and scavengers. These structures are fortified with a trifecta of barrier layers, ensuring durability even in the tumultuous rigours of the supply chain. Their commitment to endurance is evident in their innovative solutions, ensuring the integrity of barriers even during challenging times.
In this panoramic exposition of Eka Global’s odyssey, Chougule distils the quintessence of a legacy marked by innovation, resilience, and a steadfast commitment to preserving the sanctity of packaged products throughout their journey.
Makdum Jahan, the Country Manager and Director of VERIPACK ILPRA Group’s India Office, highlighted the significance of MAP technology as one of the most advanced packaging formats globally. He emphasized that MAP technology enables the extension of food shelf life without the need for additives or thermal processes. VERIPACK ILPRA Group, with its extensive expertise in niche packaging machinery, specializes in this area, particularly catering to India’s significant food industry segment of sweets and namkeens.
VERIPACK ILPRA Group, established in 2012, has been a leading provider of packaging solutions for ethnic sweets in India. They have achieved significant success in extending shelf life for these products, including installing the world’s fastest Tray Sealer and using Thermoforming machines for challenging materials like Polypropylene. Their packaging machines are designed with special features for sweets and namkeens, including real-time pressure monitoring, enhanced capabilities, and high automation. These features, including servo control, machine troubleshooting, and shelf diagnostic systems, ensure machine reliability and customer satisfaction.
Emerging Gas Mixture Formulations
Bharat notes that while there isn’t a definitive scientific consensus on the “perfect gas ratio” for MAP packaging of Indian sweets, a significant development came courtesy of Message Food Services. They unveiled the 70:30 gas ratio, a configuration that has proven effective for many types of sweets prevalent today. Despite this, a noteworthy challenge persists.
Bharat highlights that the existing MAP machinery lacks the capability to adjust gas flushing based on the distinct behaviour of different products. A breakthrough in this regard is Automap, a pioneering solution that tailors gas flushing to match a product’s behaviour and vapour pressure.
The distinguishing factor of Automap lies in its adaptability, which eliminates the need to fret over determining the ideal gas ratio. Bharat elucidates with an example: when Automap is employed for packaging milk products, the mixture contains approximately 17–18% CO2, with the remaining composition being nitrogen. However, in the case of delicacies like Kaju Katli, the Automap system adjusts to flush 23-25% CO2, with nitrogen constituting the rest.
In response to the inquiry about emerging gas mixture formulations gaining traction in MAP technology for sweets and namkeen packaging, Keyur Thakkar provided valuable insights:
Indian sweets are a diverse array of confections made from various ingredients and regional recipes. The selection of suitable gas combinations for packaging requires a thorough product analysis. Nitrogen (N2) is an inert gas with limited solubility in water and other food products, while carbon dioxide (CO2) is a colourless gas with a pungent odour when present at high concentrations. N2 acts as an asphyxiant and regulates the microbial properties of the packaged product.
In the context of Indian sweets, the packaging process can be enhanced by using nitrogen (N2) and CO2 gas combinations. However, the composition of this combination depends on the product. Therefore, a comprehensive evaluation of the product’s characteristics and requirements is necessary to determine the most suitable gas mixture. This approach ensures the gas mixture effectively preserves the freshness, quality, and safety of the packaged sweets and namkeen.
“The selection of the gas mixture in MAP technology is intricately tied to the composition and inherent attributes of the packaged product, says Chougule. ” Nitrogen and Carbon Dioxide are the cornerstones of these gas mixtures. Nitrogen assumes the role of an inert entity devoid of reactivity, thereby lending stability to the packaging environment. On the other hand, Carbon Dioxide extends its influence beyond inertness; it demonstrates a microbicidal prowess against select strains of microbes, bolstering the preservation of packaged contents.
Going on further, Chougule confirmed that, venturing beyond this fundamental pairing, the inclusion of other inert gases like Argon can be contemplated, contingent on the unique prerequisites of the packaging scenario. Leveraging our profound expertise, we stand poised to guide manufacturers of confectionery and savoury treats through the intricate tapestry of gas formulation. Our insights are poised to steer them towards optimal outcomes—a harmonious blend of product integrity and packaging innovation.
Makdum emphasized the precision and effectiveness of VERIPACK ILPRA Group’s real-time pressure monitoring system. This system is designed to identify the optimal air evacuation and gas injection points during the packaging process. As a result, it consistently achieves a 100% reduction in the oxygen residual parameter, ensuring the lowest oxygen levels possible with each packaging cycle.
By harnessing the capabilities of their advanced MAP system, VERIPACK ILPRA Group’s machines offer a higher level of control over the gas mix formulations used in the packaging process. This not only contributes to achieving the critical goal of extending product shelf life, but it also preserves the product’s visual appeal and overall quality.
Makdum highlights those aspects, such as product decoration, where ingredients like ghee, oil, and moisture are safeguarded, maintaining the product’s aesthetics and integrity.
The Visual Appeal
“We have already stated that current MAP technology would never benefit the sweets business as a whole since Indian sweets are associated with prestige, and customers are very clear that they do not want to buy packaged sweets from one’s store’, mapped Bharat.
If we continue at this rate of acceptance, it would take 100 years to alter Indian mindsets. As a result, we created a concept in which Indian sweets may be MAP in the existing sweets box in front of clients using Automap. Because most premium sweet boxes come in a variety of forms and sizes, they cannot be MAPed with standard MAP machines.
As mentioned before, Automap has no shape or size limitations; it can perform faultless MAP in any box. As a result, almost every package may be fashionable and appealing to customers while still having a lengthy shelf life, reasoned Bharat.
Thakkar discussed the dynamic landscape of the sweet industry compared to its chocolate counterpart, highlighting the direct competition between the two segments. Chocolate products have advantages such as convenient retail availability, attractive outer packaging, and extensive distribution networks. However, the sweet industry faces challenges such as short shelf life, spoilage, fungal growth, dryness, and taste deterioration. MAP technology has revolutionized the Indian sweet industry by addressing these issues and extending the shelf life of sweet products.
The global pandemic has led to a preference for pre-packaged foods, bolstering the demand for packed sweets. This shift in consumer behaviour has boosted the demand for packed sweets, which ensure hygiene, boast enhanced outer packaging, and prolonged shelf life, Thakkar elaborated.
“MAP technology has emerged as a captivating canvas to amplify the visual allure of sweets and namkeen products when they grace the shelves of retail spaces. The visual facet occupies a paramount position in the packaging of ethnic confections and savoury delights, accentuating the sensory journey of potential consumers”, voiced Chougule.
“Within this paradigm, our endeavours have culminated in the creation of distinctive contours and motifs, meticulously tailored to align seamlessly with the unique essence of each product. A tangible manifestation of this innovation lies in the novel designs curated to harmonize with the likes of Laddoos, Ghevars, and an assortment of namkeens nestled within containers and pouches. This deliberate synchronization extends beyond mere aesthetics, fostering a harmonious amalgamation of eye-catching aesthetics and precision fitment, ensuring the contents are cradled securely within their packaging sanctuary,” affirmed Chougule.
Eka Global has introduced new decoration technologies that enhance the visual appeal of their packaging. These technologies transcend conventional boundaries, weaving intricate patterns that resonate with consumers’ visual sensibilities. The company’s packaging ethos is woven with visual storytelling, enhancing the charisma of ethnic confections and savoury delights and making a significant statement on retail shelves.
Makdum highlights how VERIPACK ILPRA Group’s real-time pressure monitoring capability offers a distinct advantage in terms of controlling gas mixture ratios. This feature allows the company to tailor the gas mixtures according to the specific requirements of customer product profiles and aesthetic preferences. The advanced control provided by their MAP technology enables them to finely adjust these gas mixtures, ensuring that each product’s unique characteristics and appearance are preserved.
This control ensures the outer decorations remain undisturbed, the outer surface shines, and the inner oils and ghee remain unaffected, preserving the product’s softness and appeal. This ensures that both the packaging and the product exhibit high aesthetics and attractiveness when placed on retail shelves.
Modification of MAP Technology
Bharat’s research reveals that conventional MAP technology, used in vacuum and gas flushing procedures, can increase surface tension and water activity, leading to shelf-life disparities and stability issues in Indian sweets due to their high oil content and delicate texture, despite their harsh environmental conditions and unsanitary surroundings.
“In contrast, within the paling of Automap, a paradigm shift occurs. The automation of vacuum and gas flushing speeds obviates surface tension concerns. A poignant example can be found in baklava, a delicacy typically unsuited for conventional MAP due to its fragile texture. Astonishingly, we’ve achieved substantial shelf-life extension for baklava through the application of Automap technology,” Bharat emphasized.
“Expanding upon our innovative offerings, Message Food Services introduces Automap ATM, a solution expressly designed to address the initial microload within packaged sweets. The Automap ATM excels in eradicating moulds and bacteria, thus synergizing dual functionality to perfection,” Bharat affirmed resolutely, underscoring the holistic capabilities of their groundbreaking approach.
Driving to the point, Thakkar answered, “MAP technology stands as a critical innovation. As the culinary world embraces an array of sweets and namkeen items, each bearing unique characteristics, the need for customized MAP approaches becomes paramount. We delve into the evolution of MAP technology and how it confronts the challenges posed by diverse confections, particularly those with high oil content or delicate textures”.
The essence of MAP technology lies in its adeptness at controlling the internal atmosphere of packaged products. This process hinges on four pivotal parameters that collectively engineer the preservation prowess of MAP:
MAP Machine: A Vacuum and Gas Flushing Marvel
The MAP machine is a key component of the MAP strategy, which effectively removes residual oxygen from products and packaging to prevent spoilage. This mechanical marvel significantly extends the shelf life of packed goods by replacing oxygen with a selected gas mixture.
Barrier Packaging Materials: Guardians of Freshness
The MAP machine’s mission is completed, and high barrier packaging materials, including barrier trays and specialized lidding films, form an impermeable shield against external factors like oxygen and moisture, acting as a guardian to ensure the product remains protected from the harsh environment.
Gas Mixture Combinations: The Game Changer
MAP technology’s success relies on the use of gas mixtures, which regulate the internal atmosphere of packages, enabling the preservation of various items with unique characteristics. These gas mixtures act as conductors of freshness, balancing flavours, textures, and longevity.
Quality and Processing: The Art of Standardization
The effectiveness of MAP technology is based on the quality and precision of the packaged product, which are ensured through standardization and the care taken during preparation, which is the foundation of its effectiveness.
Triumph of MAP Over Oil-Laden Confections
MAP technology is a remarkable invention that significantly improves the quality and longevity of oil-laden confections. It prevents rapid oxidation, which can compromise the freshness and taste of these products. The vacuum and gas flushing process expels oxygen, extending the longevity of these items and preserving their taste and quality beyond conventional packaging methods.
In the wake of MAP, to effectively tackle the distinctive challenges posed by an array of sweets and namkeen variants, Chougule provides a succinct and illuminating perspective.
Chougule discusses the history of MAP technology, which has been used for over five decades to enhance Western staples like meat, cheese, and bakery items. He also details a comprehensive research and development journey since 2012, aiming to integrate MAP principles into ethnic sweets and namkeens.
The transformation of packaging involves calibrating MAP principles to match the unique characteristics of culinary creations. This is done using parameters like pH levels, free water content, redox potential, and initial microbial load to ensure the packaging barrier’s performance is tailored accurately, creating an optimal packaging environment”, Chougule responded.
“Since we are in total control of the MAP process, we have the highest capabilities to pack products with high oil content or delicate textures without disturbing the product profiles and ensuring the best product aesthetics”, cited Makdum. “For most Indian ethnic sweets and namkeens, we know the evacuation and injection points and have a repository of data on various products, which benefits our Indian customers and saves time during installation and machine commissioning timelines”.
On conclusion, Makdum said, “Today, we understand like no other the intricacies of various product surface textures, decoration, other inner and outer profiles, oil and ghee contents, etc. With VERIPACK ILPRA MAP packaging machines, customers can overcome all such product complexities and ensure inherent benefits”.