Vacuum Packaging and Modified Atmosphere Packaging: Practical Aspects of Choice for Food Production

Published:2026-11-04 · Industry News · Source: Kody Packaging Editorial
Key Takeaways
  • Application areas of vacuum packaging and MAP at enterprises of different profiles
  • Key criteria for choosing barrier materials and types of packaging equipment
  • Factors affecting the unit cost of production and delivery times of solutions

Vacuum packaging is optimal for meat and fish delicacies, hard cheeses, chilled semi-finished products and dry products, since oxygen removal slows down the development of aerobic bacteria and oxidative processes. Modified atmosphere packaging, which replaces air with a mixture of nitrogen, carbon dioxide and oxygen in controlled proportions, is more often used for fresh vegetables, fruits, baked goods, ready meals and sliced products, where preserving structure and appearance is important. When choosing a technology, one should take into account the respiration of the product, its susceptibility to mechanical damage and the required shelf life at all stages of distribution.

Materials for vacuum packaging are selected based on the level of barrier properties: for products with a long shelf life, multilayer films and laminates with low oxygen and water vapor permeability are used, while for frozen products, frost resistance and puncture resistance are additionally assessed. For MAP, thermoforming films, trays made of foamed or rigid polymers and flexible bags with the possibility of hermetic sealing are used; for products with active respiration, microperforated materials may be required. When choosing the packaging format and size, one is guided by retail chain standards, single-portion volume and the capabilities of the production line.

The cost of packaging depends on the type of barrier material, design complexity, the need for printing and the class of equipment used. Multilayer specialized laminates and custom-shaped trays usually increase costs compared to standard bags and universal films. When planning production, it is worth separately considering the costs of maintenance of packaging lines, calibration of gas mixtures and control of the tightness of finished products.

When ordering packaging solutions from suppliers, food safety requirements and the availability of permits for contact with specific types of products should be agreed in advance. Standard material and packaging formats are usually available from stock on short notice, while the production of custom printing, non-standard sizes and special barrier compositions requires additional time for manufacturing and logistics. For stable operation of the production line, it is recommended to agree on the delivery schedule in advance and test the selected materials for compatibility with existing equipment.

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