Everything You Need to Know About MAP Machines (Modified Atmosphere Packaging)
A MAP machine, or Modified Atmosphere Packaging machine, is a specialist system that replaces the air inside a package with a carefully controlled gas mixture. This process slows spoilage, oxidation and microbial growth, extending shelf life while maintaining the freshness, flavour and appearance of food. The machine works by removing ambient air from a tray or pouch, injecting the required gas blend and then sealing the package. It’s widely used in the food industry for products such as meat, seafood, ready meals, cheese, fresh produce and other perishables.
Why Use MAP Machines
The benefits of MAP machines align closely with SystemPAK’s focus on quality, safety and sustainability. Key advantages include:
- Extended shelf life: Reducing oxygen levels and using tailored gas mixtures slows deterioration, keeping food fresher for longer and reducing waste.
- Enhanced food safety: Controlled packaging environments lower the risk of contamination and support compliance with food safety standards.
- Preserved appearance and taste: Meat retains its natural colour, produce stays crisp, and bakery products maintain their texture and aroma.
- Reduced need for additives: The modified atmosphere itself helps preserve quality, meaning fewer preservatives or additives are often required.
- Greater supply chain flexibility: Longer shelf life allows for more efficient logistics, broader distribution and improved stock management.
Key Features of MAP Machines
MAP machines typically include several essential components, each playing a role in ensuring packaging performance:
- Sealing chamber: Accommodates the tray or pouch and creates the controlled environment for gas flushing and sealing.
- Gas flushing or vacuum system: Removes ambient air and introduces the gas mixture.
- Gas mixing system: Controls the ratio of gases such as oxygen, nitrogen and carbon dioxide.
- Programmable control system: Ensures consistent operation and easy integration with production lines.
- Sealing station: Uses heat or induction sealing depending on the chosen packaging materials.
- Sensors and monitoring: Detect gas levels and potential leaks for quality assurance.
- Automation level: Semi-automatic machines suit smaller runs, while fully automated systems are designed for higher throughput and continuous production.
Choosing the Right MAP Machine
Selecting the most suitable MAP machine involves considering several practical factors:
- Type of product and packaging format
- Required gas mix and ability to control proportions precisely
- Production speed and throughput targets
- Compatibility with films and trays to ensure secure seals
- Hygiene and ease of cleaning to meet food safety standards
- Monitoring, traceability and quality assurance features
- Availability of service, support and spare parts
- Total cost of ownership, including energy use, maintenance and gas consumption
MAP Machines and SystemPAK Solutions
SystemPAK provides packaging technologies designed to work seamlessly with MAP systems. Our trays and top-seal films deliver reliable sealing and controlled atmosphere performance, supporting both quality and sustainability goals. For businesses not ready to invest in a full MAP system, our sealing machines offer an effective way to achieve high-quality seals. We also provide consultancy and product trials to help determine the most effective tray, film and gas mix for different products. Sustainability is central to our approach, with many of our packaging formats being recyclable and engineered for efficient use within MAP environments.
Common Misconceptions About MAP
Some widespread myths are worth clarifying:
- MAP is not a substitute for refrigeration; it works alongside proper temperature control.
- Gas mixtures are product-specific; using the wrong mix can reduce shelf life rather than extend it.
- One machine does not fit all; different products, packaging formats and production volumes require tailored solutions.
Best Practices for MAP Performance
To achieve the best results with MAP technology, it’s important to:
- Carry out test runs before full-scale production to fine-tune gas and sealing parameters.
- Monitor gas levels regularly to ensure consistency and performance.
- Conduct routine maintenance and leak testing.
- Use high-quality barrier films and trays designed for MAP applications.
- Train operators to follow correct procedures to minimise errors.
MAP machines are a powerful way for food producers to extend shelf life, reduce waste and maintain high product quality. By selecting the right machine, gas mixture, packaging materials and operating procedures, businesses can optimise both product integrity and supply chain efficiency. SystemPAK is committed to delivering reliable, sustainable packaging solutions that integrate seamlessly with modern MAP technology, helping businesses seal with confidence.
