Vacuum packing

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Sealed food alongside a home vacuum sealer and plastic rolls used for sealing. Vacuum sealer with food sealed on wooden table and rolls of plastic for sealing.jpg
Sealed food alongside a home vacuum sealer and plastic rolls used for sealing.

Vacuum packing is a method of packaging that removes air from the package prior to sealing. This method involves placing items in a plastic film package, removing air from inside and sealing the package. [1] Shrink film is sometimes used to have a tight fit to the contents. The intent of vacuum packing is usually to remove oxygen from the container to extend the shelf life of foods and, with flexible package forms, to reduce the volume of the contents and package. [2]

Contents

Vacuum packing reduces atmospheric oxygen, limiting the growth of aerobic bacteria or fungi, and preventing the evaporation of volatile components. It is also commonly used to store dry foods over a long period of time, such as cereals, nuts, cured meats, cheese, smoked fish, coffee, and potato chips (crisps). On a more short-term basis, vacuum packing can also be used to store fresh foods, such as vegetables, meats, and liquids, because it inhibits bacterial growth.

Vacuum packing greatly reduces the bulk of non-food items. For example, clothing and bedding can be stored in bags evacuated with a domestic vacuum cleaner or a dedicated vacuum sealer. This technique is sometimes used to compact household waste, for example where a charge is made for each full bag collected.

Vacuum packaging products, using plastic bags, canisters, bottles, or mason jars, are available for home use.

For delicate food items that might be crushed by the vacuum packing process (such as potato chips), an alternative is to replace the interior gas with nitrogen. This has the same effect of inhibiting deterioration due to the removal of oxygen.

Types

Vacuum packaged ready-to-sell Jamon products. Barcelona Mercat Boqueria 9 (8271967087).jpg
Vacuum packaged ready-to-sell Jamón products.

Edge, suction, and external vacuum sealers

External vacuum sealers involve a bag being attached to the vacuum-sealing machine externally. The machine will remove the air and seal the bag, which is all done outside the machine. A heat sealer is often used to seal the pack. Typically these units use a dry piston vacuum pump which is often considered a "maintenance-free" pump. For sealing dry goods only, this is the preferred method. Moist foods are known to cause internal corrosion on these dry piston pumps.

Single chamber vacuum sealers

This video shows vacuum packaging of rice.
Tabletop vacuum packaging machine Tabletop Vacuum Packaging Machine.png
Tabletop vacuum packaging machine

Single chamber sealers require the entire product to be placed within the machine. Like external sealers, a plastic bag is typically used for packaging. Once the product is placed in the machine, the lid is closed and air is removed. Then, there is a heat seal inside the chamber that will seal the bag, after sealing the bag the chamber is refilled with air by the automatic opening of a vent to the outside. This oncoming pressure squeezes all remaining air in the bag. The lid is then opened and the product removed. Chamber sealers are typically used for low-to-medium-volume packaging. This style of vacuum machine is also capable of sealing liquids due to equal pressure in the chamber and the bag eliminating the risk of the liquid being sucked out of the open edge of the bag.

Double chamber vacuum sealers

Double chamber vacuum packaging machine XtraVac Double Chamber Vacuum Packaging Machine.png
Double chamber vacuum packaging machine

Double chamber sealers require the entire product to be placed in a plastic bag within the machine. Once the product is placed in the machine on the seal bar, the lid is closed and air is removed. Then a seal bar inside the chamber seals the product in the bag, after sealing the bag the chamber is refilled with air by the automatic opening of a vent to the outside. This oncoming pressure squeezes all remaining air in the bag. The lid is then opened and the product removed. Double chamber sealers are typically used for medium-volume packaging, and also have the capability to vacuum seal liquids. The lid generally swings from one side to another, increasing production speed over a single chamber model. Double chamber vacuum packaging machines generally have either spring-weighted lids or fully automatic lids.

Double chamber vacuum packaging machines are commonly used for:

Rotary belt type vacuum sealers

Rotary belt type vacuum packaging machine or vacuum sealer features the same function as the double chamber vacuum packaging machine as a 'vacuum bag sealer'. But the rotary belt vacuum packaging machine is more convenient, as the belt rotates automatically while the bags are placed to the sealing bar and vacuum sealing process completed. The vacuumed and sealed bags are automatically unloaded, which obviously is more convenient. The packaging plate of the machine is adjustable to 4 degrees, which allows the vacuum packaging of food with soup and liquid.

Rotary belt type packaging machines are commonly used for:

Automatic belt vacuum chamber machines

Automatic Belt Vacuum Chamber Machine. Automatic belt vacuum chamber machines offer vastly increased speed and automation and accommodate large products. VC999 K9 Automatic Belt Vacuum Chamber Machine.jpg
Automatic Belt Vacuum Chamber Machine. Automatic belt vacuum chamber machines offer vastly increased speed and automation and accommodate large products.

Automatic belt chamber sealers require the entire product to be placed in a plastic bag or flow wrapped pouch within the machine. The product travels on the conveyor belt, it is automatically positioned in the machine on the seal bar, the lid is closed and air is removed. Then a seal bar inside the chamber seals the product in the bag. After sealing the bag, the chamber is refilled with air by the automatic opening of a vent to the outside. This oncoming pressure squeezes all remaining air in the bag. The lid is then opened and the product removed. Automatic belt vacuum chamber machines are typically used for high-speed packaging of large items, and also have the capability to vacuum seal liquids. The lid generally travels straight up and down.

Automatic belt vacuum chamber packaging machines are commonly used for:

Next-generation machines look similar but are much easier to operate and maintain. R-Series Right Front thermoforming roll stock vacuum MAP and skin packaging machine by VC999.png
Next-generation machines look similar but are much easier to operate and maintain.

Thermoforming HFFS vacuum packaging machines

Thermoform packaging machines are used in larger production facilities for vacuum packaging products. VC999 i-Series Thermoform Packaging Machine.png
Thermoform packaging machines are used in larger production facilities for vacuum packaging products.

Vacuum packaging in large production facilities can be done with thermoforming machines. These are Form-Fill-Seal style machines that form the package from rolls of packaging film (webbing). Products are loaded into the thermoformed pockets, the top web is laid and sealed under a vacuum, MAP (modified atmosphere), or skin packaging producing rapidly packaged products. Thermoforming can greatly increase packaging production speed. Thermoformed plastics can be customized for size, color, clarity, and shape to fit products perfectly, creating a consistent appearance. One of the most commonly used thermoformed plastics is PET, known for a high-strength barrier resistant to outside tampering and an ease of molding into designated designs and shapes. Some common uses for Thermoforming in vacuum packaging include:

Food storage

Food safety

A cut of wild-caught elk meat in a vacuum sealed bag Elk steak.jpg
A cut of wild-caught elk meat in a vacuum sealed bag

In an oxygen-depleted environment, anaerobic bacteria can proliferate, potentially causing food-safety issues. Some pathogens of concern in vacuum packed foods are spore-forming non-proteolytic Clostridium botulinum , Yersenia enterocolitica, and Listeria monocytogenes . [3] Vacuum packing is often used in combination with other food processing techniques, such as retorting or refrigeration, to inhibit the growth of anaerobic organisms. [3]

Shelf life

Depending on the product, atmosphere, temperature, and the barrier properties of the package, vacuum packaging extends the shelf life of many foods. [4] [5] The shelf life of meats can be extended by vacuum packaging, particularly when used with modified atmosphere packaging. [6] [7]

High barrier-chamber vacuum shrink bags

The amount of shelf life enhanced by a vacuum bag is dependent on the structure in the material. A standard vacuum bag is composed of a PA/PE structure where PA is for puncture resistance and PE is for sealing. The high barrier category includes the usage of more layers focused on the prevention of oxygen permeability, and therefore shelf life protection.[ citation needed ] There are two materials used in high barrier structures, polyvinylidene chloride (PVDC) and ethylene vinyl alcohol (EVOH).[ citation needed ] Shelf life indication can be effectively measured by how many cubic centimeters of oxygen can permeate through 1 square meter of material over a 24-hour period. A standard PA/PE bag allows on average 100 cubic centimeters, PVDC allows on average over 10, and EVOH on average 1 cubic centimeter. Multi-layer structures allow the ability to use strong oxygen-barrier materials for enhanced shelf life protection.[ citation needed ]

Freezer burn

When foods are frozen without preparation, freezer burn can occur.[ citation needed ] It happens when the surface of the food is dehydrated, and this leads to a dried and leathery appearance. Freezer burn also changes the flavor and texture of foods. Vacuum packing reduces freezer burn by preventing the food from exposure to the cold, dry air.[ citation needed ]

Related Research Articles

<span class="mw-page-title-main">Food preservation</span> Inhibition of microbial growth in food

Food preservation includes processes that make food more resistant to microorganism growth and slow the oxidation of fats. This slows down the decomposition and rancidification process. Food preservation may also include processes that inhibit visual deterioration, such as the enzymatic browning reaction in apples after they are cut during food preparation. By preserving food, food waste can be reduced, which is an important way to decrease production costs and increase the efficiency of food systems, improve food security and nutrition and contribute towards environmental sustainability. For instance, it can reduce the environmental impact of food production.

<span class="mw-page-title-main">Jerky</span> Lean meat dried to prevent spoilage

Jerky is lean trimmed meat cut into strips and dehydrated to prevent spoilage. Normally, this drying includes the addition of salt to prevent bacteria growth. The word "jerky" derives from the Quechua word ch'arki which means "dried, salted meat".

<span class="mw-page-title-main">Packaging and labeling</span> Enclosure or protection of products for distribution, storage, and sale

Packaging is the science, art and technology of enclosing or protecting products for distribution, storage, sale, and use. Packaging also refers to the process of designing, evaluating, and producing packages. Packaging can be described as a coordinated system of preparing goods for transport, warehousing, logistics, sale, and end use. Packaging contains, protects, preserves, transports, informs, and sells. In many countries it is fully integrated into government, business, institutional, industrial, and for personal use.

<span class="mw-page-title-main">Beef aging</span> Process of preparing beef for consumption

Beef aging or ageing is a process of preparing beef for consumption by aging it, in order to break down the connective tissue within the meat.

Thermoforming is a manufacturing process where a plastic sheet is heated to a pliable forming temperature, formed to a specific shape in a mold, and trimmed to create a usable product. The sheet, or "film" when referring to thinner gauges and certain material types, is heated in an oven to a high-enough temperature that permits it to be stretched into or onto a mold and cooled to a finished shape. Its simplified version is vacuum forming.

A hermetic seal is any type of sealing that makes a given object airtight. The term originally applied to airtight glass containers, but as technology advanced it applied to a larger category of materials, including rubber and plastics. Hermetic seals are essential to the correct and safe functionality of many electronic and healthcare products. Used technically, it is stated in conjunction with a specific test method and conditions of use.

<span class="mw-page-title-main">Sous vide</span> Cooking method using prolonged low temperatures

Sous vide, also known as low-temperature, long-time (LTLT) cooking, is a method of cooking invented by the French chef Georges Pralus in 1974, in which food is placed in a plastic pouch or a glass jar and cooked in a water bath for longer than usual cooking times at a precisely regulated temperature.

<span class="mw-page-title-main">Heat sealer</span> Machine for joining thermoplastic materials using heat

A heat sealer is a machine used to seal products, packaging, and other thermoplastic materials using heat. This can be with uniform thermoplastic monolayers or with materials having several layers, at least one being thermoplastic. Heat sealing can join two similar materials together or can join dissimilar materials, one of which has a thermoplastic layer.

<span class="mw-page-title-main">Modified atmosphere</span>

Modified atmosphere packaging (MAP) is the practice of modifying the composition of the internal atmosphere of a package in order to improve the shelf life. The need for this technology for food arises from the short shelf life of food products such as meat, fish, poultry, and dairy in the presence of oxygen. In food, oxygen is readily available for lipid oxidation reactions. Oxygen also helps maintain high respiration rates of fresh produce, which contribute to shortened shelf life. From a microbiological aspect, oxygen encourages the growth of aerobic spoilage microorganisms. Therefore, the reduction of oxygen and its replacement with other gases can reduce or delay oxidation reactions and microbiological spoilage. Oxygen scavengers may also be used to reduce browning due to lipid oxidation by halting the auto-oxidative chemical process. Besides, MAP changes the gaseous atmosphere by incorporating different compositions of gases.

<span class="mw-page-title-main">Blister pack</span> Type of packaging

A blister pack is any of several types of pre-formed plastic packaging used for small consumer goods, foods, and for pharmaceuticals.

<span class="mw-page-title-main">Induction sealing</span> Process of bonding thermoplastic materials by induction heating

Induction sealing is the process of bonding thermoplastic materials by induction heating. This involves controlled heating an electrically conducting object by electromagnetic induction, through heat generated in the object by eddy currents.

<span class="mw-page-title-main">Food packaging</span> Enclosure and protection of nutritional substances for distribution and sale

Food packaging is a packaging system specifically designed for food and represents one of the most important aspects among the processes involved in the food industry, as it provides protection from chemical, biological and physical alterations. The main goal of food packaging is to provide a practical means of protecting and delivering food goods at a reasonable cost while meeting the needs and expectations of both consumers and industries. Additionally, current trends like sustainability, environmental impact reduction, and shelf-life extension have gradually become among the most important aspects in designing a packaging system.

<span class="mw-page-title-main">Fish processing</span> Process from catching to selling fish

The term fish processing refers to the processes associated with fish and fish products between the time fish are caught or harvested, and the time the final product is delivered to the customer. Although the term refers specifically to fish, in practice it is extended to cover any aquatic organisms harvested for commercial purposes, whether caught in wild fisheries or harvested from aquaculture or fish farming.

Aseptic processing is a processing technique wherein commercially thermally sterilized liquid products are packaged into previously sterilized containers under sterile conditions to produce shelf-stable products that do not need refrigeration. Aseptic processing has almost completely replaced in-container sterilization of liquid foods, including milk, fruit juices and concentrates, cream, yogurt, salad dressing, liquid egg, and ice cream mix. There has been an increasing popularity for foods that contain small discrete particles, such as cottage cheese, baby foods, tomato products, fruit and vegetables, soups, and rice desserts.

<span class="mw-page-title-main">Vertical form fill sealing machine</span>

A vertical form fill sealing machine is a type of automated assembly-line product packaging system, commonly used in the packaging industry for food and many other products. Walter Zwoyer, the inventor of the technology, patented his idea for the VFFS machine in 1936 while working with the Henry Heide Candy Company. The machine constructs plastic bags and stand-up pouches out of a flat roll of film, fills them with product, and seals them. Both solids and liquids can be bagged.

Fillers are used for packaging, mainly for food/beverage but for other products as well. These are used to fill either a bottle or a pouch, depending on the product.

<span class="mw-page-title-main">Currency packaging</span>

Currency packaging includes several forms of packing cash for easy handling and counting. Many systems use standard color-coding or are marked to indicate the amount in the package.

<span class="mw-page-title-main">Packaging machinery</span>

Packaging machinery is used throughout all packaging operations, involving primary packages to distribution packs. This includes many packaging processes: fabrication, cleaning, filling, sealing, combining, labeling, overwrapping, palletizing.

<span class="mw-page-title-main">Pasta processing</span> Process of making pasta

Pasta processing is the process in which wheat semolina or flour is mixed with water and the dough is extruded to a specific shape, dried and packaged.

<span class="mw-page-title-main">Case-ready meat</span>

Case-ready meat, retail-ready meat, or pre-packaged meat refers to fresh meat that is processed and packaged at a central facility and delivered to the store ready to be put directly into the meat case.

References

  1. Perdue, R (2009), "Vacuum Packaging", in Yam, K L (ed.), Encyclopedia of Packaging Technology, Wiley (published 2010), ISBN   978-0-470-08704-6
  2. Soroka, W. Illustrated Glossary of Packaging Terminology (Second ed.). Institute of Packaging Professionals.
  3. 1 2 Mills, John; Donnison, Andrea; Brightwell, Gale (2014). "Factors affecting microbial spoilage and shelf-life of chilled vacuum-packed lamb transported to distant markets: A review". Meat Science. 98 (1): 71–80. doi:10.1016/j.meatsci.2014.05.002. PMID   24875594.
  4. Gorris, L G M (1992). "Modified Atmosphere and Vacuum Packaging to Extend the Shelf Life of Respiring Food Products" (PDF). HortTechnology. 2 (3): 303–309. doi: 10.21273/HORTTECH.2.3.303 . Retrieved August 14, 2018.
  5. Beltran, David (2005). "Effect of different sanitizers on microbial and sensory quality of fresh-cut potato strips stored under modified atmosphere or vacuum packaging" (PDF). Postharvest Biology and Technology. 37: 37–46. doi:10.1016/j.postharvbio.2005.02.010 . Retrieved August 14, 2018.
  6. Garcia-Esteban, Marta (2004). "Comparison of modified atmosphere packaging and vacuum packaging for long period storage of dry-cured ham: effects on colour, texture and microbiological quality" (PDF). Meat Science. 67 (1): 57–63. doi:10.1016/j.meatsci.2003.09.005. hdl: 10171/22986 . PMID   22061116 . Retrieved August 14, 2018.
  7. Seidman, S C (1983). "Vacuum Packaging of Fresh Beef: A Review". Journal of Food Quality. 6 (1): 29–47. doi:10.1111/j.1745-4557.1983.tb00755.x.

Further reading