Dry Ice Snow Modified Atmosphere Packaging
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Solution Overview
Problem
Current modified atmosphere packaging (MAP) methods require a large headspace to maintain optimal shelf life for oxygen-sensitive foods, leading to increased transportation costs, packaging material usage, and storage space inefficiencies due to the slow sublimation of solid dry ice.
Innovation Solution
The use of dry ice snow and a packaging system with a heat sealable polymer film and one-way valves, allowing for a reduced headspace volume by controlling CO2 gas release and absorption, optimizing the packaging design to minimize material usage and enhance production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solid dry ice is used in MAP, then CO2 atmosphere is provided, but sublimation is slow leading to large headspace requirements
Solution Approach 1:
The patent segments the solid dry ice into snow form with particle sizes of 0.1-2.0 mm. This segmentation dramatically increases the surface area to volume ratio, accelerating sublimation rate. The fine particles sublime quickly to generate sufficient CO2 atmosphere while allowing reduced headspace volume, resolving the contradiction between reliable atmosphere generation and volume efficiency.
Solution Approach 2:
The patent changes the physical parameter of dry ice from solid blocks to snow particles with specific size distribution (0.1-2.0 mm). This parameter change transforms the sublimation characteristics, enabling rapid CO2 generation within a compact volume. The modified physical state allows the system to achieve reliable shelf life extension without requiring large headspace.
2Reliability
If large headspace is used in MAP, then optimal shelf life is achieved, but transportation costs and packaging material increase
Solution Approach 1:
By segmenting dry ice into snow particles, the system generates CO2 atmosphere efficiently in a reduced volume. This eliminates the need for large headspace, thereby reducing packaging material requirements and transportation costs while maintaining optimal shelf life through adequate CO2 atmosphere generation.
Solution Approach 2:
Changing dry ice to snow form with controlled particle size enables the system to achieve the same preservation effect with significantly reduced headspace volume. This parameter change directly reduces packaging material usage and transportation expenses while preserving shelf life benefits.
3Speed
If dry ice snow is used, then sublimation speed increases, but pressure control becomes critical
Solution Approach 1:
Segmenting dry ice into fine snow particles accelerates sublimation but also generates pressure rapidly. The patent addresses this by implementing pressure-regulated one-way valves that vent excess CO2, controlling internal pressure while maintaining rapid atmosphere generation. This resolves the contradiction between fast sublimation and pressure management.
Solution Approach 2:
The patent introduces one-way valves as intermediary components that mediate between the rapid sublimation process and pressure control requirements. These valves allow CO2 to escape when pressure exceeds a threshold, preventing package rupture while maintaining the benefits of fast sublimation from dry ice snow.
4Productivity
If reduced headspace is used, then transportation efficiency improves, but CO2 atmosphere generation may be insufficient
Solution Approach 1:
The segmented dry ice snow form compensates for reduced headspace volume by providing dramatically increased surface area for sublimation. This enables sufficient CO2 atmosphere generation within compact packaging, achieving both transportation efficiency and reliable atmosphere generation for shelf life extension.
Solution Approach 2:
The parameter change from solid dry ice to snow particles transforms the sublimation kinetics, enabling adequate CO2 generation in reduced volumes. This allows the system to improve transportation efficiency while maintaining sufficient atmosphere generation through enhanced surface area to volume ratio.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces packaging material requirements, lowers transportation costs, and extends shelf life by maintaining a modified atmosphere with minimal oxygen concentration, while ensuring the packaging can handle the pressure generated by CO2 sublimation without rupture.
Implementation Method 1
The use of dry ice snow and a packaging system with a heat sealable polymer film and one-way valves, allowing for a reduced headspace volume by controlling CO2 gas release and absorption
Implementation Method 2
at least one one-way valve that opens and allows gas to escape the modified atmosphere packaging, when an internal pressure of the packaging exceeds a given pressure limit
Implementation Method 3
at least the heat seal section comprises a heat sealable polymer film having a sealing temperature range of at least 35 °C and preferably at least 45 °C
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The present invention provides a modified atmosphere packaging method, comprising the following steps: providing a modified atmosphere packaging (1,5,9) made in a gas impermeable material, the packaging is heat sealable at a heat sealing section and comprises at least one one-way valve (6) for allowing gas to escape the packaging; adding dry ice snow (4) and a food product (2) to the modified atmosphere packaging (6); evacuating gas from the modified atmosphere packaging (1,5,9) before heat sealing; and heat sealing the modified atmosphere packaging at the heat sealing section.