Modified Atmosphere Packaging Using Gas Mixture
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Solution Overview
Problem
Current modified atmosphere packaging methods are inefficient and costly due to the use of pure gases, leading to inaccurate gas composition and prolonged packaging processes, resulting in increased costs and gas loss.
Innovation Solution
A method and apparatus that utilize a mixture of atmosphere modification gases with pressurized air to create a modified atmosphere within packages, allowing for better control and reduced gas loss, thereby accelerating the packaging process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pure gases are used to establish modified atmosphere in packages, then the atmosphere composition can be controlled, but the packaging process becomes slower and costs increase
Solution Approach 1:
The invention changes the parameter of gas composition by using pre-mixed gas blends with specific ratios (e.g., 20% O2, 5% CO2, 75% N2) instead of pure gases. This allows accurate atmosphere control while reducing the total volume of gas needed and improving packaging speed
Solution Approach 2:
The gas mixture is prepared in advance before packaging. The atmosphere composition is predetermined and mixed, eliminating the need for slow in-line gas adjustment during the packaging process, thus improving productivity while maintaining composition accuracy
2Manufacturing precision
If pure gases are used for modified atmosphere packaging, then the desired atmosphere can be established, but gas loss to ambient atmosphere increases and costs rise
Solution Approach 1:
By using gas blends with lower concentrations of expensive pure gases (e.g., using 5% CO2 instead of pure CO2), the invention reduces the amount of valuable gas that can be lost, while still achieving the desired atmosphere composition in the package
Solution Approach 2:
The invention uses cost-effective gas blends that can be readily replenished rather than expensive pure gases. The reduced cost per unit allows for more frequent recharging of packages with minimal economic impact, effectively reducing the loss burden
3Manufacturing precision
If gas flushing is performed to establish modified atmosphere, then the atmosphere composition is improved, but the packaging process is significantly slowed down
Solution Approach 1:
The gas mixture is prepared in advance and ready for immediate introduction into packages. This eliminates the time-consuming step of slow gas flushing during packaging, reducing process time while maintaining composition accuracy
Solution Approach 2:
The invention uses a shorter, more intense gas introduction process with pre-mixed gases rather than prolonged flushing. The pre-prepared gas blend achieves the desired atmosphere faster, reducing the time the package needs to be open or in the flushing process
4Manufacturing precision
If modified atmosphere packaging is performed with pure gases, then the atmosphere can be controlled, but packaging costs increase due to gas expenses and loss
Solution Approach 1:
The invention changes the cost parameter by using gas blends with lower concentrations of expensive pure gases. This reduces the cost per package while maintaining the functional atmosphere control needed for produce preservation
Solution Approach 2:
The invention adopts cost-effective gas blends that are cheaper to purchase and replenish. The reduced cost allows for economical packaging operations while maintaining atmosphere control functionality
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 enables the production of modified atmosphere packages more efficiently and cost-effectively by ensuring accurate gas composition and minimizing gas loss, thereby improving packaging speed and reducing waste.
Implementation Method 1
providing the modified atmosphere in the package volume by providing a gas mixture of at least one atmosphere modification gas and pressurised air in the package volume
Data Source
AI summary
A method of manufacturing a modified atmosphere package is provided which comprises the steps of: providing a portion of packaging material; providing a portion of produce; forming, from the portion of packaging material and the portion of produce, a closed package defining a package volume and containing in the package volume the portion of produce and a modified atmosphere. The modified atmosphere is modified with respect to the ambient atmosphere. The method comprises providing the modified atmosphere in the package volume by providing a gas mixture of at least one atmosphere modification gas and pressurised air in the package volume. An associated apparatus is also provided.