In modified atmosphere packaging (MAP), the gas mixture is not random: each food has its ideal composition, balancing bacterial inhibition, colour stability, structural integrity and shelf life. Choosing the wrong mixture can halve shelf life or ruin product appearance.
The three main MAP gases and their functions
CO₂, N₂ and O₂ are food-grade gases (E290, E941, E948) approved for MAP packaging in the EU. Each has a specific function and their combination determines preservation effectiveness.
- CO₂ (E290): bacteriostatic and fungicidal, soluble in fats and water
- N₂ (E941): inert, replaces O₂ without chemical effects on the product
- O₂ (E948): maintains red colour in meat, needed for respiring products
- Ar (Argon, E938): N₂ alternative for some cheeses and delicate products
MAP mixtures by food category
The following are standard reference mixtures; exact composition must always be validated on the specific product with shelf life tests.
- Fresh red meat: 70% O₂ / 20% CO₂ / 10% N₂
- Minced meat: 70-80% O₂ / 20-30% CO₂
- Fresh poultry: 30% CO₂ / 70% N₂
- Fatty fish (salmon, tuna): 40% CO₂ / 30% O₂ / 30% N₂
- Lean fish (cod, sea bream): 40% CO₂ / 60% N₂
- Hard and semi-hard cheeses: 100% CO₂ or 30% CO₂ / 70% N₂
- Bakery products (bread, pizza): 60-70% CO₂ / 30-40% N₂
- Salads and fresh vegetables: 3-5% O₂ / 5-10% CO₂ / rest N₂
- Refrigerated ready meals: 30% CO₂ / 70% N₂
How to manage gas in the production process
MAP gas is supplied in cylinders or bulk cryogenic systems. For production above 50,000 trays/day, an on-site bulk system with N₂ generator is worth considering, reducing gas cost by 40-60% compared to cylinders. The gas mixer must guarantee ±1% precision in final composition.
- Cylinders: flexible, suitable for production < 10,000 trays/day
- Cryogenic bulk: lower cost, suitable for medium-large production
- On-site N₂ generator: high initial investment, very low operating cost
- Certified gas mixer: ±1% precision mandatory for shelf life validation
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