Tuesday, August 23, 2011

Improved Modified Atmosphere Packaging Technology

Visit the website of CVP Systems, Inc., and the first image you’ll see is Vice President and General Manager Chris van Wandelen performing a fierce karate chop on a stack of concrete bricks, breaking them clear in half. As he is also a martial arts expert, what you’re seeing is the real thing—no special effects. The video reflects the company’s motto, “Breaking Down Barriers,” which van Wandelen uses to inspire a team building spirit among employees. The same can be said for the performance of the company’s MasterPACKer Eco+ automated case-ready packaging machine, which knocks down road blocks to real and measurable energy and materials savings. The introduction of this machine has further solidified CVP’s reputation as a leader in modified atmosphere packaging.

CVP Systems, Inc.

CVP Systems, Inc. formed in 1972 when Coronet Container Corporation, based in Lombard, Ill., was required to change its technology based on industry requirements to extend shelf life for perishable products. These requirements stated that materials must be enclosed inside a vacuum-sealed package before being placed inside a corrugated box, rather than directly inside. A separate division, Coronet Vacuum Packaging, was developed and split from Coronet Containers in 1975 to become CVP Systems, Inc., based in Downers Grove, Ill., a Chicago suburb. The company employs 40 employees globally; a regional sales force covers the United States, and agents are also located in Europe and Latin America. Industries served by CVP are red meat, poultry, fish, produce and fruit, cheese, nuts, snack foods, and spices. Its modified atmosphere packaging technology also is used in industries other than food, such as for cube reduction and anti-oxidation systems, metal parts packaging, and document storage.
MasterPacker Eco+
MasterPACKer Eco+

Modified Atmosphere Packaging

Worldwide, Tesco, a global grocery and general merchandise retailer headquartered in Cheshunt, U.K., initiated the demand for modified atmosphere packaging technology in the early 70s. It became one of the first grocers to move away from employing an onsite butcher to using a central processing/distribution system. CVP Systems, in attempt to meet the demand by large poultry and meat packaging companies looking to extend their products’ shelf life, offered its modified atmosphere packaging solutions. This high-efficiency system for packaging of poultry and meats removes air from a package and introduces a new more beneficial atmosphere, depending on the specific product application requirements. Specific mixtures for low-ox applications can be comprised of a mixture of 69.6% nitrogen (N2), 30% carbon dioxide (CO2), and .4% carbon monoxide (CO) or 70% nitrogen and 30% carbon dioxide; it’s based on the premise that bacteria have a difficult time surviving in a low-ox environment because they need oxygen to survive and multiply,” said van Wandelen.

Some applications need only high-ox (70% oxygen, 30% carbon dioxide); however, high O2 applications do not attain quite the same shelf life extension as low O2. To improve its technology in modified atmosphere packaging, CVP engineers, through extensive research and development, created its MasterPACKer and just last year its “next generation” MasterPACKer Eco+.  The machine is designed for high-speed cycling and features a high-velocity “Quick Draw” snorkel. In the various process cycles, overwrapped trays containing product are robotically loaded onto a servo driven infeed conveyer. Two to eight trays are inserted into a mother bag as the machine indexes and transfers them to the next station, where a Quick Draw snorkel simultaneously draws a vacuum and inserts a pre-set amount of gas and then seals the bag.

 High-Velocity Quick-Draw Snorkel.jpeg
CVP Systems, Inc. developed its High-Velocity Quick-Draw Snorkel, which as part of its MasterPACKer Eco+™, provides efficient vacuum and gas insertion during the modified atmosphere packaging process.

Free-Flow Gas Systems vs. MasterPACKer Eco+™

Machines using a free-flow gas system for modified atmosphere packaging cannot create a vacuum from below the package and therefore use an open tube to release a continuous flow of gas into the package to displace the oxygen. “Much of the gas in a free-flow system is released into the atmosphere, resulting in a large amount of wasted gas as well the related environmental impact,” said van Wandelen. “When you compare waste between these systems and ours, taking into account the process of creating and transporting the bags, the amount of material used in the process, and the backside of the landfill effect upon disposal of the bag, the MasterPACKer Eco Plus+ reduces each of these components by 60%, whether you’re using a low- or high-ox dose. This is greatly significant from a cost and an environmental perspective and considering the overall carbon footprint.”