CAS & MAS

Controlled Atmospheric Storage & Modified Atmospheric Storage

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 1

 Controlled atmosphere (CA) and modified atmosphere (MA) storage are
technologies for extending the shelf life of foods, especially fruits and
vegetables; and for eliminating pests in stored grains and oilseeds.
 The most important application of CA and MA is for long-term storage of
apples.
 The shelf life of certain other fruits (pears, sweet cherries) and vegetables
(cabbage) can also be extended by these methods.
 MA can extend the shelf life of meat, fish, poultry, fresh pasta,
sandwiches, eggs, and bakery products.
 As grains and oilseeds are more stable than high moisture foods (e.g., fruits,
vegetables, meats), CA and MA are used primarily for disinfestation rather
than for increasing the shelf life

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 2

CONTROL ATMOSPHERE and MODIFIED
ATMOSPHERE

Control atmosphere (CA):

It generally refers to decreased O2 and increased CO2 concentrations, by a
precise control of the gas composition.

Modified atmosphere (MA):

It is used when the control of the storage atmosphere is not closely controlled,
such as in plastic film packaging.

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 3

DIFFERENCE

CA: Gas atmosphere is continuously controlled throughout the storage period

MA: Gas composition is modified initially and it changes dynamically depending

on the respiration rate of produce and permeability of film or storage structure
surrounding the produce

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 4

Principle

 The principle behind controlled and modified atmosphere technologies is to

reduce the rate of respiration, reduce microbial growth, and retard enzymatic
spoilage by changing the gaseous environment surrounding the food product.
 This is achieved by reducing the concentration of oxygen (O2), which is required
in respiration, or by adding an inhibitory gas such as carbon dioxide (CO2) or
carbon monoxide (CO).
 The balance between O2 and CO2 is critical, and an optimal ratio is required for
each specific product.
 A major difference between CA and MA storage is in the degree of control of
the gaseous composition of the storage atmosphere.
 The CA implies a higher degree of control than MA in maintaining specific levels
of O2, CO2, and other gases.

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 5

 In MA storage the composition of the atmosphere surrounding the product
is generally created and maintained by the interaction of the commodity’s
respiration with the permeation of respiratory gases through the packaging
material.
 Modified atmosphere conditions can also be established and adjusted by
pulling a slight vacuum and replacing the package atmosphere with a
desirable gas mixture, which can be further, adjusted through the use of O2,
CO2, or Ethylene (C2H4) absorbers.
 In CA storage facilities, both temperature and gas composition of the
storage atmosphere are regulated or controlled.
 The gas concentration ranges encountered in CA storages are 1 to 10% O2, 0
to 30% CO2, and the balance is nitrogen (N2).
 Air consists of approximately 78% N2, 21% O2, 0.03% CO2, and traces of
several other gases that have no physiological significance.

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 6

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 7
Controlled Atmospheric Packaging

 The technique of modification of the atmosphere surrounding perishable

products is referred to as CAS.
 In CAS, the atmosphere is created artificially and the gas composition is
continuously monitored and adjusted to maintain the optimum gas concentration.
 There are different types of controlled atmosphere storage depending mainly on
the method or degree of control of the gases.
 Mainly two type of control atmosphere storage systems like
1. Static controlled atmosphere storage
2. Flushed controlled atmosphere storage
 Static is where the product generates the atmosphere.
 Flushed is where the atmosphere is supplied from a flowing gas stream.
ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 8
Historical development

 The first commercial applications of the use of modified gas atmospheres

were for CAS of fruits and vegetables.
 Scientific investigations on the effect of gases on extending the shelf life of
foods were conducted in 1930 on fresh meat.
 Fresh carcass meat was exported from New Zealand and Australia under CAS
in the early 1930s.
 It was reported that a doubling of the shelf life of refrigerated pork and
lamb when these meats were stored in an atmosphere of 100% CO2.
 Early developments were generally for storage and transportation of
bulk foods.

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 9

Beneficial Effects of CAS

Using CAS has a wide range of benefits such as the following:

 A considerable decrease in respiration rate of fruits and vegetable
 A reduction in the effect of ethylene on metabolism due to the
interaction of O2 with ethylene.
 An extension in storage life, which can even be doubled, in as much as the
over ripening is delayed.
 The preservation of an excellent firmness of meat, due to effect of CO2
concentration on the enzymes acting on cellular membranes.

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 10

 5. A high turgidity is achieved, such that fruits become more juicy and
crispy.
 6. A smaller loss of acidity, sugars and vitamin C, so that the nutritional and
sensory quality is higher.
 7. A limited degradation of chlorophyll, with a consequent higher stability of
colour.

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 11

 ATMOSPHERE CONDITIONING

 The reduction of O2 level inside the storage rooms can be biologically

achieved by means of fruit respiration, or by O2 burning, or by replacing air
by feeding nitrogen.
 In first case, the reduction in O2 down to a steady state level takes place
within 15-25 days, with a slow and progressive decrease thereof.
 When a non-biological system is used, O2 can be reduced to levels of 6-8%
within 24 hrs and the subsequent lowering to the desired levels for storage
can take place via respiration.

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 12

 The reduction in O2 level can be rapid only if the fruits have reached a
temperature lower than 5°C.
 The fastest reduction in O2 level in the atmosphere is obtained by using
nitrogen generators (by now, a widely used system), or by feeding liquid N2.

 Lowering O2 down to steady state controlled atmosphere levels by

means of non- biological techniques is disadvantageous from a financial
standpoint, due to the high consumption of fuel or of nitrogen.
 Nitrogen generator selectively separate air to produce an enriched nitrogen
system.

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 13

 The storability of fruits and vegetables is strictly related to their respiration
rate, which is an expression of metabolic activity.
 Aerobic respiration requires O2, and results in CO2 and heat release.
 More than 95% of the energy released is lost as heat.
 The temperature decrease, in particular if helped by modification of the
atmosphere leads to a reduction in respiration rate, and therefore to an
increase in storage life in fruits with climacteric respiration.
 Selection of the most suitable atmosphere depends on cultivars, stage of
maturity, environmental and cultivation parameters.

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 14

Requirements for Ideal CAS

 CA storage room
 Temperature control
 Humidity control
 Gas control
 Scrubbers

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 15

CA Storage room

 A gas tight room is an obvious prerequisite for achieving a good controlled

atmosphere storage system.
 Thus it is necessary to make room walls gas -tight.
 In order to ensure that the walls are gas tight to wall of CA storage they are
lined with sheets of galvanized steel.

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 16

Temperature Control

 The main way of preserving fruits, vegetables and meat in storage or during
long distance transport is by refrigeration, and controlled atmospheres
are considered a supplement to increase or enhance the effect of
refrigeration.
 CA storage is only successful when applied at low temperatures.
 Standard refrigeration units are therefore integral components of CAS
system.
 Temperature control is achieved by having pipes containing a refrigerant
inside the storage.
 Ammonia or chlorofluorocarbons are common refrigerants.

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 17

Humidity Control

 Most fruits, vegetables and meats, which are kept in CA storage, require a
high relative humidity, generally the closer to saturation the better, so long
as moisture does not condense on the foods.
 If the refrigerant temperature is low compared to the store air
temperature then water will condense on the evaporator.
 This removal of moisture from the store air, reduces its relative humidity,
which results in the stored food losing moisture by evaporation-transpiration.
 To reduce food desiccation the refrigerant temperature should be kept
close to the store air temperature.

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 18

Gas Control

 The atmosphere in a modern CA store is constantly analyzed for CO2 and O2

levels using an Infrared gas analyzer to measure the gas content in the
store constantly.
 There are also ethylene analyzers that continuously measure ethylene
concentration in the store.
 In storage rooms where low ethylene is essential, checks can be made that
the ventilation and ethylene removal systems are operating correctly.

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 19

Scrubbers

 The composition of the gas mixture inside the storage rooms undergoes
continuous change as a function of the metabolic activity of the stored
product and scrubbers are necessary to absorb excess CO2.
 Scrubbers are generally classified according to the absorbent material:
CA(OH)2, NaOH, H2 O, zeolites, activated charcoals.
 They are also classified according to the mode of absorption (i.e. chemical
or physical), or to the mode of air passage through the absorbing agent.
 Scrubbers using activated charcoal are currently the most popular.
 Gas removal with this type of equipment is based on the fixing of CO2 in a
particular way, and releasing it again on contact with atmospheric air, even
at room temperature.
ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 20
Adverse Effect

 CA storage has also adverse effects, at O2 levels below 1%, in the absence of
CO2, anaerobic conditions can prevail with the consequent formation of
alcohol and physiological changes.
 High CO2 and low O2 may cause abnormality in metabolism in fruits and
vegetables.

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 21

BENEFICIAL EFFECTS OF PROPER CA
STORAGE

 Inhibition of the browning of cut surface(cut fruits and vegetables),

 Better flavour retention (pineapple, cabbage),
 Reduction of disorders and decay (berries),
 Higher nutritional value after storage (vitamin C).

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 22

DISADVANTAGES OF PROPER CA
STORAGE

 It is quite expensive.
 Temp. control required.
 Different gas composition for each type of product.
 Special operation and operator training required.
 Once pack opens or leaks the benefits are lost.
 May cause irregular ripening of fruits (banana, mango, pear, and tomato, at O2
below 2%, CO2 above 5% for > 1 month).
 May cause certain physiological disorders.
 May enhance anaerobic respiration and development of off-flavors.

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 23

RECENT DEVELOPMENTS IN CA STORAGE

 Recent improvements include maintaining CA during transport in refrigerated

marine containers.
 CA transport of banana permits the harvest at a more fully-mature stage.
 In addition to CA, there is also a continuing increase in the use of plastic films
and MAP.

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 24

Modified Atmosphere Packaging (MAP)

 MAP is the replacement of air (N2 content 78%, O2 content 21%, CO2 content
0.035%, together with water vapour and traces of inert gases) in a pack
 Filling with a single gas or mixture of gases; the proportion of each
component is fixed when the mixture is introduced.
 Certain additives are incorporated into storage space to extend shelf-life.
 This is referred to as a type of Active Packaging.

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 25

 Modified atmosphere can be created passively.
 In passive modification, the respiring product is placed in the storage and
sealed hermetically.
 Only the respiration of the product and the gas permeability of the
space influence the change in gaseous composition of the environment
surrounding the product.

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 26

 If the products respiration characteristics are properly matched to
the space permeability values, then a beneficial modified atmosphere can
be passively created within a space.
 Carbon dioxide absorbents/emitters, ethanol emitters and ethylene
absorbents can be used to control oxygen levels inside the MA pack.

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 27

 The appropriate absorbent materials are placed alongside with the food.
 By their activity, they modify the headspace of the package and thereby
contribute to extend the shelf-life of the contents.
 In case of active modification, two basic techniques are employed to replace
air in MAP i.e. Gas flushing and Compensated Vacuum.

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 28

Machine Systems For MAP

 Gas Flush Technique

 The gas flush technique is normally accomplished on a form fill-seal machine.

 The replacement of air inside a package is performed by a continuous gas stream.
 This gas stream dilutes the air in the atmosphere surrounding the food product.
 The great advantage of the gas flush technique is the speed of the machine.
 Since the action is continuous, the product rate can be very high.

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 29

 Compensated Vacuum

 The compensated vacuum technique removes the air inside by absorbing the vacuum
in the package.
 Then breaking the vacuum with the desired gas mixtures.
 The speed of operation of the equipment is slower than the gas flush technique.
 When considering the Oxygen sensitive food items, compensated vacuum is the best
choice.

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 30

Historical development

 Commercial retailing of fresh meat in MAP tray systems was introduced in

the early 1970s.
 European meat processing and packaging developed during the 1980s
with centralized production of MAP meat in consumer packs for distribution
to retail outlets.
 In the past few years, there has been a considerable increase in the range of
foods packed in modified atmospheres for retail sale including meat, poultry,
fish, bacon, bread, cakes, crisps, cheese and salad vegetables.

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 31

Gases used in MAS

 In MAP, the pack is flushed with a gas or a combination of gases.

 The common gases used are oxygen, nitrogen and carbon dioxide.
 Traces of carbon monoxide, nitrous oxide, ozone, argon, ethanol, vapour
and Sulphur dioxide are also used.
 Only minimum oxygen levels are used to pack food under MA because
oxygen reacts with the foodstuff resulting in the oxidative breakdown of food
into their constitutive parts.
 Oxygen also combines easily with fats and oils causing rancidity.

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 32

 Nitrogen is an inert gas.
 It has no anti-microbial activity and acts as a cushion, thereby preventing
pack collapse.
 Since it displaces oxygen from the pack, oxidative rancidity is delayed.

 Carbon dioxide is responsible for the bacteriostatic and fungi static effect in
MA packaged food.
 It retards the growth of molds and aerobic bacteria.
 The inhibitory effect of carbon dioxide to micro-organisms is increased as
the temperature is lowered because of increased solubility.

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 33

  O₂ absorber:- Iron powder is used commercially as the active ingredient.
Ex. FeO, Fe₂O₃, Fe₃O₄

  CO₂ absorber:- Lime(freshly hydrated high calcium lime

(Ca(OH) ),activated charcoal, ₂ magnesium oxide)

  Ethylene absorber:- Potassium permanganate, builder clay powder,

hydrocarbons, silicones

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 34

TWO TYPES OF MA

Active modification
 The atmosphere is modified by pulling a slight vacuum and replacing the
packaging atmosphere within the desired gas mixture.
 Displace or remove gases in package
 Replace with mix of desired gases and seal
 Better shelf life is achieved with Active Modification

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 35

Passive modification
 Modification is achieved by respiration of commodity within the package and
depends on the characteristics of the commodity and the packaging

 Product packaged with selected film

 Desired atmosphere develops naturally over time
 Takes longer to achieve desired atmosphere in package

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 36

ADVANTAGES & DISADVANTAGES

Advantages
 Fresh appearance.
 Potential shelf-life increase by 40 – 50%.
 Reduced economic losses.
 Product distributed over long distances.
 Increased market area.
 Provides a high quality product.

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 37

Disadvantages
 Visible added cost.
 Temperature control necessary.
 Different gas formulation needed for each product type.
 Special equipment and training required.

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 38

FUTURE CHALLENGES OF MAP

 MAP undoubtedly enhances the shelf life of products without preservatives.

 The success of MAP depends on many factors including
1. Good initial product quality
2. The appropriate gas mixture of the product
3. Reliable packaging equipment
4. Maintenance of controlled temperatures

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 39

 It is important to realize that MAP storage not only improves the quality but
also delays the rate of spoilage.
 This will slowly emerge as the preservation cum packaging technology of
future, propelling the food industry into a new era of food products,
distribution and marketing.

ADBULWAHID, DEPARTMENT OF FOOD TECHNOLOGY, TASC 40