Product spoilage poses a significant economic burden to the global food industry and compromises food security. With exposure to air being a leading cause of product loss and waste, manufacturers and supply chain professionals have turned to reduced oxygen packaging as a preventive measure.

How Oxygen Drives Product Loss

Oxygen increases microbial activity and oxidation, resulting in food degradation and product loss. The science behind this effect reveals that exposure to oxygen facilitates bacterial growth, which speeds up the rate at which produce goes bad.

Although today’s packaging technology can reduce oxygen levels around food and extend its shelf life, exceedingly low oxygen concentrations may introduce other harmful microbes and unusual flavors, especially if the product becomes too warm. Leaving air inside the package is another common problem that decreases its freshness.

Other research shows that 31% of all food production in the U.S. goes to waste at the consumer and post-harvest levels, including meat, poultry and fish. Microbial damage, pest infestations and vector activity are contributing factors to unfavorable conditions, underscoring the need for effective oxygen management to ensure food safety and security.

Technologies Driving Reduced Oxygen Packaging

Technological advancements are enhancing the use of reduced oxygen packaging for food products. Manufacturers and supply chains are implementing these new tools and best practices to improve shelf life and prevent early spoilage.

Modified Atmosphere Packaging

Modified atmosphere packaging (MAP) remains a primary solution for those seeking to preserve food freshness and mitigate revenue loss due to food waste. Manufacturers do this by altering gas composition, usually by replacing oxygen with nitrogen, carbon dioxide (CO2), and other gases, which slows aerobic microbial growth and oxidation.

The type of nitrogen you use is crucial. Food-grade nitrogen must meet a purity standard of 99% or higher to comply with regulations and increase quality control. Overall, the process requires stringent process management and advanced technology, along with product-specific atmospheres, to balance respiration and gas exchange.

Vacuum Packaging and Active Packaging

The food industry has long used vacuum packaging to suck out most of the air surrounding meats and other high-spoilage products. However, this can give the meat a purple appearance, which does not appeal to many customers.

Integrating vacuum packaging with MAP has helped preserve meat’s freshness and natural coloration. It is important to note that even with the combined method, about 0.5% to 5% of oxygen may remain inside the package.

Active packaging takes this approach further by incorporating specialized oxygen absorbers, antioxidants and antimicrobials directly into the packaging system. The results prolong shelf life and enable the product to adapt to environmental changes.

Oxygen Scavengers

Oxygen scavengers provide precise environmental management in food packaging by absorbing remaining air, ensuring safer and fresher distribution. Natural oxygen scavengers, such as sodium erythorbate and alpha-tocopherol, are the most promising options for slowing spoilage and enhancing sustainability.

In one study, sodium erythorbate reduced headspace oxygen to 0% within 10 days in citrus juice packaging. Alpha-tocopherol lowered oxygen from 20.9% to 18% over 60 days. While these approaches show remarkable outcomes, natural scavengers usually need a transition metal catalyst and are more costly.

Packaging's Role in Modern Delivery Process

Aside from controlling atmospheric conditions, packaging protects food products during turbulent delivery. For example, the e-commerce and direct-to-consumer food markets are growing rapidly, expected to reach $1688.9 billion by 2030 at a 17.2% compound annual growth rate. Packaging must be strong enough to handle the demands of the shipping life cycle.

The structural integrity of food packaging materials is particularly critical for the safety of temperature-sensitive goods in the cold chain. Their designs must ensure proper insulation and maintain the right conditions from the warehouse to the consumer’s doorstep.

Packaging is also important at the retail level. Grocers must be able to handle, store and stack goods efficiently, avoiding damage to the product and preventing waste before it ever reaches buyers. For perspective, 72.5% of meat and seafood items are lost to spoilage and packaging damage at the retail level. Poor product casing may also result in returned shipments to manufacturers and food waste sent to landfills.

Quantifying Cost Savings and Shelf Life Improvement

Reduced oxygen packaging, smart monitoring and enhanced logistics have provided robust financial and sustainability opportunities by lowering food waste across the supply chain. Most notably, yearly spoilage-related inventory losses fell from $570 billion in 2020 to $238 billion in 2022. For food manufacturers and retailers, the numbers have translated to significant savings.

Further research indicates that investments in reducing food loss and waste — including reducing oxygen in packaging — can yield $14 in economic returns for every dollar invested, with lower procurement, handling and disposal expenses. The results make reduced oxygen and food waste indispensable methods for gaining profits and improving resilience.

Integrating Oxygen Monitoring for Smart Packaging

Integrating innovative packaging with real-time oxygen monitoring reduces food spoilage and increases product value.

Maintaining CO2 levels at 20% to 30% and balancing nitrogen have been especially critical to preventing bacterial growth in the meat industry, thereby enhancing product safety and appearance. For produce, utilizing low oxygen with higher CO2 slows respiration and extends shelf life without the need for refrigeration.

The most advanced intelligent packaging systems use sensors and indicators that monitor environmental conditions in real time, including temperature, humidity and gases. Some devices detect microbial activity on food and its wrapping. These devices trigger alarms, enabling manufacturers to intervene and address food loss and waste before it occurs.

Barcodes and radio frequency identification technologies further enable transparency and traceability of food throughout every stage of the supply chain — a necessity for perishable goods.

Barriers to Implementation

Reduced oxygen packaging has several proven benefits, but challenges persist for its widespread implementation. Ensuring a positive return on investment remains a concern for manufacturers, as cutting-edge technologies, such as sensors and upgraded machinery, are expensive and require significant capital expenditures.

Meeting compliance standards and incorporating new tools into your existing systems also present obstacles. New technology may have intricate mechanisms that are incompatible with legacy equipment, while you may need to contend with different regional criteria that require strict documentation and reporting.

Likewise, training the workforce on the latest processes and technologies is challenging, but it delivers substantial opportunities for greater efficiency, automation and higher product grade.

Recommendations for Packaging and Supply Chain Leaders

It is best to audit your current oxygen management practices to determine the amount of air remaining in finished products. Evaluate the precision of gas mixtures and recalibrate your sensors and indicators to pinpoint areas for improvement.

Investing in digital sensors and real-time monitoring systems will support excellent financial returns by delivering valuable, real-time insights. However, your team must be up-to-date on this equipment to maximize efficiency and promptly address negative product conditions.

Revisit performance benchmarks and track oxygen control practices to reap the most savings. Refining your food safety strategy is crucial for maintaining your reputation and upholding quality standards.

Preserving Food Safety and Profitability

Maintaining market competitiveness and consumer trust is paramount within the food industry. Adopting reduced oxygen packaging and smart monitoring technologies can help manufacturers meet compliance regulations, ensure food safety and boost profit margins.