Ensuring food safety throughout the supply chain, including during packaging and distribution, is critical. Packaging these foods extends shelf life, protects against contamination, pest attacks, pilferage, rancidity, and various forms of spoilage and taste loss. It also facilitates safer transportation of the food, allowing for critical product information to be communicated on the packaging itself, such as nutritional facts, origin, and safe handling instructions, all of which benefit consumers.

Safety Imperatives

MAP plays a vital role in reducing foodborne illness risks and extending shelf life, making it essential to adhere to food safety regulations and guidelines, including labeling requirements and approved packaging materials. MAP technology can impact the sensory qualities of ready-to-eat foods, such as taste, texture, and appearance. Therefore, precise control of the packaging process is necessary to preserve these qualities and reduce the need for added preservatives.

Leak Testing

Proper leak testing is crucial to prevent unnecessary returns, loss of reputation, legal consequences, and business loss. For quality assurance, users can opt for sample or in-line testing solutions—based on CO₂ or a water bubble test. Reliable package leak detection systems are easy to operate and capable of detecting even the smallest leaks, with tests logged and documented digitally for customer assurance.

System Maintenance

From mixing gasses to introducing them into packaging, utmost care is required. A faulty mixture or leak can compromise product quality, leading to nutrient, taste, color, or structural degradation, and potential contamination by microorganisms. To ensure consumer safety, rigorous testing and maintenance are essential, requiring high-quality equipment and stringent hygiene standards. Inline gas analysis can monitor the modified atmosphere continuously to support this.

Tests

Once packaged, products must be tested for the correct gas composition and leaks. Only through this rigorous approach can the full benefits of MAP be realized, ensuring top-quality products reach consumers. Proper sanitation of MAP equipment is critical to prevent contamination, as improper handling can increase the risk of food waste. Careful consideration of these factors during packaging can mitigate such risks.

Gas Monitoring

Ambient air gas monitoring systems protect employees and ensure safe CO₂ use, which, though non-toxic, can be hazardous in confined spaces. Accumulations of CO₂ can displace oxygen, posing health risks as concentration increases. Monitoring systems with acoustic and visual alarms provide safety by alerting personnel when gas levels exceed safe limits. Controlled atmospheres are also used for ripening control, such as in chambers with ethylene.

Consumer Education

Educating consumers on safe handling and storage of MAP-ready foods is essential. Labels must provide critical information like ingredients, nutrition facts, expiry dates, and allergy warnings, empowering consumers to make informed decisions.

Nichrome MAP Solutions

If you’re seeking a thali packing machine, tray sealing machine, container sealing machine, nitrogen packing machine, or food tray sealing machine with MAP technology—also known as controlled atmosphere packaging—for fresh food, Nichrome is the ideal choice. As leaders in packaging machines, automatic filling machines, and sealing machine manufacturing, Nichrome India delivers comprehensive integrated packaging solutions.

Conclusion

In summary, quality control in MAP for ready-to-eat foods is not just about extending shelf life but ensuring safety, enhancing sensory experience, and upholding consumer trust. From stringent leak testing to system maintenance and consumer education, every aspect of the MAP process contributes to delivering safe, high-quality products, supported by Nichrome’s advanced packaging solutions.

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Ready-to-eat (RTE) foods are those foods that do not need any further processing. These meals are cleaned, cooked and packaged before they reach retail shelves. Some varieties might need to only be heated before they are ready for consumption. 

The shifting lifestyles of consumers are behind the growing demand for RTE foods. The prevalence of families with multiple sources of income and the increase in the number of working women have driven the demand for RTE foods. Since consumers now have less time to cook, they are on the lookout for food products that are functionally expedient and portable, while still being delectably full of flavour. 

Advantages of RTE Foods: 

• Saving Time – Saving the time and energy expended in cooking is the most obvious benefit of RTE foods. This is helpful for many busy people who don’t have the luxury of spending an hour or more on prepping, serving and eating a meal.
• Increased Convenience – RTE foods can be reheated and consumed at any time of the day or night. This is particularly beneficial for those who work late nights or at odd hours.
• Ready Availability – RTE foods can be purchased at any time and are available at many places. There are many brands and recipes to choose from, and they are available at different price points.
• Safety – RTE foods are quite safe and hygienic as they are manufactured and packed in well-protected conditions and processed following the rules and regulations set by the government. 

Nichrome’s RTE Packaging Machines 

Nichrome is a leader in food packaging solutions and offers some exemplary machines for ready to eat food packaging with the latest technology from Europe. 

Pick-Fill-Seal Machine 

The pick-fill-seal machine offered by Nichrome is an RTE packaging machine which utilises highly versatile rotary technology. This machine can conveniently pack a diverse range of ready-to-eat foods in attractive and innovative packaging while preserving the freshness of the products. This instant food packaging machine is robust and compact and easy to clean and maintain. 

This is a highly precise PFS packaging machine and is controlled by a PLC that has the latest-gen synchronised motion Servo system. 

Nichrome has also innovated an advanced variant of this packaging technology that allows for 2 or 3 fillers to dispense different types of ingredients in the same pouch. 

This machine can pack in pouch formats like 3 side seal, 4 side seal, stand up pack, stand up with zipper and Doy pack with spout. 

Essential features of these machines are: 

• Servo-driven precision indexing
• Precision cam-operated mechanism
• Less power consumption
• Operator friendly, easy to clean and Maintain
• Compact and versatile design
• PLC-based machine with touchscreen interface
• No pouch, no fill, no seal interlock
• Pouch open error, no fill interlock
• Heater malfunction error interlock
• Low air pressure alarm
• Machine guards with safety interlock
• Hygienic stainless steel construction available
• Contact parts SS316, SS304 available 

Thermoforming Tray Sealing Machine 

Nichrome also offers the Athena Thermoforming Tray Sealing machine from Tecnovac, Italy. This food tray sealing machine has the capability to seal and pack products in a protective atmosphere also known as Modified Atmosphere Packaging (MAP). It can also pack all kinds of trays and jars with a ‘Skin effect’. This machine from Nichrome is the optimal solution for small and medium-sized enterprises (SMEs) due to its sturdy stainless steel structure and ease of maintenance. 

This horizontal form fill seal machine ensures that products are kept safe and hygienic till they land on the consumers’ table. This functionality of the machine is essential for producers of cut fruits & vegetables, fish & meat, namkeen & sweets and even ready-to-eat meals like biryani. 

MAP packaging machines extract oxygen and carbon dioxide from the air in the trays, replacing them with nitrogen or mixed air to ensure that the food does not deteriorate. The tray is then sealed properly to retain this gas mixture.

 Conclusion 

RTE meals are designed to save time and effort for modern working-class families who may not have the luxury of time to prepare a changing and diverse variety of meals. With most families becoming dual-income families, the demand for RTE foods is on an inexorable rise.

Connect with Nichrome to discuss your RTE packaging requirements. Nichrome has the expertise and experience to provide effective solutions to quickly and efficiently pack savoury meals and ready-to-cook ingredients while ensuring no compromise in taste, hygiene and presentation.

As an established packaging machine manufacturer, Nichrome has a proactive practice of working with customers to understand the challenges and requirements of the product they want to package. Nichrome’s diverse portfolio of integrated packaging solutions includes box packaging machines, carton packaging machines, spice packaging machines, flow wrap machines, tin packaging machines and tin filling machines among many others. Its global presence has been built on the platform of its potent in-house R&D and manufacturing capabilities. For further information about Nichrome’s RTE packaging solutions and other cutting-edge integrated packaging solutions, visit www.nichrome.com.

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The pandemic has only added to the situation, causing the market to boom further.

Today, supermarkets and restaurants too are opting for packaged staples, pre-packaged salads and cut vegetables, etc. Many food sellers are shifting to selling pre-made meals that are then frozen or packaged in film-covered trays.

HOW TO CHOOSE THE RIGHT FOOD PACKAGING MACHINE

Needless to say, you must go for the food packaging machine that suits your business requirement the best, there are some basic criteria to consider.

Size and weight of the machine:

The space you have for the machine and its operators plays an important role when selecting your food packaging machine. Size and weight of the machine should suit your facility.

Ease of operation:

Keep in mind the skills and aptitude of your staff who are going to operate the machine. Go for a food packaging machine that your operators can handle easily, or can be easily trained to operate.

Cost of running & maintenance:

Find out the average cost of running the machine you propose to purchase. Regular use means it will require regular maintenance, so ask about annual maintenance contracts. Sometimes, parts may need to be repaired or replaced. Be aware of such expenditures when calculating investment cost and ROI.

Flexibility for growth/diverse products:

While you will be buying the automated packaging machine for a specific product, choose a machine that has the flexibility and versatility to package other products too. With minimum adjustments and easy changeover. After all, you may expand your product range in the near future, and your current packing machine should be capable of handling it. Most Vertical Form Fill Seal Machines work flawlessly with various packaging products no matter what the size, shape or content you put in the bags.

Reliability of the manufacturer:

Be aware of the manufacturer’s track record. You might even contact other customers to find out their experience, and get first-hand information regarding services and support.

LEADING FOOD PACKAGING SOLUTIONS INDIA

In India, Nichrome is a pioneer and leader in food packaging solutions. For over four decades, Nichrome has designed and developed food packaging machines, filling systems and integrated packaging solutions for packaging edible grains, pulses, powders, liquids, viscous and ready-to-eat foods.

As top packaging machine manufacturer, Nichrome offers a range of machines and technologies for practically every possible food application.

Main technologies offered by Nichrome:

• VFFS – high-speed, accurate vertical packaging machines for the widest range of liquids, solids, powders & viscous
• HFFS – linear technology offering outstanding versatility for different products and diverse pouch formats
• VFFS Multilane–sachet filling machines, generally used for smaller pouch sizes and sachet packaging, popular in the hospitality & travel industries
• PFS (Pick-Fill-Seal) – Rotary technology, preferred for packing ready-to-eat foods in innovative pouch formats
• Preformed Tray Sealing – Italian technology for packing ready-to-eat and ready-to-cook foods in protective modified atmosphere (MAP)
• Tin Filling – PLC-controlled line for packing powders, sugar, rice, dry fruits, candies, pan masala, etc. in a variety of tin sizes

Main food applications served by Nichrome:

• Milk and liquids – Nichrome’s Filpack Servo 12K is India’s fastest milk/liquid packaging machine
• Oil and viscous – Nichrome’s Filpack Servo SMD offers innovative, high-speed packing in 3-side seal pillow pouches
• Sugar – Nichrome offers multiple machines to pack sugar in quantities up to 10 Kgs
• Salt – Machines with anti-corrosive construction and minimum moving parts designed specifically for salt packaging
• Snacks – A range of machines for different snacks. Wing 200 E-line is designed especially for start-ups & SMEs
• Powders – Nichrome’s Maxima 400 is the fastest powder packaging machine for ground spices, soup mixes, pre-mix powders, dairy whitener, etc.
• Grains and pulses – Nichrome’s Excel Plus series has a solution for practically every food grain and pulse
• Tea & coffee – From small sachets to bulk packs, Nichrome’s range of tea packaging and coffee packaging machines can handle it all
• RTE/RTC – Nichrome’s PFS, with special RTE fillers and rotary filling & sealing technology, is the ideal RTE packaging machine for ready-to-eat and ready-to-cook foods

CONCLUSION

Whether you are a large MNC with a range of food products or a snack producing startup; a dairy looking to package the raw milk collected or a hotel introducing ready meals; a supermarket selling cut vegetables & fruits or an edible oil factory – trust Nichrome to provide the most efficient and cost-effective packaging solutions India. Highly reputed amongst automatic filling machine manufacturers, Nichrome assures innovative designs and customisation, high quality manufacturing, reliable spares & service support, and dedicated partnering from concept to commissioning.

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