Food-grade nitrogen generator: A cost-effective way to extend the shelf life of food

Food providers are always looking for ways to extend shelf life. Enhanced shelf life allows manufacturers to extend their geographic reach and also for the product to remain on shop shelves and in consumers' homes for longer. Modified Atmosphere Packaging (MAP) is a commonly used technique in the food processing industry for extending shelf life using a food-grade nitrogen generator.

The MAP process involves displacing the air within a package with a protective gas to keep oxygen at controlled levels (less than 2 per cent). Too much oxygen and moisture in a package often leads to bacterial growth and oxidation, resulting in spoilage, inconsistent flavours, poor product quality, and a shorter shelf life. Nitrogen is frequently used as a protective gas due to its inert and dry qualities.

Nitrogen sources

In terms of nutrition, nitrogen can be obtained from external suppliers in the form of high-pressure tanks, dewars, or bulk liquid supply. On-site nitrogen generation It can also be possible using standard compressed air with an internal food-grade nitrogen generator. An internal generator separates nitrogen and oxygen from the air and can often be the most efficient and cost-effective method of supplying nitrogen for MAP applications.

Disadvantages of a supplier with a food-grade nitrogen generator

Reliance on external suppliers can present several challenges, including uncontrollable price increases, contract negotiations, tank hire fees, compliance with international requirements, hazardous material fees, delivery surcharges, and local and state taxes. Issues such as scheduling conflicts, delivery delays, and lengthy procurement processes can slow down operations.

This all adds up to additional administrative work and increased operational costs. The delivery approach also does not align with the trend towards lean production techniques and the development of fewer, more efficient supply chains.

Precautions must also be taken when handling and storing high-pressure cylinders. A dangerous situation can arise if a cylinder falls and a valve breaks, which could cause the cylinder to become a projectile.

Easy to operate

A food-grade nitrogen generator, for example, produces a continuous supply of high-purity nitrogen within minutes of start-up. The installation involves simply connecting the inlet port of the unit to a standard compressed air line and connecting the outlet to your nitrogen line.

Improve quality, maintain, and reduce costs

The quality of the final product is the most important aspect in food manufacturing, as well as, for example, carrying out Compressed air systems maintenance service for food businesses. Customers expect consistent freshness and flavour every time they open a new food package. Bacterial growth in the final package reduces shelf life and ultimately leads to an unhappy customer. Dry nitrogen packaging will solve these issues and provide a better customer experience. Furthermore, using an on-site nitrogen gas generator not only improves operational efficiency but also reduces overhead costs, a rare combination.

Summary of benefits of having a food-grade nitrogen generator

The generation of food-grade nitrogen or even the promotion of On-site nitrogen generation offers certain features and benefits which we see below:

• Having a food-grade nitrogen generator or your own nitrogen supply eliminates the challenges associated with external suppliers.
• On-site nitrogen generation is also good for the environment and represents a sustainable approach to gas supply. Producing nitrogen off-site in fractional distillation plants and transporting it to end-users is energy-intensive and can generate large amounts of CO2 emissions.
• The price of our nitrogen is constant. Supplier nitrogen is subject to price increases, rental contracts, hazardous materials fees, shipping surcharges, local and state taxes, etc. A food-grade nitrogen generator offers long-term price stability.
• Its cost increases in relation to the use of bulk, dewar, or cylinder nitrogen.
• Costs decrease with increasing usage for a nitrogen generator.
• Nitrogen has a very low boiling point, and it continuously evaporates when supplied as bulk liquid or in dewars. That can be very costly if these gases are not recaptured.
• A nitrogen generator removes the required contracts from bulk gas suppliers. No more automatic renewals, automatic increases, or written 1-year contract termination notices.
• Ease of installation. Introduce compressed air and purge nitrogen. Compare this to the installation requirements of a bulk tank, which include a concrete pad, fencing and significant square footage.
• Full commissioning and factory testing procedure prior to delivery.
• Very little maintenance or supervision required once the system is operational.
• Improve the quality of food by removing oxygen, moisture, and all other contaminants from within packaging.
• Extend the shelf life of the product and ensure the quality and integrity of the original product.

Some companies in the industry use their own food-grade nitrogen generator during the packaging process to provide a sterile and controlled environment for their product. At the time of packaging, this way the highest possible quality, flavour and freshness is offered. For example, in coffee production, using a food-grade nitrogen generator for packaging operations is key. Each coffee package is flushed with nitrogen to ensure product integrity and maximise shelf life. The food-grade nitrogen generator complies with all the purity and variable flow controls that are needed in that coffee manufacturing industry, and this way the desired uptime performance is reached, ensuring that in the end customers are happy.

Adding value and extending the shelf life of products in the food sector is possible thanks to a food-grade nitrogen generator. We invite you to subscribe to our Newsletter, and discover the best recommendations and practices for generating greater profitability in your industry, especially if it is food-related.