MAP Trays (which stands for Modified Atmosphere Packaging) has long been a cornerstone in the food industry, for meat, fish products and ready-meals, due to its ability to extend shelf-life and maintain product freshness. Traditionally, MAP trays have been constructed from plastics such as PET and PP. However, the environmental impact of plastic waste has driven the industry towards more sustainable alternatives, leading to the development of fibre-based MAP trays.
Understanding MAP trays, its technology and its mechanism
Modified Atmosphere Packaging (MAP) is a preservation technique that adjusts the atmospheric composition inside a package to extend its shelf-life and maintain the quality of perishable products like meat. With MAP, food is packaged under a protective atmosphere which slows down the chemical reactions that cause product deterioration. MAP is an established technology proven to significantly slow the process of decay and extend the shelf-life of packaged foods, naturally and without preservatives. By precisely controlling the levels of gases such as oxygen, carbon dioxide, and nitrogen, MAP slows down microbial growth and oxidation, preserving colour, texture, flavour, and nutritional value.
Key components of MAP packaging include:
- Barrier Properties: The packaging must be impermeable to gases and moisture to maintain the modified atmosphere.
- Sealing Technology: A secure seal ensures that the desired atmosphere is preserved without leaks.
- Gas Permeability Management: The packaging material must balance breathability with protection, especially for fresh produce.
Challenges of Creating Fibre-Based MAP-Compatible Trays
Unlike traditional plastic trays, fibre-based materials like moulded pulp or paper inherently lack the gas and moisture barrier properties required for MAP. Overcoming this involves advanced technological innovation:
- Barrier Coatings: Special food-safe coatings or laminates are applied to fibre trays to achieve impermeability to gases and moisture. These coatings must be biodegradable or recyclable to maintain the environmental benefits of fibre.
- Material Engineering: The base fibre structure must be designed to withstand the rigors of manufacturing, transport, and handling without compromising on gas barrier properties or structural integrity.
- Sealing Technology: Fibre trays must be compatible with existing sealing machines. Achieving reliable sealing is more complex with fibre trays. The laminates developed by ThermoFibre have been specially designed to adhere to conventional lidding film. It is critical that laminate does not detach when peeling the lidding film off. ThermoFibre has a patented technique to ensure the laminate is securely adhered to the tray when peeling the lidding film off.
- Durability Under Pressure: Fibre trays must be sturdy enough to hold food products, tolerate moisture from fresh meat, maintain their structural integrity under modified atmospheric conditions and the rigours of the supply chain.
- Recyclability Integration: While achieving MAP compatibility, the tray materials and coatings must remain recyclable, avoiding contamination of recycling streams.
Striking the right balance among these challenges is essential to producing efficient fibre-based MAP trays. At ThermoFibre, our team of experts brings over 30 years of experience in fiber innovation, rigorously testing and refining tray compounds to develop durable, fibre-based, MAP-compatible solutions that perform reliably across all environments.
Environmental Benefits of Fibre-Based MAP Trays
Transitioning to fibre trays for MAP offers profound environmental advantages, addressing some of the biggest challenges in modern packaging:
- Reduction in Plastic Waste
Traditional MAP trays are predominantly made from non-renewable, non-biodegradable plastics, which contribute significantly to environmental pollution. Fibre-based MAP trays can replace a very large portion of plastic content, offering a sustainable alternative. - Renewable Resources
Fibre trays are typically derived from renewable plant-based materials like sugarcane bagasse, wood pulp, or paper. This reduces dependency on fossil fuels and supports circular economy principles. - Recyclability and Compostability
Unlike conventional plastic trays, fibre-based trays can be recycled in paper waste streams. ThermoFibre has patented the Eco-Peel technology for removing the laminate after use, allowing the fibre tray to then be compostable. This reduces landfill burden and encourages better waste management practices. - Lower Carbon Footprint
The production of fibre materials typically requires less energy and generates lower greenhouse gas emissions compared to plastic manufacturing. Furthermore, lightweight fibre trays can reduce transportation emissions. - Consumer Appeal and Regulatory Compliance
With increasing consumer awareness and government regulations aimed at reducing plastic waste, fibre-based MAP trays align perfectly with the demand for eco-friendly packaging. They help brands build trust while adhering to strict environmental policies. - Advancing the Circular Economy
Fibre-based MAP trays contribute to a circular economy by utilising renewable materials and enabling recyclability at the end of their life. This closes the loop on material usage, reducing dependency on resources and minimizing waste throughout the supply chain.
Industry Significance
The development of MAP-compatible fibre trays is a testament to the food packaging industry’s commitment to innovation and sustainability. While plastic trays have been the norm due to their barrier properties and durability, the introduction of fibre-based alternatives demonstrates that eco-friendly solutions can meet stringent performance standards.
Originally introduced in 2018 at the All4Pack show in Paris, ThermoFibre demonstrated that such innovations were achievable and implementable at scale. By leading the charge in sustainable MAP packaging, ThermoFibre opened the door to an industry-wide technology that is now becoming the norm to provide solutions that benefit both the planet and the food industry.
This move not only reduces plastic waste but also inspires further innovation across the packaging sector, ensuring that sustainability becomes an industry-wide standard.
Conclusion
The progression and recent endorsement of fibre-based MAP trays marks a pivotal movement in the food packaging industry, driven by environmental considerations and consumer preferences. Long may this continue.
