Tips for Vacuum Sealing
Vacuum sealing is a technique that not only extends the shelf life of your food but also maintains its quality. By removing air from a package and sealing it to create an airtight environment, this method preserves perishable goods from spoilage. It provides barrier protection against external elements, keeping your food fresh and safe to consume.
Fundamentals of Vacuum Sealing
Vacuum sealing is based on a proven principle: by extracting air from a package, the amount of oxygen, which is a key contributor to product oxidation and microbial degradation, is significantly reduced.
The primary goal is to eliminate oxygen, which supports the growth of aerobic bacteria or fungi and speeds up the oxidation of fats, which can cause rancidity. By creating an airtight environment, vacuum sealing helps preserve product quality, freshness, and longevity.
The basic principle behind vacuum sealing is to create a low-oxygen environment that significantly slows down the deterioration process. This is achieved by extracting air and sealing the package tightly so that no new air can enter. The reduction of oxygen in the packaging also limits the growth of aerobic bacteria and fungi and decreases the oxidation rate.
How Vacuum Sealing Works
The process of vacuum sealing typically involves several key steps:
- Product placement: The product is placed inside a vacuum-compatible bag or container. The bag’s material must be strong enough to withstand punctures yet flexible enough to form a tight seal.
- Air Removal: A vacuum sealer machine extracts the air from the bag or container. This machine can be a simple manual device used in homes or a complex automated system used in commercial settings.
- Sealing the Package: The bag’s opening is sealed using heat once the air is evacuated. This heat melts a section of the bag, creating an impermeable seal that prevents air from re-entering.
- Final Inspection and Storage: The sealed package is then inspected for integrity to ensure there are no leaks, and it’s stored in a way that maximizes the benefits of vacuum sealing, such as in cool, dry places.
Types and Mechanisms
The vacuum sealer’s role is in the effectiveness of vacuum sealing by tightly closing packages from which the air has been evacuated. There are several types of vacuum sealers, each suited to different needs and scales of operation:
- External Vacuum Sealers: These are commonly used in home kitchens and small businesses. They involve placing the open end of the vacuum bag outside the machine. The air is sucked out, and then the bag is sealed.
- Chamber Vacuum Sealers: More sophisticated and suitable for commercial use, these sealers allow the entire bag to be placed inside the chamber. Once the lid is closed, the machine removes the air from the chamber, ensuring a consistent and high-quality vacuum. This type is ideal for liquids or moist items since the atmospheric pressure inside and outside the bag remains equal.
- Nozzle Vacuum Sealers: These are typically used for large-volume packaging in industrial settings. They have a retractable nozzle that provides strong suction and can handle heavier-duty bags.
- Automatic Belt Vacuum Sealers: Designed for high-volume, continuous sealing processes, these machines use conveyors to feed bags through the sealing process, making them ideal for industrial applications where speed and efficiency are crucial.
Sealant Materials: Properties and Suitability
The choice of sealant materials in vacuum sealing is crucial for ensuring the integrity and effectiveness of the sealing process. These materials must possess certain properties to withstand the stresses of vacuum sealing and provide the necessary barrier against air and moisture. Common materials include:
- Polyethylene (PE): It is often used for its flexibility and strength and is suitable for consumer goods and non-aggressive products. It forms the inner layer of many multi-layer films used in vacuum sealing.
- Polypropylene (PP): Known for its excellent chemical resistance and barrier properties, polypropylene is used for products that require higher temperature resistance during sealing.
- Nylon (Polyamide – PA): Nylon is used for its toughness and ability to form a very durable seal. It is ideal for products that require robust mechanical properties and puncture resistance, such as vacuum-packed meats with bone.
- Polyvinylidene Chloride (PVDC): This material offers superior barrier properties against oxygen and moisture, making it suitable for highly perishable goods.
- Ethylene-Vinyl Alcohol (EVOH): Known for its exceptional gas barrier properties, EVOH is typically used in multi-layer barrier films to enhance the shelf-life of oxygen-sensitive products.
In response to increasing environmental concerns, there has been significant development in biodegradable and sustainable materials for vacuum sealing:
- Polylactic Acid (PLA): PLA is a biodegradable polymer derived from renewable resources like corn starch or sugarcane. It is used in vacuum sealing for products that require lower barrier properties and shorter shelf life.
- Polyhydroxyalkanoates (PHA): PHAs are biodegradable polymers produced by microbial fermentation of sugars or lipids. They are suitable for applications requiring better moisture barrier properties.
- Starch-based Blends: These materials are often blended with other biodegradable polymers to improve their mechanical and barrier properties. They are used in more eco-friendly packaging solutions.
- Recycled Materials: Advances in recycling technologies have allowed for the use of recycled plastics in vacuum-sealing films without compromising the quality and safety of the sealed product.
Applications in Various Industries
| Industry | Application of Vacuum Sealing |
|---|---|
| Food Industry | Vacuum sealing is pivotal in the food sector, where it helps in prolonging the shelf life of products like meats, cheeses, vegetables, and prepared foods. By reducing food waste and retaining nutritional value, this method supports sustainable food management practices. |
| Pharmaceuticals | In the pharmaceutical industry, vacuum sealing protects medications and medical devices from contamination and moisture, ensuring their efficacy and longevity. |
| Electronics | Sensitive electronic components are often vacuum-sealed to prevent the accumulation of dust and moisture, which could otherwise lead to corrosion or functional failures. |
| Aerospace and Automotive | Components in these industries are vacuum-sealed to prevent atmospheric degradation and ensure the integrity of critical systems under extreme environmental conditions. |
| Textiles and Artifacts | Vacuum sealing is also applied in the preservation of important textiles and historical artifacts, providing a controlled environment that significantly slows down the degradation process. |
Incorporating Desiccants and Oxygen Absorbers
Combining vacuum sealing with desiccants and oxygen absorbers significantly enhances product longevity and quality. Reducing oxygen and moisture in the package drastically slows oxidation and microbial growth, extending the shelf life of perishable goods far beyond what vacuum sealing alone can achieve.
These methods help maintain food products’ color, texture, and nutritional value. In non-food applications, they prevent the deterioration of chemical compounds and physical degradation due to moisture and oxygen exposure.
By providing an optimal storage environment, this integrated approach reduces spoilage and waste, which is particularly crucial in industries like food, pharmaceuticals, and electronics. To maximize the efficacy of desiccants and oxygen absorbers in vacuum-sealed packages, adhere to the following best practices:
- Calculate the Required Amount: Use formulas or guidelines provided by manufacturers to determine the right amount of desiccants and oxygen absorbers needed based on the package size and the product type.
- Ensure Airflow: Arrange the package contents to allow for adequate airflow around the desiccants and oxygen absorbers. This ensures that all parts of the package environment are adequately treated.
- Seal Integrity: Check the seal after vacuum sealing to ensure no leaks. Even a small leak can negate the effects of desiccants and oxygen absorbers by allowing air and moisture to enter.
- Regular Testing: Periodically test the efficacy of the packaging solution on the stored product, particularly for products with long shelf lives, to ensure that the desiccants and oxygen absorbers perform as expected.
Conclusion
By extending the shelf life of perishable goods such as food products, vacuum sealing technology reduces the amount of food that spoils before it can be consumed. This not only conserves resources but also decreases the volume of waste sent to landfills.
It also helps in efficiently using resources by preserving the quality and usability of products over longer periods, thus reducing the frequency of production cycles for replacements.Advances in vacuum sealing materials, including the development of biodegradable and recycled options, support the move towards more sustainable packaging solutions.
At Stream Peak International, we globally supply oxygen absorbers and desiccants. Our desiccant bag manufacturing plant is ISO 9001 and 14001 certified, ensuring top-quality production standards and environmental management. Additionally, we maintain a dedicated in-house QA lab to uphold the highest quality assurance standards.