Effective packaging is critical for extending the shelf life and quality of packaged products. Among the various packaging methods and techniques available, nitrogen flushing is popular due to its ability to preserve various consumer goods. 

Learn how nitrogen flushing compares to other industrial packaging methods.

What Is Nitrogen Flushing?

Nitrogen flushing is a packaging method that involves displacing the oxygen in a package with nitrogen gas before sealing it. This process creates an inert atmosphere inside the package, which helps prevent oxidation, rancidity and microbial growth.

Nitrogen flushing is used in the food industry to preserve the freshness, flavor and nutritional value of products such as snack foods, nuts, coffee, dairy products, meats and baked goods. The oxygen-free environment created by this method extends the shelf life and quality of food. It is also used in packaging electronics, pharmaceuticals and moisture-sensitive products. 

Nitrogen is non-toxic, non-flammable and does not affect product quality. However, nitrogen flushing requires specialized equipment and a controlled environment, which can increase the cost of packaging in business operations. It may be unsuitable for all product types and less effective for highly porous materials. 

The Role of Nitrogen and Oxygen in Packaging

Nitrogen is an inert gas that makes up about 78% of the Earth’s atmosphere. In product packaging, nitrogen is a neutral filler gas that displaces oxygen, moisture and other gases that degrade product quality. It prevents oxidative reactions that cause discoloration, degradation and oxidation, extending the shelf life and quality of packaged products. 

Oxygen is a highly reactive gas that can cause food spoilage. Oxidation reactions triggered by oxygen can lead to the breakdown of fats, vitamins and other nutrients, resulting in color changes and flavor deterioration. Moreover, oxygen supports the growth of aerobic bacteria, molds and yeasts, which can cause food to spoil rapidly.

Various industrial packaging methods, including vacuum sealing and nitrogen flushing, manipulate the levels of nitrogen, oxygen and other gases to create optimal storage conditions for different products. These methods aim to extend the shelf life of food, preserve nutritional value and maintain the sensory qualities of the packaged food.

Other Industrial Packaging Methods and Techniques

In addition to nitrogen flushing, several other packaging methods extend the shelf life of food and other packaged products. Each consumer goods packaging method has unique advantages, limitations and applications.

Canning

Canning involves sealing products in airtight metal containers and heating them to a specific temperature to destroy microorganisms and enzymes. The process creates a vacuum seal that prevents oxygen from entering the container, extending the product’s shelf life. 

Canning is commonly used for packaging food products such as fruits, vegetables, soups and meats. It is also used to maintain the stability and prevent contamination of industrial products, like paints and chemicals. This method requires high-temperature processing, which can alter the texture, flavor and nutritional value of some products. The canning metal containers can be heavy and unsuitable for all product types.

Vacuum Sealing

Vacuum sealing removes air from a package before sealing it, creating a tight-fitting package that conforms to the product’s shape. This process reduces oxidation and moisture exposure, extending product shelf life. 

Vacuum sealing is commonly used for packaging nuts, coffee, textiles, electronics and industrial components. It is a simple, cost-effective method that helps prevent corrosion, moisture damage and dust contamination. However, vacuum sealing does not provide a complete oxygen barrier. The tight-fitting package can cause compression damage and may not be suitable for delicate or fragile products.

Modified Atmosphere Packaging (MAP)

MAP involves modifying the gas composition inside a package to create an optimal environment for the specific product. The most common gases used in MAP are nitrogen, carbon dioxide and oxygen. The gas mixture is tailored to the product’s storage requirements, helping to extend its shelf life.

MAP is widely used in packaging food, pharmaceuticals, medical devices and electronic components. It helps maintain sterility, prevent oxidation and control moisture levels. However, MAP can be more expensive than other packaging methods and techniques and may not be feasible for all product types.

Active Packaging

Active packaging involves incorporating active components into the packaging material or within the package to enhance product preservation. Active components used include:

Oxygen absorbers
Moisture absorbers
Ethylene absorbers
Antimicrobial agents
Corrosion inhibitors

Besides food packaging, active packaging is used in various industries, including electronics, pharmaceuticals and industrial goods. The active components protect sensitive products from environmental factors that cause degradation, such as oxygen and moisture. However, active packaging components may interact with the product or affect its properties. 

Aseptic Packaging

Aseptic packaging involves sterilizing the product and the packaging material separately and then filling and sealing the package in a sterile environment. This process allows for the packaging of shelf-stable products without preservatives. It’s commonly used in pharmaceutical and medical device industries, where sterility is critical. 

Aseptic packaging ensures products remain free from microbial contamination throughout their shelf life. Maintaining sterility requires specialized equipment and strict process controls, making it expensive.

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Comparing Nitrogen Flushing to Other Packaging Methods

Nitrogen flushing offers several advantages over other preservation methods, making it the preferred choice for many food production companies and manufacturers.

Shelf Life and Quality of Packaged Products

Nitrogen flushing excels at extending product shelf life while maintaining quality. By creating an oxygen-free environment, nitrogen flushing prevents oxidative deterioration and degradation more effectively than methods like vacuum sealing or active packaging. It results in consumer goods packaging that remains stable and functional for longer periods. 

Cost-Effectiveness

While nitrogen flushing requires specialized equipment and nitrogen gas, it can be a cost-effective preservation method in the long run. The extended shelf life of packaged products achieved through nitrogen flushing reduces waste and allows for more efficient inventory management. Additionally, nitrogen is readily available and less expensive than other packaging gases. 

Environmental Impact

Nitrogen flushing has a lower environmental footprint than some other preservation methods. Nitrogen is a natural and non-toxic gas that does not leave residues in the product or the environment. Additionally, nitrogen-flushed packaging often uses recyclable materials, reducing waste compared to single-use packaging. 

Enhance Product Shelf Life and Quality With Nitrogen From Meritus Gas Partners

Nitrogen flushing is an effective packaging method for preserving product quality and enhancing shelf life. It’s a cost-effective, environmentally friendly option for manufacturers across various industries. When implementing nitrogen flushing for packaging, partnering with a reliable nitrogen gas supplier is critical. Through our network of industrial gas distributors, Meritus Gas Partners provides high-quality nitrogen gas for your packaging needs. Whether you require pure nitrogen or custom gas blends for your packaging, we have the expertise and resources to support your operations.

By choosing Meritus Gas Partners, you gain access to a trusted network of local gas suppliers that combine personalized service with the stability and resources of a larger company. Contact us today to find a nitrogen gas supplier near you and elevate your consumer goods packaging with nitrogen flushing.

Volume Calculations

Legend

• SCF (standard cubic foot) gas measured at 1 atmosphere and 70°F.
• Nm³ (normal cubic meter) gas measured at 1 atmosphere and 0°C.
• Liquid measured at 1 atmosphere and boiling temperature.

Founded by Holt Rast in 1976, Rast Construction specializes in heavy and municipal work, including water, sewer, gas pipelines, plant facilities, boring, tunnels, sub-aqueous, grading, steam, chilled water lines and other specialties.

Rast Construction relies on Atlas Welding Supply to provide nitrogen tube trailers for various jobs that require pipe pressure testing. Pipe pressure testing is carried out after the installation of any pipeline before it is put into use.

The purpose of the pressure testing is to investigate the various limits of the pipeline–testing areas such as the reliability, maximum capacity, leaks, joint fittings and pressure. Without this information the pipe can not be put into service and the owner/operators have no confirmation that the pipe meets certain specifications. There are two commonly used methods for pressure testing piping: a hydro-static test or Hydrotest and a pneumatic test.

Hydrotest vs Pneumatic Pressure Testing

A hydrotest, also known as a hydro-static test, is performed by using water as the test medium. A pneumatic test, on the other hand, uses air, nitrogen, or any non-flammable and non-toxic gas as the test medium.

A Nitrogen Tube Trailer Solution for Rast Construction

For Rast Construction, a nitrogen pneumatic pressure test was the most cost-effective and time-saving solution. While water is less an expensive test medium than nitrogen, nitrogen gets the job done significantly quicker, which is a huge benefit to Rast Construction. And because Rast Construction needed a large volume of nitrogen, a nitrogen tube trailer was ideal. A tube trailer delivers the required supply of nitrogen straight to Rast Construction job sites.

“We hook the nitrogen tube trailer up right on our job site,” said John W., part owner of Rast Construction. “And it only takes a few hours, where water would take a week or so to drain and dry out. Huge time savings!” 

At Atlas, our mission is to provide customers with the best equipment and supplies to do their jobs better. We are proud of the solution we provided Rast Construction and the partnership we have formed.

“I can’t compliment Atlas enough,” John said. “They bend over backwards to make sure we have the trailer where we need it and when we need it. They handle all the logistics, so we don’t have to worry about whether or not we have an adequate supply of nitrogen.” 

Thank you, Rast Construction, for trusting us with your gas supply needs!

Request a Solution from Atlas Welding Supply

Founded in 1944, Atlas Welding Supply provides you with the equipment and supplies to do your job better. With decades of experience in gas and welding applications, we are confident we can be your trusted partner for everything from supplying the appropriate gas, troubleshooting equipment, or providing customized solutions for your project for maximum efficiency