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Maker - Product Challenge

Products

Technologies

About us

Changemakers

Technology Supplier Masterpack Group

Masterpack Group is a premier industrial packaging company specializing in Modified Atmosphere Packaging (MAP) and Flexible Intermediate Bulk Containers (FIBC) technology. With headquarters and an R&amp;D center in the Netherlands, and a Sales Office in the United States, Masterpack operates globally through five production sites, delivering custom solutions to meet diverse customer needs. Their innovative technologies enhance product protection, extend shelf life, and improve overall product quality.

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The sensors and monitoring systems from daughter company Somsix allow for precise monitoring of oxygen, temperature, and humidity levels in every bag, ensuring optimal conditions and minimizing waste. The Masterpack production facilities are fully certified and integrate cleanroom production technology, ensuring high-quality, contamination-free packaging. Masterpack’s commitment to sustainable development includes initiatives like the Social Accountability Management System (SA8000) in Bangladesh, promoting education and better opportunities for employees and their families.

About Masterpack & Somsix

When storing your nuts, seeds, and milk powders in bulk, the big bag sizes usually range from 250 kg to over 2,000 kg. <a href="https://www.masterpackgroup.com/">Masterpack</a> has now come up with a smaller alternative. We spoke to Jos Smeitink, Director of Business Development, who introduced the compact modified atmosphere packaging (MAP).
<h2>The long-awaited compact MAP has a major impact on storing organic products</h2>
Jos explains that more and more people are opting for organically grown food, and MAP plays a pivotal role in storing these products.

“These companies cannot use any pesticides and they are plagued with insects that are eating away at the packed or the organic food products. The MA process of Masterpack Group will store food products under low oxygen, because of the low oxygen all insects in the FIBC will die,” says Jos.

However, the applications of compact MAP don’t stop here. Jos states that there is no specific industry or customer segment for the compact MAP and everyone looking to store their products in a modified atmosphere can use these bags.

“In general you could say that shelf-life, depending on your product, will be extended for six months to 12 months at least,” explains Jos.

Although for some products the shelf life can be even longer. For seeds, it can be even way over two years.
<h2>Super-fast processing of 25 kg bags with the easy cap</h2>
Masterpack’s innovations extend even further, as they have developed the easy cap, that you can apply to your compact bags.

“It’s much faster in handling, connecting the MA machine to the bag, and closing the valve. It’s called easy cap but it is actually a valve,” clarifies Jos.

Using it is as easy as it sounds: put it on the bag, and switch on the MA machine, when the process is done you can close the cap with its connector and then remove it. So there is no need to screw the cap onto the machine and then unscrew it later on.

So everything sounds compact and easy, right? We know that there is more to come from Masterpack and we’re staying tuned to see how they continue to innovate the packaging industry!

An organic way of killing insects! MA concept, now available for 25 kg bags

While Modified Atmosphere Packaging (MAP) has long been synonymous with big bags and bulk storage, Masterpack is rewriting the rules, introducing a game-changing solution for smaller-scale packaging.
<h2>Store smaller quantities with the same quality</h2>
Picture this: delicate goods, once resigned to the constraints of bulk storage, now finding refuge in packages weighing a mere 10 to 35 kilograms. Thanks to <a href="https://blog.masterpackgroup.com/biofach-2024-compact-map-machine?hs_preview=KlMYPjuP-155211777607">Masterpack's innovation</a>, the benefits of MAP are now accessible to a whole new realm of products. With the technology, Oxygen content can be reduced to below 2% which results in a significantly extended shelf life for the packaged product. Without the need for chemical treatment, MAP is perfect for storing organic food.

And it's not just about the product; it's about the process. With Masterpack's easy cap technology, sealing and monitoring oxygen levels have been made even easier. The Compact MAP machine is purpose-built for handling these smaller packages with precision and efficiency.

From big bags to compact bags: use MAP in both

<span data-contrast="auto">When we think of pistachios, our minds travel to Italy: gelato al pistachio, crema di pistachio, pesto al pistachio, the list goes on. </span><span data-ccp-props="{&quot;201341983&quot;:0,&quot;335559739&quot;:160,&quot;335559740&quot;:259}"> </span>

<span data-contrast="auto">But before these mouthwatering dishes can be made, you must harvest and transport the nuts. Alas, you are faced with many challenges, starting with another pistachio lover and the harvesters' worst enemy: the navel orangeworm.</span><span data-ccp-props="{&quot;201341983&quot;:0,&quot;335559739&quot;:160,&quot;335559740&quot;:259}"> </span>

<span data-contrast="auto">The little menace disrupts the harmony of your pistachio storage, wreaking havoc by feeding on pistachio kernels, driving up the processing costs, and contaminating the nuts with Aspergillus spp., a fungus that facilitates the poisonous aflatoxin. </span><span data-ccp-props="{&quot;201341983&quot;:0,&quot;335559739&quot;:160,&quot;335559740&quot;:259}"> </span>


<h2>Modified atmosphere conquers the worm attack <span data-ccp-props="{&quot;201341983&quot;:0,&quot;335559739&quot;:160,&quot;335559740&quot;:259}"> </span></h2>
<span data-contrast="auto">You can protect your nuts from worms by having good orchard practice. Here the modified atmosphere (MA) technology from Masterpack steps in, to give you a hand in the battle with the pests. You can apply it in hermetically sealed big bags, making it a biobased substitute that eliminates insects. In addition, it reduces mold formation, respiration, and auto-oxidation which can cause fat degradation and rancidity.</span><span data-ccp-props="{&quot;201341983&quot;:0,&quot;335559739&quot;:160,&quot;335559740&quot;:259}"> </span>

<span data-contrast="auto">Using Masterpack’s technology you can modify the levels of Oxygen, Nitrogen, and Carbon Dioxide inside the storage bags. You should store pistachios under low Oxygen (~1%), which will reduce respiration, in the short-term inactivating and eventually killing all stages of insects. In addition, it will obstruct the formation of molds by preventing the sporulation of fungal spores and reducing toxic compounds such as mycotoxin. Moreover, it halts the formation of mycelium, a part of the moldy fungus. MA also comes in handy avoiding the auto-oxidation of the fats inside the nuts, ensuring a better taste, smell, and color of your pistachios. </span><span data-ccp-props="{&quot;201341983&quot;:0,&quot;335559739&quot;:160,&quot;335559740&quot;:259}"> </span>

<span data-contrast="auto">If the Oxygen level is not low enough to control both insects and/or molds, Masterpack’s equipment allows you to lower the Oxygen levels to 0.5% or increase the CO2 levels in the gas mixture to 10-30%. That is toxic for both molds and insects but is still considered a biological treatment. MA is, therefore, ecologically friendly with the potential to prolong the shelf-life of your pistachios significantly, and most importantly get rid of the infestations of gritty worms. </span><span data-ccp-props="{&quot;201341983&quot;:0,&quot;335559739&quot;:160,&quot;335559740&quot;:259}"> </span>

Outsmarting the pistachio-greedy worm while storing your nuts

Like superheroes, we all have our own personal kryptonite to face... but unfortunately, the dairy powder is burdened with more than just one adversary.

Temperature, humidity, light exposure, and oxygen are the four factors that can impact the quality of milk powder during storage and transportation, compromising its nutritional value, color, and flavor.

Big bags, also known as Flexible Intermediate Bulk Containers (FIBCs), can take on the challenge of adequately storing milk powder while maintaining its freshness and shelf life.


<h2>Safety First: The stringent regulation of milk powder in infant formula</h2>
We spoke with Tim De Winter, Managing Director of <a href="https://www.masterpackgroup.com/" target="_blank" rel="noopener">Masterpack</a>, a Dutch company specializing in creating FIBCs in combination with Modified Atmosphere.

“<em>The implementation of BRC certifications and adherence to ISO 10,000 clean room standards is essential to minimize the risk of contamination and guarantee the safety and quality of milk powder throughout its journey</em>,” says Tim.

FIBCs come with a liner that protects milk powder from any type of contamination. The fabrics and materials used for the liner undergo migration tests to prevent harmful substances from entering the powder during transportation.

“<em>Our FIBCs are tested worldwide, including the EU, US, Japanese, and Chinese markets. By meeting the standards of these four major markets, we cover about 99% of the required tests. This means we can deliver to the rest of the world, including South America and Russia, where most tests are already covered</em>,” explains Tim.
<h2>Ensure the shelf life during long-distance travel</h2>
Milk powder is hygroscopic, meaning it readily absorbs moisture from its surroundings and is sensitive to temperature and oxygen.

“<em>Modified atmosphere big bags prevent powder degradation during long-distance transport. To preserve quality and prevent clumping, humidity must stay below 65%, while oxygen levels must be kept under 4% to maintain taste, flavor, texture, and prevent discoloration</em>” continues Tim.

FIBCs are equipped with a UV stabilizer that prevents the bag from breaking down when exposed to light.

“<em>Destination country determines the liner color – black or blue -  based on the country's sunlight exposure. It’s different if you ship your bag to the Middle East or the Netherlands</em>,” claims Tim.
<h2>Reducing food waste in transport by 50% with recyclable bags and oxygen monitoring</h2>
Masterpack leads the fight against food waste. With non-invasive sensor technology on the big bag, Masterpack monitors oxygen levels during transportation by protecting and preserving milk powder. This could reduce food waste by more than 50% in the supply chain, as 30-40% of all food generally goes to waste.

Big bags are also made of 100% recyclable polypropylene. The challenge, though, lies in the liner's recycling difficulty due to PA and EVOH layers.

“W<em>e are actively working on developing a greener liner. The concept involves removing the PA layer and utilizing PE while retaining the EVOH layer, which constitutes less than 5% of the material</em>,” concludes Tim.

This approach leads to the creation of a sustainable film. Be prepared because the market launch of sustainable film is just around the corner!

Preserve your milk powder during transportation. Big Bags: “Challenge accepted!”

What do Turkey, Italy, Oregon, Azerbaijan, Chile, and Georgia have in common?

Surely they are all on someone's must-see list -<em>definitely on ours</em>- but some have been lucky enough to visit all these beautiful countries. More than someone, we should say something.

We are talking about the sweet fruits of the hazel tree: hazelnuts.



Hazelnuts are great travelers; just think they travel many miles every day before reaching their destination market. For instance, 3,453.8 is the number of kilometers they have to cover to get from Turkey to the shelves of Dutch supermarkets.

The main problem with hazelnuts, and fresh products in general, is the long-term storage; one may wonder how they are still fresh and possess all the organoleptic qualities after such a long journey.

It’s not as simple as it sounds; generally, it has been estimated that up to 30-40% of fresh food may be wasted along the supply chains due to storage conditions.
<h2>What causes rancidity in hazelnuts when stored for a long time?</h2>
Having a high oil content - about 65% of its kernel weight – and being rich in unsaturated fatty acids, hazelnuts are highly sensitive to rancidity. Rancidity occurs when the fats inside the nuts, especially the unsaturated fats, get oxidized. This means that the hazelnuts were stored for a long time in the presence of air.

Rancidity is also stimulated by the product’s humidity, which causes the deterioration of the oils in the hazelnut (oleic and linoleic acids), thus producing fatty acids that lead to increased auto-oxidation of the product.

Not only does this lead to food waste and subsequent loss of business money for the companies involved, but rancid hazelnuts can have harmful impacts on your body.

But how can we ensure that hazelnuts do not go rancid when stored for so long?
<h2>Store your hazelnuts under Modified Atmosphere to fight rancidity</h2>
We raised the topic with Tim De Winter, Managing Director of Masterpack, a Dutch company specializing in creating Modified Atmosphere packaging. With its sustainable technology, the company won Packaging Innovation Contest De Gouden Noot (The Golden Walnut) in October 2022.

“<em>Hazelnuts stored at low oxygen concentrations (under 1-2% O<sub>2</sub>) are much less affected by rancidity because low oxygen avoids autooxidation of the fats in the kernel</em>,” Tim explains.

“<em>Using Masterpack Modified Atmosphere technology, manufacturers can reduce and control the oxygen levels within the packaging to create the right environment for an extended product shelf life</em>.” Tim continues.

You can also monitor the oxygen level during the whole transport without damaging the packaging film, thanks to their non-invasive sensor technology. Because the packaging is left intact, your hazelnuts are prevented from being exposed to air while avoiding contamination risk.

By preserving the product and extending the shelf life, the Modified Atmosphere technology help to reduce food waste in the supply chain.

Say no to food waste. How to protect your hazelnuts from going rancid along the supply chain

<span data-contrast="auto">The plant-based food market is forever grateful to cashews, from which many cheeses, dressings, yogurts, and ice creams are produced offering an alternative to dairy products.</span><span data-ccp-props="{&quot;201341983&quot;:0,&quot;335559739&quot;:160,&quot;335559740&quot;:259}"> </span>

<span data-contrast="auto">However, storing and transporting them can prove to be a rather ungrateful task because you have to consider the biological activity and respiration of the nuts, which can lead to quicker deterioration, a decrease in freshness, and shorter storage life. In addition, you must consider their ability to absorb odors from other commodities stored nearby.</span><span data-ccp-props="{&quot;201341983&quot;:0,&quot;335559739&quot;:160,&quot;335559740&quot;:259}"> </span>


<h2><span class="TextRun SCXW81741357 BCX9" lang="EN-US" xml:lang="EN-US" data-contrast="auto"><span class="NormalTextRun SCXW81741357 BCX9">Halt the</span><span class="NormalTextRun SCXW81741357 BCX9"> processes with MAP</span></span><span class="EOP SCXW81741357 BCX9" data-ccp-props="{&quot;201341983&quot;:0,&quot;335559739&quot;:160,&quot;335559740&quot;:259}"> </span></h2>
<span data-contrast="auto">Masterpack thankfully has sought to resolve these issues with modified atmosphere packaging (MAP), which allows you to control the levels of Oxygen, Nitrogen, and Carbon Dioxide inside big bags. By reducing the Oxygen levels to 1-2% you can put a stop to the metabolic processes of your cashews that occur after harvesting. </span><span data-ccp-props="{&quot;201341983&quot;:0,&quot;335559739&quot;:160,&quot;335559740&quot;:259}"> </span>

<span data-contrast="auto">You have to keep in mind that for storing the kernels for a long time, a water content of 4.5-6% is recommended to reduce the biological activity of the cashew nut. Therefore, the cashews should be properly dried before storing them. You should also keep the relative humidity inside the bags around 55-65% because excessive dryness may lead to breakage of the nuts. On the other hand, humidity values higher than 70% allow the development of bacteria, mold, or the production of poisonous aflatoxin. </span><span data-ccp-props="{&quot;201341983&quot;:0,&quot;335559739&quot;:160,&quot;335559740&quot;:259}"> </span>

<span data-contrast="auto">Luckily, with the technology from Masterpack, you can control the relative humidity and create a perfect environment for the nuts, guaranteeing your cashews a longer shelf-life. By being airtight, MAP also safeguards your cashews from various odors, ensuring a fresh taste and smell to your product.</span><span data-ccp-props="{&quot;201341983&quot;:0,&quot;335559739&quot;:160,&quot;335559740&quot;:259}"> </span>

<span data-contrast="auto">In addition, using MAP for storing and transporting your nuts prevents mold, kills insects, and reduces auto-oxidation. Therefore, the overall quality of your nuts is protected from pests, fungi, and rancidity.</span><span data-ccp-props="{&quot;201341983&quot;:0,&quot;335559739&quot;:160,&quot;335559740&quot;:259}"> </span>

Taming the respiration and biological activity of cashews

<div class="RichText3-paragraph--withVSpacingNormal RichText3-paragraph Typography Typography--m">So much food loss occurs during processing that the phenomenon merited its own UN SDG (12.3.1a).</div>
<div class="RichText3-paragraph--withVSpacingNormal RichText3-paragraph Typography Typography--m"></div>
<div class="RichText3-paragraph--withVSpacingNormal RichText3-paragraph Typography Typography--m">Flexible Intermediate Bulk Containers have made transport storage and distribution much more secure. But they are not the final answer to food waste. Humidity, heat, and other atmospheric factors directly impact, and producers must keep an eye on them to prevent loss.</div>
<div class="RichText3-paragraph--withVSpacingNormal RichText3-paragraph Typography Typography--m"></div>
<div class="RichText3-paragraph--withVSpacingNormal RichText3-paragraph Typography Typography--m"><a class="PrimaryLink BaseLink" href="https://www.somsix.com/" target="_blank" rel="noreferrer noopener">Somsix</a> devised a system to do just that. An award-winning system, actually.</div>
<div class="RichText3-paragraph--withVSpacingNormal RichText3-paragraph Typography Typography--m"></div>
<div class="RichText3-paragraph--withVSpacingNormal RichText3-paragraph Typography Typography--m">The patented valve technology is fitted with intelligent sensors that monitor temperature, oxygen level, moisture, and a host of other elements in real-time.</div>

#Changemaker: FIBC with brains

Masterpack Group Expertise 

get in touch

Masterpack Group’s technical experts are ready to assist with your packaging needs. With global offices in Asia, Europe, and the Americas, they provide tailored solutions and ongoing support to optimize your supply chain. Whether you require innovative MAP solutions or specialized FIBC materials, Masterpack’s dedicated team ensures you receive the best possible packaging to protect and preserve your products. Contact their experts today to discover how Masterpack can enhance your business operations.

Connect with the experts at Masterpack

Manufacturers requiring big bag packaging have specific sizes, shapes, and material requirements to ensure their products can be handled safely during transportation and storage. However, the FIBC manufacturing process is only sometimes considered sustainable since these big bags are made of polyethylene, which is difficult to recycle. An ideal solution would be working on preventing waste by producing custom-made big bags of the exact right sizes and shapes required by the manufacturer to save on excess offcuts and material costs and minimize production waste.
<h2>Preventing 10-20% of waste by producing big bags in custom shapes, sizes, and material</h2>
Masterpack Group, a leading expert in innovative packaging solutions for bulk materials, designed custom big bag containers used as packaging that provide increased protection, prolong product shelf life, and optimize storage space. FIBCs are available in different shapes, such as circular or U-shape. They can be equipped with specific liner materials like conductive, aluminum, anti-static, dissipative, metalized OPP, or whichever is best for your product. Liners also help protect products from oxygen, moisture, and other possible contaminants while providing safe filling and discharge. The FIBCs are hygienic, and the PE films used as liners are designed and fabricated according to the correct size, not cut to shape from a big tubular PE film. This method minimizes waste in the production of each liner.

Modified Atmosphere Big Bags

When sealing large bags containing bulk products, a sealer must be reliable to keep the MAP safe in order to avoid products going to waste due to subpar sealing quality. Manual operation for sealing is still very common in the industry, but it is prone to error and inconsistent output. Automating the sealing process can minimize operator error and produce consistently secured sealing.


<h2>Automated complete sealing by single-button operation</h2>
The Automatic Spout Sealer, from Somsix, is a sealing system for large bags used in industrial applications. The system features automated, user-friendly controls where the sealing settings can be preset for a consistent output in every cycle. This method significantly reduces operator error over manual hand-operated sealers. The operator simply positions the spout in the seal mouth and presses one button to execute the sealing process, including the cooling necessary after heating for a complete and secured seal.

Automatic FIBC Sealing machine

Every year, more than 200 million FIBCs are filled with food for storage and transport. Products must be kept in the ideal conditions to maintain their quality from production up to packaging, storage, and delivery. By controlling oxygen levels during packaging and continuously monitoring the conditions in each package, food manufacturers can benefit from less waste within their supply chain, where up to 40% of the food waste occurs.


<h2>Remote monitoring of conditions inside each modified atmosphere bag to prevent waste</h2>
The Modified Atmosphere Sensor, from Somsix, is a monitoring device for oxygen levels and other conditions inside bulk packages. The device is available in 3 monitoring categories. The first category is called modified atmosphere (MA) sensors for FIBCs. It features remote monitoring of oxygen, temperature, and humidity wherever the FIBCs are located. The second category is a custom sensor, which monitors specific data or packaging applications based on client requests, while the third category is called basic manual probe, where a probe and a set of MA sensors are used for monitoring.

These sensors are mainly developed to allow monitoring of modified atmospheric conditions inside the packages in the most non-invasive and cost-effective way. All sensor caps are easy to install, provide accurate analysis, and monitor each bag every 6 hours. Data collected are sent directly to the operator through a software portal. The monitoring system also allows certification of product quality from departure to arrival.

Sensor for Modified Atmosphere FIBCs

Products packed in large bulk bags, such as FIBCs, require vacuum pressure and accurate oxygen or nitrogen content control. Modifying the atmosphere inside the packaging by lowering oxygen levels to 1% or less can protect the products from molds and other microorganisms, as well as insects and rodents, resulting in a prolonged product shelf life.


<h2>Creating an atmosphere with oxygen levels below 1% inside your bulk bags</h2>
The Vacuum and Gas Injection Machine, from Somsix, is a system used to create the optimum atmosphere conditions inside FIBCs or large bags during the packaging of bulk products. The unit allows the operator to create a vacuum and insert the necessary gases in a single cycle to increase productivity. The procedure is done by removing air from a sealed container before injecting essential gases like oxygen, nitrogen, or carbon dioxide into that container. It can also reduce oxygen levels in FIBCs down to 1% or lower in a very short time.

The system has an integrated leak test at the end of each cycle to automatically check for possible leaks in every bag. This feature prevents costly and time-consuming errors. The entire system is built based on food-grade standards guaranteeing hygienic operation.

Vacuum and Gas Injection System for FIBCs

Masterpack Packaging Solutions

MAP Packaging 

Somsix Valves

About Masterpack

Basically, to make milk powder, you need to remove the water content from the liquid milk and turn it into powder. How to do it? After pasteurizing and homogenizing the milk, milk’s water content is removed through filtration, evaporation, and drying. You have then to cool and sieve it before filling the containers. Here's how you get milk powder.

Milk powder

Cashews come from a tropical tree native to Central America. They have become prominent and your nut mix will not be complete without them. The cashew processing method involves roasting, shell drying, peeling, grading, fumigation and packaging. You have to conduct these processing methods with care to obtain quality cashew nuts. In order to achieve this, you'll need the appropriate machinery for your cashew processing plant.

Cashews

In Ancient Rome, hazelnut plants were valuable gifts as it was believed to bring happiness. In modern days, hazelnuts still bring happiness, mainly in the form of Nutella. While most nuts are botanically classified as fruits, hazelnuts are, along with chestnuts and acorns, <em>true nuts. </em>Once harvested, the nuts are dried and ready to be processed in various hazelnut processing equipment.

Hazelnuts

Pistachio nuts offer several health benefits and are very nutritious. The most common way they are enjoyed is when they are roasted or eaten raw. Generally, pistachios are harvested when the shell splits. They are mechanically shaken and caught in a tarp. Furthermore, you can hull and dry them properly before roasting. To achieve all of this, you will need special pistachio processing equipment

Pistachios

Peanuts, also known as groundnuts are one of the most popular edible seeds in the world. You can eat them as-is or process them further into on-the-shelf products like peanut butter, oil, snacks, and soups. Depending on what you want to make, some peanut manufacturing processes include roasting, frying, boiling, grinding, pressing, and coating the peanuts.

Peanuts

What are you Packing? 

Masterpack Group is a leading developer of high-end packaging solutions for big bags, and flexible intermediate bulk containers (FIBCs).