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Rising to the Challenge

Updated: Aug 2, 2021

The team at Packaging Automation like a challenge but when they were recently approached by an existing customer looking to reduce O2 residual levels below 1%, they were, of course, naturally nervous!

Gas residual are the levels of the gases which have been sealed into the pack when it has been gas flushed.

Was it really possible, could we achieve it?

But of course, Simon and the Test Kitchen team at Packaging Automation were undeterred, always up for a challenge, they set about trying to achieve the impossible.

To make the challenge even more tricky the product was pitted olives, presenting the problem of lots of air pockets and a deep pot to fill!

Up until now this customer had been using Map V (vacuum pack), the team trialled lots of different options for them in our Test Kitchen with gas flushing eventually achieving the best result and what a result: residual levels lower than 1% , not just delivered against client expectations but exceeded them! It definitely pays to #AskSimon.

If you want to achieve the best possible packaging for your products and want to try some packaging alternatives, then contact our Trial Facility.

Our trial facility at our factory in Knutsford, Cheshire offers you the opportunity to carry out tests using your proposed packaging materials with your product incorporating the process steps you intend to use (MAP, Skin PAC, chill, freeze or cook) to verify the results prior to investment in machinery. Shelf ready pack concepts can be produced to validate pack integrity and for performance trials such as shelf life and transit trials.

​Our packaging seal technologist can guide you through the development of new packaging concepts including selecting environmentally friendly alternatives to plastic packaging and can help you access our vast database of packaging suppliers.

“I met Simon on the back of the PPMA show last year and he has been helping to support our plastic free agenda since. He has been a source of knowledge as we explore paper-based materials and their sealing capabilities. Simon is incredibly proactive when it comes to investigating new materials and is always on hand when we have quality and technical issues that we are trying to resolve. His honest approach enables us to get answers quickly and it has been a pleasure to collaborate with him as we try to turn the tap down on plastic production. The service Simon provides is excellent and I look forward to continue working with him and the rest of the team at PA on paper-based materials over the coming year.” Hannah Pollard Senior Packaging Technologist Iceland Foods

Tel: 01565 756555 Email:

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