Pistachio is a nutritious food containing a high volume of vitamins, minerals, and fatty acids. This popular and beloved nut is considered as one of our country's important export products. Therefore, proper packaging, maintaining its quality, appearance, taste, and freshness during transportation is of great importance. Pistachio producers are constantly seeking ways to preserve its freshness and extend its shelf life.
West Asia Steel Company is one of the factories active in the field of production of packaging machinery for food products. This company also produces pistachio packaging machines. In this article, we introduce these machines.
Nutritional Properties of Pistachios
Pistachios are rich in healthy nutrients such as healthy fats, fiber, protein, a wide range of vitamins, and essential minerals like vitamin B6, copper, manganese, phosphorus, and potassium. They are a good source of antioxidants including vitamin E and have a low glycemic index, making them an excellent snack for maintaining blood sugar levels.
Challenges of Pistachio Storage
One of the key challenges in storage of pistachio is insect infestation. Insects such as the maggot-like navel orangeworms can infest pistachios before harvest, leading to damage and spoilage. Ensuring proper storage conditions to prevent infestation is crucial.
Another important factor to consider is the drying of pistachios. This process is essential for reducing water content and ensuring long-term storage. Without adequate drying, pistachios can mold, spoil, and lose their quality.
In addition to insect infestation and drying, discoloration of the shells during transportation and storage can also decrease the value of pistachios. Proper packaging is of great importance to prevent this issue.
Mold growth is another problem that can occur during storage, leading to the growth of mycelium, unpleasant odors, and the production of mycotoxins like aflatoxin (a fungal toxin). Proper storage conditions, such as low humidity and temperature, can help prevent mold growth.
During pistachio storage, autoxidation is also a concern. The breakdown of fats, mainly unsaturated fats, can result in the formation of free fatty acids, off-flavors, off-colors, and rancidity in pistachios.
Ultimately, the biological activity of the product can increase moisture levels and odors during storage. Monitoring and controlling packaging conditions are essential to prevent these issues and ensure the quality of the nuts.
Pistachio Packaging Using Modified Atmosphere Technique
During packaging, modified atmosphere packaging (MAP) uses specific gases to create a sterile environment for food packaging. This technique extends the shelf life of snacks, allowing them to arrive fresh at grocery stores. By employing a modified atmosphere consisting of a mixture of gases, the process slows down food aging and prevents spoilage and decay.
Environments rich in oxygen provide conditions for the growth of bacteria such as mold. Nuts like pistachios, walnuts, almonds, etc., quickly deteriorate when exposed to oxygen for extended periods.
One of the essential gasses used in MAP is nitrogen. Nitrogen, an odorless and tasteless gas, does not affect the taste of food, especially dry foods that need to remain crisp and fresh. By delaying oxidation, controlling the fats and oils in food, and extending the freshness of the product, nitrogen aids in prolonging the shelf life of products. Injecting nitrogen into the packaging and removing oxygen significantly inhibits oxidation and reduces the growth rate of microbes. Moreover, nitrogen helps extend the shelf life of pistachios, preserving quality, preventing decay, and reducing production costs. Filling bags containing pistachios with nitrogen (thus removing oxygen) eliminates moisture and mold growth. Consequently, pistachios can remain fresh, delicious, and visually appealing for a longer period.
Benefits of Packaging Pistachios Using Modified Atmosphere Method
Modified Atmosphere Packaging (MAP) addresses the challenges related to bulk pistachio storage.
- Preventing insect infestation: One of the key benefits of Modified Atmosphere Packaging is its ability to prevent insect infestation. This packaging method involves using suitable packaging materials, sending out air from the environment, and replacing it with low amounts of oxygen to prevent the maggot-like navel orangeworms.
- Maintaining visual appeal: Modified Atmosphere Packaging can help prevent color changes during transportation and storage by minimizing pistachios' exposure to light and oxygen. This contributes to maintaining visual appeal and preventing a decrease in nutritional value.
- Reducing the risk of mold growth and spoilage: Additionally, Modified Atmosphere Packaging helps to control moisture levels during storage, reducing the risk of mold growth and other forms of spoilage. By reducing exposure to oxygen, it also helps prevent self-oxidation, off-flavors, and sour tastes.
- Reducing food waste: The use of Modified Atmosphere Packaging increases product shelf life and reduces food waste.
- Enhancing product safety: Controlling the gas composition during packaging using Modified Atmosphere Packaging leads to a decrease in pathogen growth and enhances product safety.
- Preserving texture and color: Modified Atmosphere Packaging prevents color changes, preserves the texture and flavor of pistachios, and enhances their appearance.
- Cost savings: By increasing shelf life and reducing product losses, packaging and storage costs are reduced.
- Chemical-free preservation: Modified Atmosphere Packaging enables pistachio preservation without the use of chemicals, providing a more sustainable and healthier choice for consumers.
- Greater control over the consumer supply chain: Modified Atmosphere Packaging allows for greater control over the supply chain, reducing the risk of contamination during transportation or storage and enabling quick identification and resolution of any issues.
Overall, the use of Modified Atmosphere Packaging can improve the shelf life and quality of pistachios by providing a controlled storage environment.
Materials used in pistachio packaging.
In the field of packaging, the selection of materials plays a crucial role in preserving the quality and increasing the shelf life of the product. Materials used in pistachio packaging include:
- Polyethylene (PE): Polyethylene is used to prevent pistachio spoilage and is flexible enough to take on various shapes.
- Polypropylene (PP): Polypropylene has high strength and heat resistance, making it suitable for packaging by seal vacuum to maintain the taste and freshness of pistachios.
- Metal containers: Metal cans such as tin, aluminum, and steel are used for pistachio packaging to protect them from bacteria and contaminants, ensuring their long shelf life.
- Surface coating films for packaged trays: Various types of films used in pistachio packaging include:
- Plastic films
- Metallized films
- Anti-fog films
- Breathable films
- Aluminum films.
Types of Pistachio Packaging
Suitable pistachio packaging includes flexible packaging and cans.
Flexible packaging
Flexible packaging refers to packaging that can easily change shape when filled with products. The best example of flexible packaging is pouches. Other examples of flexible packaging include bags, plastic pouches, and tubes.
Pistachio packaging in flexible packaging materials has the following advantages:
- Longer shelf life: Flexible packaging with nitrogen increases the shelf life of pistachios and prevents them from spoiling.
- Stability in packaging: Flexible packaging is environmentally friendly and can be used more than once.
- Cost-effective: Using this packaging is very cost-effective.
- Lightweight: Flexible packages are lightweight, making them easy and inexpensive to transport.
Can Packaging
Another method of packaging pistachios is using cans. Cans are considered a very safe solution for packaging as they protect the products from various environmental conditions. Cans can be made of glass, cardboard, metal, etc., depending on their application. The most common cans used for packaging pistachios are plastic cans, which have better properties. Metal cans are also used for pistachio packaging, with tin, aluminum, and steel being preferred types of metals. Packaging pistachios in cans has various advantages:
- Cans provide the best sealing for pistachios.
- They offer the best protection for pistachios against bacteria, moisture, and other contaminants.
- They have a high durability, increasing the shelf life of packaged pistachios.
- They are recyclable, thus helping to preserve the environment.
- The surface of cans is more suitable for decorations, labeling, and other designs compared to other methods.
Various Types of Pistachio Packaging Machines
In the pistachio packaging process, various machines are used in automatic, semi-automatic, and manual forms:
- Automatic seal vacuum machine
- Semi-automatic vacuum sealing machine
- Cellophane wrapping machine
- Manual sealing machine
- Thermoforming machine
- Filling machine
Automatic Tray Sealer
One of the machines manufactured by West Asia Steel Company is an automatic tray sealer for packaging pistachios. The operation process of this machine is as follows:
Trays are automatically placed on the machine or by an operator, and the product is loaded into them through fillers.
Then, the trays containing the product are directed into the machine, and packaging is done by injecting nitrogen gas into the trays and sealing.
Finally, the automatic labeler takes care of sticking the labels.
The automatic tray sealer machine is designed to be used for trays of different sizes. In fact, each machine has different molds that are used for packaging trays with different shapes. The operator places the mold in the machine and adjusts the settings according to the new mold.
The auxiliary equipment used in the production line of this machine includes:
- Automatic container loader
- UV tunnel
- Single-row to multi-row converter and vice versa
- Fillers
- Automatic rower
- Automatic denester
- Traffic table
- Metal detector
- Check weigher
Semi-automatic Tray Sealer Packaging Machine
Another production machine by West Asia Steel Company is the semi-automatic tray sealer machine for packaging pistachios. Unlike the automatic machine, number of steps are performed by the operator. The mold of this machine is also changeable and can be used for trays of different sizes.
Manual Sealing Machine
A manual sealing machine is used for producing products by low capacity and is suitable for household use. In this machine, placing trays into the mold, picking up packaged products from the machine, and manually applying pressure to seal the film onto the tray are done by the operator. It is possible to manufacture molds for trays of various shapes and dimensions in this machine.
Thermoforming machine
Another machine used for packaging pistachios is the thermoforming machine. The packaging process of this machine is as follows:
- The thermoforming machine can package products inside plastic trays. However, the most significant difference between this machine and seal vacuum machines is the production of trays by the machine. Initially, a film is placed in the machine and then formed by the mold. After shaping, packaging cuts are made.
- Following the packaging, fillers begin to fill the trays. Then, nitrogen gas injection and vacuum process are carried out.
- Furthermore, the labeler proceeds to stick the labels, and the packaging is completed.
The Price of the Pistachio Packing Machine
As you know, the prices of manufacturing machines by West Asia Steel Company are influenced by various factors such as:
- Being automatic, semi-automatic, or manual
- The auxiliary equipment used
- Packaging method
- Production capacity and speed
- Tray size
- The produced product, etc.
Therefore, if you intend to purchase a pistachio packaging machine, first determine your desired machine and the necessary auxiliary equipment. Then, contact our experts. They will provide you with a price estimate for your desired machine in the shortest possible time.
Choosing the Best Packaging Machine
When choosing the right machine for your production, you can follow the following guidelines:
- Price of pistachio packaging machine: Initially, plan for a business that leads to your success. Then allocate a budget for a suitable packaging machine. Investing in a high-quality packaging machine will help you achieve your goal.
- Quality of pistachio packaging machine: After determining your budget, look for a machine that offers the highest quality within your budget. If possible, you can even adjust your budget slightly to acquire a machine with high accuracy.
- Reputable manufacturer: Before purchasing a machine, research different companies and choose a reputable and well-known company.
- Choosing a machine according to your needs: First gather information about the desired production capacity, tray sizes, production speed, packaging method, etc. Then order a machine that meets your production needs.
- Technical services: Choose a supplier that provides the best technical services such as machine repair and maintenance, and other after-sales services.
West Asia Steel Company is one of the most reputable manufacturers of packaging machines. This company specializes in producing pistachio packaging machines in various sizes, shapes, and prices. Therefore, if you intend to purchase a packaging machine, contact our experts to become familiar with our services and products.
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