Super Storage Pail - Filling with CO2 gas

Grain-filled super pail using Mylar film T Lumen Foods' Super Pailhe scientific principles which govern proper long-term food storage are well-known, and yet there is quite a bit of variance among those in the long-term food storage business as to their methodologies. We've gotten numerous queries from our regular customers, as well as prospective purchasers, as to what techniques we use to preserve our Y2K meal systems.
Initially, knowing from experience that our meals, with their low A(w), or free water content, and high pH and solutes, could last for several years, we used conventional polyprop packaging and strong corrugated boxing.
This month, we converted our packaging systems to our own version of the "super pail," and began employing the following techniques. We decided to make this change as a matter of added long-term storage insurance, so that the product would, indeed, have a guaranteed 5 year shelf-life.

Preparing Super Pails Thick, High Air Barrier Polyprop
and/or Metalized Polyester (Mylar)
We've had over 12 years experience in working with a wide variety of laminated packaging materials: styrene, polypropylene, metalized polyester, etc. We know their properties because it's our business: virtually all Lumen Foods' own meat replacement products are what food technicians call "intermediate moisture" or "IM mode" foods. That is, they fall between 15% and 50% moisture -- the low end of that scale in our case.
In working with U.S. World Foods we developed a dry-blend business that pulled these moisture figures more in the 4% to 12% range. Most foods that are 4% or under in moisture content, unless they are high in fats, are fairly easy to store in a cool, dry place -- provided they are given protection from outside contamination or infestation. If you rise above that figure, you usually need protection from moisture and/or ambient oxygen.
Without trying to get too technical, there are several other factors that enter into the food storage equation when choosing a packaging "film":
Available Moisture - As alluded to above, there is the amount of "free water," which when expressed as a ratio to water which cannot be used by organisms to reproduce ("bound water"), is known as the Aw factor. All Lumen Foods' Y2K meal systems have a naturally low Aw factor, which automatically helps their shelf-life.
pH Factor - Foods, whether assisted by naturally-occurring acidic preservatives or because of the addition of food grade acidulents or both, tend to last longer when their are on the acidic or low pH side. Numerous studies have shown that preservatives, that is compounds, natural or man-made, which act as shelf-life extenders in foods, generally work better in a more acidic environment. All Lumen Foods', with only minor exceptions, fall in the 3.2 to 4.8 range. That is, they are mildly acidic, helping to fend off microorganisms - especially with the assistance of potassium sorbate in our own meat replacements.
Light Emissions - Light produces heat and heat ages most foods. For this reason, metalized polyester is popular in the food storage business because it is opaque (non-transparent) and helps block out light. Lumen Foods uses metalized polyester sparingly where the food in question needs extra protection. Most of the benefits of this material (often called "Mylar" even though this is just a Dupont trademark and there are many other films on the market that are also made of metalized polyester that do essentially the same thing) are cancelled if the food to be stored is simply kept in a cool, dry DARK place anyways.

CO2 Regulator Valve Nitrogen or CO2 Gas Flushing?
Plus Oxygen Absorbers.
Besides moisture, the next greatest threat to storable foods is O2, or atmospheric oxygen. Minimizing oxygen is critical because without eliminating oxygen, insect infestation and microorganisms can wreak havoc. Also, fats cannot go rancid (oxidize) without oxygen, and virtually all grains, beans, nuts, and seeds contain fats.
Heated CO2 We use heated CO2 gas, as well as liquid nitrogen, in our operation. We have found that each have their strength: CO2 is heavier than nitrogen and serves better in some applications. Whereas foods with higher moisture contents should not be packed with CO2 because of the opportunity for creation of unwanted carbonic acid.
In addition, for added security we use oxygen absorbers. These oxygen-stealing pouches not only grab remaining oxygen in the pail after it has been sealed, but they help create a slight suction within the pail itself. If you have not already done so, you might want to read our section on oxygen absorbers.

The final touches... The Final Touches
It doesn't do any good to create a low moisture, virtually oxygen-free container if oxygen has a way of re-entering the container after its sealed. For this reason, we take special precautions to ensure that the lid, with its embedded rubber seal, is firmly seated on the body of the pail.
All pails are kept in an FDA-approved warehousing facility that is regularly monitored for pests and other sources of infestation.
Finally, your super storage pail is shipped on an approved carrier (either UPS or common carrier) with special "fragile" markings to alert delivery personnel as to the special care we want for our customers' product.
Before ordering, we ask that you thoroughly read through the Y2K portion of our FAQ pages. However, if you have further questions about any aspect of our preservation process, please email us.

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