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Vacuum level is one of the most critical yet often overlooked factors in thermoforming vacuum packaging. It directly impacts product shelf life, seal integrity, and overall packaging quality.

What is the Vacuum Level in Packaging?

Vacuum level refers to the amount of air removed from the package before sealing. It is usually measured in mbar (millibar) or as a percentage of air removed.

A lower pressure (higher vacuum) means less oxygen inside the package, which helps preserve the product.

Why Does Vacuum Level Matter?

The vacuum level determines how well the product is protected from:

• Oxidation
• Bacterial growth
• Moisture damage
• Spoilage

Even small variations can significantly affect the final packaging result.

How Does Vacuum Level Impact Shelf Life?

Does higher vacuum always mean better shelf life?

Not always.

• High vacuum: Best for meat, fish, and solid foods
• Moderate vacuum: Better for delicate or soft products
• Low vacuum + MAP: Ideal for products needing gas balance

Too much vacuum can sometimes damage product texture, especially for soft or liquid items.

What happens if the vacuum level is Too Low?

If the vacuum is insufficient:

• Oxygen remains inside the package
• Shelf life decreases
• Risk of microbial growth increases
• Packaging may look loose or inflated

This often leads to poor product quality and customer dissatisfaction.

What happens if the vacuum level is Too High?

Excessive vacuum can cause:

• Product deformation (especially soft foods)
• Liquid extraction from products
• Seal stress or film collapse
• Poor visual presentation

This is why precise control is essential.

How Do Thermoforming Machines Control Vacuum?

Modern thermoforming vacuum packaging machines use:

• High-performance vacuum pumps
• Pressure sensors
• PLC-controlled settings
• Adjustable vacuum cycles

This allows operators to fine-tune vacuum levels based on product type.

Can Vacuum Level Be Combined with MAP?

Yes, many thermoforming machines use Modified Atmosphere Packaging (MAP) along with vacuum.

In this process:

1. Air is removed
2. Gas mixture (CO₂, N₂, O₂) is injected
3. The package is sealed.

This combination provides better control over product preservation and appearance.

How to Choose the Right Vacuum Level?

It depends on the product:

• Meat & Fish: High Vacuum
• Prepared meals: Medium vacuum or MAP
• Snacks: Low vacuum or nitrogen flushing
• Medical items: Controlled vacuum for protection

Testing and calibration are key for optimal results.

Why is Vacuum Optimization Important for Businesses?

Proper vacuum control helps:

• Reduce product waste
• Improve shelf life
• Enhance packaging appearance
• Maintain consistent quality
• Increase customer trust

Is Vacuum Level a Competitive Advantage?

Yes. Businesses that optimize vacuum settings can achieve:

• Better product preservation
• Lower returns and spoilage
• Higher efficiency in production

It's a small technical factor that makes a big commercial difference.