Crispy, salty, smoky bacon is one of life’s greatest pleasures. But that freshly-cooked taste rapidly declines as the bacon sits in its package. Within days, it becomes limp and soggy. Preventing this rapid deterioration has long posed a challenge for bacon producers and consumers alike.
Now, exciting innovations in gas-flushing technology are revolutionizing the world of packaged bacon. Gas-flushing gives bacon significantly longer shelf life, maintaining its texture and flavor for weeks rather than days. But what exactly is gas-flushed bacon? How does it work? And is it worth the hype? Let’s dive into everything you need to know about this bacon breakthrough.
What is Gas Flushing?
Gas flushing refers to the process of replacing oxygen in food packaging with inert gases like nitrogen or carbon dioxide. This inhibits aerobic bacteria growth and oxidation reactions that cause food to spoil.
During gas flushing, food packages are placed in a sealed chamber The oxygen is sucked out via vacuum and replaced with the desired inert gas mixture This new modified atmosphere creates an optimal climate to maintain food freshness.
Gas flushing technology has been used for years to package items like coffee, snacks, and cheese More recently, bacon producers have started utilizing it as well
Why Gas Flush Bacon Packages?
Traditionally packaged bacon relies solely on refrigeration and preservatives to prevent spoilage. But exposure to oxygen still takes a toll. Fat oxidation causes rancid flavors. Bacteria thrive, creating “bacon bits” of slime and sludge.
Gas flushing bacon packs creates a protective shield, preventing oxygen from working its ruining ways. Nitrogen and carbon dioxide halt both oxidation and aerobic bacteria growth. The bacon stays fresher, longer.
Studies show gas-flushed bacon maintains desirable flavors, textures, and colors for over 40 days refrigerated, compared to just 14 days for normally-packaged bacon. With over 3X longer shelf life, gas-flushing is a serious game changer.
The Gas Flushing Process for Bacon
Producing gas-flushed bacon requires a few specialized pieces of equipment and some key steps:
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Modified Atmosphere Packaging Machine: Uses vacuum suction to remove oxygen from packages before injecting the replacement gas mixture.
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Inert Gas Tanks: Food-grade nitrogen and/or carbon dioxide tanks connected to the MAP machine provide the gases.
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Gas-Tight Bacon Packages: Packs must have minimal air permeability so gases don’t escape. Common options are vacuum pouches or trays with rigid lids.
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Package Filling: Sliced, cured bacon is placed into packages, leaving minimal headspace.
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Vacuum Suction: Air is removed from the filled packages via vacuum, lowering internal oxygen levels.
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Gas Injection: Packages are flooded with a precise mixture of nitrogen, carbon dioxide, or other inert gases.
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Sealing: Packages are sealed shut to prevent gas leakage.
<img src=”https://i.ibb.co/0j7gxxJ/gas-flushed-bacon-process.png” alt=”Gas Flushing Process Diagram” border=”0″ />
The basic gas flushing process for packaged bacon. [Image Source]
And voila! The result is bacon packs pumped full of protective gases rather than air. This gas-flushed bacon stays fresh, delicious, and cook-ready for much longer than traditionally packaged pork belly.
The Benefits of Gas-Flushed Bacon
Why should bacon lovers be excited about this new gas flushing tech? Here are some of the biggest benefits:
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3-4X Longer Shelf Life: Keeps bacon tasting great for over a month versus just 1-2 weeks.
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Prevents Discoloration: The pinkish-red color stays vibrant thanks to minimized oxidation.
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Maintains Texture: Stays desirably crispy when cooked rather than getting limp and soggy.
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Retains Fresh Flavors: No rancid or off tastes from fat oxidation.
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Inhibits Bacterial Growth: Minimizes unsafe microbial blooms like pseudomonas.
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More Convenience: Less frequent bacon shopping with longer fridge life.
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Less Food Waste: Extended shelf life prevents premature spoilage.
For bacon aficionados, gas-flushed packs are a dream come true. You can stock up on bacon when it’s on sale, keep leftover strips fresher, and reduce waste.
Types of Gases Used for Flushing Bacon
Typically, gas-flushed bacon utilizes a mixture of nitrogen and carbon dioxide. However, other gases may also be used. Here are some common options:
Nitrogen
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Provides an inert barrier layer that prevents oxygen exposure.
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Makes up 50-80% of typical gas mixtures.
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Has no odor or flavor impact.
Carbon Dioxide
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Inhibits growth of aerobic microorganisms.
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Makes up 20-50% of many gas blends.
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In high amounts, can slightly alter bacon’s flavor.
Argon
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Also inert and can replace some nitrogen.
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More expensive so usually a minor component.
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Provides added oxygen barrier.
Carbon Monoxide
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Stabilizes color so packages look redder.
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Banned in many countries due to health concerns.
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Allows very low oxygen levels (<0.5%).
The exact gas mixture can be customized to balance factors like shelf life, safety, cost, and taste. Nitrogen does the heavy lifting on barrier protection while CO2 pulls double duty as antimicrobial agent and oxidization preventer.
Is Gas-Flushed Bacon Safe?
Despite its high-tech image, gas-flushed bacon undergoes no new chemical processes compared to traditional bacon. The meat itself is identical – it is just packaged differently.
The gases used are all food-safe and commonly found in the air we breathe. In fact, gas flushing improves safety by inhibiting the growth of harmful microbes like pseudomonas and E. coli.
However, there are two concerns consumers may have:
Carbon Monoxide Use
While CO helps stabilize color, health agencies like the FDA have concerns about safety. CO bonds tightly to proteins like hemoglobin and myoglobin. Overexposure in meat may pose cardiovascular risks. Most gas-flushed bacon sold in the US avoids CO.
Botulism Risk
Heavily reducing oxygen could increase botulism risk in some foods. But bacon’s very low moisture content means botulism is not a concern. Proper refrigeration provides an added safety net.
As long as gas-flushed bacon avoids CO and is properly chilled, there are no significant risks. In fact, the extended shelf life results in less premature spoilage and waste.
Availability and Cost of Gas-Flushed Bacon
Gas-flushed bacon availability has steadily grown over the past decade. While niche at first, it can now be found at many major grocery chains like Kroger, Safeway, Costco, and Whole Foods.
Brands offering gas-flushed bacon lines include:
- Oscar Mayer
- Smithfield
- Hormel
- Applegate
- Niman Ranch
- Tyson
- Wellshire Farms
Despite the extra processing, gas-flushed bacon costs just slightly more than traditional packs – usually around a $1 premium per pound. This small splurge gets you substantially longer freshness.
For food service operations like restaurants, gas-flushed bacon offers even bigger potential cost savings by reducing waste from spoilage.
The Future of Gas-Flushed Bacon
Thanks to its clear benefits, gas-flushed bacon seems poised to become the new norm. As packaging technology improves, gas flushing will likely spread to more meat, poultry, and seafood products.
In the future, we may see wider use of newer shelf life-extending gases like ozone and hydrogen peroxide. Intelligent packaging that tracks internal gas levels will enable even better freshness.
One day, all our bacon – as well as other perishable goods – may arrive in our kitchens packaged in protective, life-extending atmospheres. Gas flushing helps make this food waste-slashing future closer to reality.
So next time you browse the bacon section, keep an eye out for gas-flushed packs and their longer freshness lifespans. While the packaging may look similar, the contents inside are shielded from oxygen in innovatively modified atmospheres – helping your bacon stay deliciously crispy and mouthwateringly meaty for weeks rather than just days.