We package with an airspace in our packages. We use 30%CO2 and 70%N2 to fill this airspace after pulling partial vacuum with a thermoforming packager. We used to have an oxygen level requirement in our finished packages of 0.5% to 2.0% and all was pretty good. We recently changed our oxygen level requirement in the finished package to 2.0% to 3.5% and all is not so good. We have a 4-track, 2-row configuration so we seal eight packs per cycle. With the old lower O2 levels we could hold a spread across the eight packages in a cycle of about 0.5% (highest O2 reading to lowest O2 reading in a cycle) and it was not hard producing in spec packages. Now that we are at the higher O2 level requirement we are LUCKY if we can hold a 1.5% spread so we are fighting constantly to remain in spec and really slowing production. Has anyone experienced anything like this?
Thank you in advance for any information relating to this that you can provide.