Ultra high-purity nitrogen generator NITROBERG®

inerthigh-purityfor the food industry

Overview NITROBERG® nitrogen generators produce nitrogen on site from compressed air using PSA technology, delivering the purity and flow required for modified-atmosphere food packaging (MAP). Proper sizing matches the pack residual-oxygen target, machine purge performance and line flow rather than defaulting to the highest purity available.

Key facts

• Typical MAP purity band: 99.5 % to 99.9 %
• NITROBERG® range capacity (packaging grades): up to 990.3 Nm³/h at 99.5 %
• Example air factor at 99.5 %: 2.9 (m³ compressed air per Nm³ N₂)
• Conformity: PED 2014/68/EU (notified body NB 2912)

What nitrogen does in food packaging Nitrogen is inert and displaces oxygen in pack headspace, slowing oxidation of fats and pigments and limiting growth of aerobic spoilage organisms. For crush-sensitive products the gas also cushions the pack. Application methods include continuous flush or evacuation-and-flood depending on the target residual oxygen and machine principle.

Residual oxygen and packaging performance Generator purity defines the lower bound for achievable pack oxygen, but actual residual oxygen depends on purge time and nozzle geometry, machine principle (flush vs evacuation) and seal integrity. Define the product's residual-oxygen target first, verify machine and seal performance, then select generator purity accordingly.

Process steps affecting residual oxygen

• 1. Gas purity at the generator — sets the floor for pack values.
• 2. Purge time and nozzle geometry — how completely air is displaced before sealing (machine setting).
• 3. Machine principle — flushing typically leaves more oxygen than evacuating and flooding.
• 4. Seal integrity — seam leaks allow air ingress over time and reduce shelf life.

Purity table

• 99 % | 10,000 ppm | ≈1.0 % O₂ in the gas — gas itself begins to limit pack oxygen | Air factor 2.6
• 99.5 % | 5,000 ppm | ≈0.5 % O₂ — common working point for flushed lines | Air factor 2.9
• 99.9 % | 1,000 ppm | ≈0.1 % O₂ — used for tighter targets or sensitive products | Air factor 3.4
• 99.99 % | 100 ppm | Below what a packaging machine normally achieves | Air factor 4.6
• 99.999 % | 10 ppm | Laboratory/electronics territory, not packaging | Air factor 6.4

NITROBERG® sizes (selected values at packaging grades)

• NITROBERG® 500 — N₂ at 99.5%: 6.2 Nm³/h | N₂ at 99.9%: 4.1 Nm³/h | Compressed air at 99.5%: 18.0 Nm³/h
• NITROBERG® 700 — 17.4 Nm³/h | 11.5 Nm³/h | 50.3 Nm³/h
• NITROBERG® 900 — 38.2 Nm³/h | 25.3 Nm³/h | 110.8 Nm³/h
• NITROBERG® 1100 — 68.2 Nm³/h | 45.1 Nm³/h | 197.8 Nm³/h
• NITROBERG® 1200 — 84.3 Nm³/h | 55.8 Nm³/h | 244.5 Nm³/h
• NITROBERG® 1300 — 119.0 Nm³/h | 78.7 Nm³/h | 345.2 Nm³/h
• NITROBERG® 1500 — 233.1 Nm³/h | 154.2 Nm³/h | 676.0 Nm³/h
• NITROBERG® 1700 — 335.7 Nm³/h | 222.0 Nm³/h | 973.5 Nm³/h

How to calculate line demand

• Start from the pack headspace volume × purge factor = gas per pack.
• Multiply by packs per minute × 60 to obtain Nm³/h.
• For multiple lines apply a realistic simultaneity factor rather than summing peaks.
• Check compressed-air availability and quality because the air factor (function of chosen purity) runs every operating hour.

Compressed air and cost Each PSA size consumes a defined compressed-air per Nm³ ratio. Example: a line needing 80 Nm³/h N₂ requires ~232 Nm³/h compressed air at 99.5 % but ~512 Nm³/h at 99.999 %. Compressor sizing and electricity use depend strongly on specified purity, so selecting the appropriate purity has a major OPEX impact.

What a nitrogen generator needs on site

• Operating pressure: 10 bar
• Compressed air inlet pressure required: 7 bar(g)
• Compressed air quality: ISO 8573-1:2010 Class 1.4.1
• Sound level: 55–78 dB(A)
• Ambient temperature: +5 °C to +40 °C

Advantages and service

• On-site nitrogen production with adjustable purity to match pack requirements and avoid unnecessary compressed-air costs.
• Wear parts and filters are standard, widely available components.
• Continuous purity monitoring with zirconia analyser, trend recording and alarm functions for traceability.
• Manufactured in Germany; standard warranty 3 years, extendable to 5 years with service contract.

Technical characteristics / specifications

• Series: NITROBERG® (BERG GaseTech)
• Typical purity range for MAP: 99.5 % to 99.9 % (up to 99.999 % available for specialised uses)
• Maximum capacity in the series (packaging grade): up to 990.3 Nm³/h at 99.5 %
• Example air factors: 2.6 (@99%), 2.9 (@99.5%), 3.4 (@99.9%), 4.6 (@99.99%), 6.4 (@99.999%)
• Operating pressure: 10 bar
• Recommended compressed-air inlet pressure: 7 bar(g)
• Compressed-air quality required: ISO 8573-1:2010 Class 1.4.1
• Sound level: 55–78 dB(A)
• Ambient temperature range: +5 °C to +40 °C
• Conformity: PED 2014/68/EU (NB 2912)
• Manufacturing origin: Made in Germany
• Typical warranty: 3 years standard, up to 5 years with service contract
• Available sizes: 18 sizes in the NITROBERG® range (selected models listed above)