Retort Pouch

Guided By:Dr. P.A.Pawar

Presented By:Miss Ankita Govind ChaudhariB.Tech. Final Year (Food Tech.)E-mail Id: harshada.23aug@gmail.comContact No.: 9423545582

Introduction Urbanization has increased the intake

and demand for processed foods. There is a trend towards replacing

traditionally cooked foods with processed foods.

Processed foods may not be nutritionally balanced unless fortified.

Sugar, a processed food, provides empty calories.

Types of Foods Processed Foods Instant Foods Fast Foods Street Foods Unhealthy (Junk) Foods Convenience Foods Ready-to-Eat Foods

Retorting The retorting or

sterilization process (technology that destroy all harmful microorganisms hence increases the shelf life of food) ensures the stability of the Ready-to-Eat foods in retort pouches, on the shelf and at room temperature.

Retort Pouch

Retort Pouch A retort pouch is a type of food packaging made

from a laminate of flexible plastic and metal foils. It allows the sterile packaging of a wide variety of food and drink handled by aseptic processing, and is used as an alternative to traditional industrial canning methods. Packaged foods range from water to fully cooked, thermo-stabilized high-caloric meals such as Meals, Ready-to-Eat (MREs) which can be eaten cold, warmed by submersing in hot water, or through the use of a flameless ration heater, a meal component introduced by the military in 1992.

Retort Pouch Styles 3-Side Seal 4-Side Seal Stand Up Stand Up Fitment Pre-made Form Fill Seal

Construction A retort pouch is constructed from a flexible metal-

plastic laminate that is able to withstand the thermal processing used for sterilization.

The food is first prepared, either raw or cooked, and then sealed into the retort pouch. The pouch is then heated to 116-121°C for several minutes under high pressure inside a retort or autoclave machine. The food inside is cooked in a similar way to pressure cooking. This process reliably kills all commonly occurring microorganisms (particularly Clostridium botulinum), preventing it from spoiling.

Material of Package Polyester (PET) – provides a gloss and rigid layer, may be printed

inside Nylon (bi-oriented polyamide) – provides puncture resistance Aluminum (Al) – provides a very thin but effective gas barrier Food-grade cast polypropylene (CPP) – used as the sealing layer Polyethylene (PE) – can be used instead of PP as a sealing and

bonding layer

This multi-layer structure prevents the retort pouch from being recycled into other retort pouches or food packaging. However, the material can be recycled into an aluminized resin or up-cycled into textile materials. The weight of a pouch is less than regular cans or bottles, and the energy required to produce each pouch is less than competing packaging from metals, paper, and glass.

Preparation time is reduced to a great extent.No storing, buying or planning of ingredients.Can hardly get any leftovers.Could have a variety of items.Faster presentation and easy cleaning up.Less spoilage and waste occur with packaged convenience foods.Transportation is cheaper especially in concentrated form.Cost efficient for mass production and distribution.

May be less meat, fish, or cheese than you would include in homemade versions.Cooking time is sometimes increased for thawing or longer baking time.Harder to control fat, salt and sugar levels.Cost per serving may be higher than homemade.Convenience foods are typically high in calories, fat, saturated fat, sugar, salt, and trans-fats.They tend to lack freshness in fruits and vegetables.

ADVA

NTAG

ESDISADVANTAGES

Quality of Retort Food Safety - should be free from chemical additives and

preservatives High Nutritional value – proteins, fat, carbohydrate,

vitamins, minerals etc. Good Taste Food Appeal – is the sum of sensory characteristics:

appearance, flavor, smell and texture. Suitability and Consumer Value: - freshness, shelf

stability, suitability for the intended purpose and convenience.

Reasonable price.

Quality for Retort Pouch Low gas permeability (oxygen) Low moisture permeability Low hydrophilic properties Heat sealable and sterilisable Constructed of appropriate material Resistant to penetration by fats, oils and other

food components Physical strength to resist physical abuse during

processing Absence of solvent residues. Bonding materials for the laminates must not

migrate into the foods. High light barrier.

Advantages of Retort Packaging

Pouch laminates permits less chance to overcook during the retorting thus products having better color, texture & less nutrients loss.

It requires less energy for sterilization. It requires less disposal & storage space. Low oxygen & moisture permeability. Shelf stable for longer time & requires no

refrigeration. Sun light barrier, light weight, easy to open.

Retort

Vertical Still RetortMalo Cooker/Retort

Full Water Immersion Retort

Partial Water Immersion Retort

Water Spray Retort

Steam/Air Retort

Hydrostatic Cooker

Rotary Continuous Cooker

ACB Hydrolock Continuous Cooker

Types of Retort

Shaka RetortMicrowave Retort

Vertical Still Retort Batch‐type Non‐agitating No overpressure Basket used to hold product Limited efficiency Best suited for small batches Used for processing metal cans Suitable for multiple package sizes Manual operation for loading and unloading

Malo Cooker/Retort Batch operation No overpressure Craterless system Designed for processing metal cans Often configured to fit existing facilities Loaded via conveyor Cans are discharged into canal system for

cooling Efficient system Single operator can manage multiple retorts

Full Water Immersion Retort Batch operation Still or agitating Overpressure First used for glass jars Now used for a variety of package formats Water is heated in a vessel above the cook

chamber to 133°C Super‐heated water is used to immerse packages A circulation pump is used to ensure proper heat

distribution

Partial Water Immersion Retort

Batch operation Still or agitating Overpressure Selected for closely fit containers High power pump is used to move water

through unit Water is moved to transfer heat Common applications include Tetra Recart

and small tins

Water Spray Retort Batch operation Still or agitating Overpressure Uses pump to force super heated water

(>121°C) throughout the vessel Nozzles provide very uniform heating

pattern Improved process control Optimal for pouch processing

Steam/Air Retort Sterilization is through introduction of

steam A fan circulates the steam to provide

uniform heating Suitable for multiple package types Packages are cooled with recirculated

water Process method was invented by

Lagarde

Hydrostatic Cooker Continuous cooker Best suited for large quantities of containers Designed to process metal cans Cans enter warm water chamber Conveyed into steam chamber Time and temperature are set based on

sterilization needs Cans exit through cold water Height is often 12.2 Meters Cans may be rotated to minimize heat damage

Rotary Continuous Cooker Continuous system Used extensively for cans Lacks overpressure control Cannot be used for pouches Set for a specific can size Cans are rotated as they cycle through

process Targeted for high volume applications

ACB Hydrolock Continuous Cooker Continuous cooker Overpressure Multiple package formats

Metal cans Glass jars Plastics bottles Thermoformed tubs Pouches

High volume applications Retail products with cook time of less than 30

minutes

Shaka Retort Batch operation Agitating Overpressure control Best suited for cans, plastic bottles or

thermoformed trays Packages must be secured in special racks Product is shaken vigorously Small batch sets Significantly reduced cycle time Reduced energy consumption

Microwave Retort Known as MATS (Microwave Assisted Thermal

Sterilization) Batch operation Product of partnership between industry and

academia Significant quality improvement for hard to

process products Requires metal‐free packaging materials Thermoformed trays and pouches Well suited for thick, difficult to process products

Machinery & Utilities of Retort Processing

Automatic Filling Machine

Band Sealer Canning Seamer Cartoner Caser Check Weigher Cup-Filling Machine

Air Compressor Blower Web Exhaust Pipes Boiler

Machinery Utilities

Automatic Filling Machine

Band Sealer

Can Seamer

Cartoner Caser

Processing Requirement

Pouch Filling Opening Filling

2 Part Seal Contamination

Evacuation Steam, vacuum Sealing

Impulse, Constant Heat, Ultrasonic 2 Step

Cooling

DryingCartoningCasing

Inspection pt.Retort unloading

Retorting

Product Preparation

Vacuum Production

Automatic or Manual Transport

Packing and retort loading

Vacuum Sealing

Weighing

Filling of Product

Pouch OpeningPre-Formed Retort Pouch

Cont. retorting

Inspection pt.

Pre Formed Retort Pouches

Retort Film Web (Reel)

Vacuum Production

Forming Into Pouch

Vacuum Sealing

Automatic or Manual filling of Product

Heat Processing and CoolingSteam Cooker or Seam Air Mixer

Secondary Packaging

Surface Drying

Weigh and Filling Into Pouch

Form-Fill Seal Retort Pouch

Pouch Handling

Flexibility Pouch Loading Rack Movement Crate Movement

Loading Racks Conveying system

Design of even flow of pouches Synchronize line speeds Seamless conveyors & smooth conveyor

surfaces

Manual System Automated System

Retort Racks Metal

Automation Plastic

Manual Material selection

Rack Design Compartments Rack Depth Smoothness/Edges Rack quantity (3x)

Retort Overpressure Pouch Expansion

Heating Cooling

Compensation

Post Retort Handling

After Unloading Following pressure cooling and removal

in racks or trays from the retort, the pouches must be dried, inspected and placed in some form of outer packaging.

When dry, pouch seal may once again visually checked or inspected for leaks, ruptures or weak points that have been shown up during retorting.

This should not involve manual handling of the individual pouches.

Outer Packaging The secondary packaging of retort

pouches for storage and distribution may either involve packing each pouch in printed carton or, alternatively packing a number of pouches in a transit case, possibly incorporating vertical dividers.

Retort Pouch Integrity &

Defects

Defects

Abrasion Channel Leaker Contaminated

Seal

Puncture Seal Creep Swollen Package Wrinkle Non‐bonding Cut Fracture Leaker

Pouch Integrity Test Seal inspection

X‐ray HVLD

Seal strength & inspection Pouch burst strength Leak detection

Dye Vacuum Pressure Decay Ultrasound

Microbial Quality Check

Example

Soya Pea Curry

Market

Economic Analysis Packaging Industry is one of the fastest growing

industries in the world representing a 11% growth in volume terms. Global packaging market is approx. $433 billion.

Indian packaging industry is the sixth largest market in the world with a turnover of $24.6billion in 2013. The industry is expected to grow at 12.3% CAGR during next 4-5 years to become the fourth largest global market, with sales of $42.7bn( Indiapack 2013).

Since retort pouch technology offers alternative to canned RTE foods retorted foods have the potential to tap the canned market which contributes around 60% of Indian RTE food market.

Major Players MTR Gits ITC Bambino Kohinoor Tasty Bites Satnam Overseas

Prices The prices of most of the brands in this

segment range from Rs25/- to Rs40/- for a typical 285g dish.

The Kitchens of India range of ITC comes in tin packs and is priced ranging from Rs110 to Rs150 for 450g.

Thank You for Your Time &

Patience