Retort pouch packing, aseptic packaging

1. RETORT POUCH PACKING
&
ASEPTIC PACKAGING
OBT554
UNIT 2
Dr K.Geetha
Associate Professor, Dept of Biotechnology,
Kamaraj College of Engg &Tech, Madurai

4. Retort Pouch

6. Retort Pouch
 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.

7. Retort Pouch Styles

8.  3-Side Seal
 4-Side Seal
 Stand Up
 Stand Up Fitment
 Pre-made Form Fill Seal
Retort Pouch Styles

9. Construction
 Constructed from a flexible metalplastic laminate
that is able to withstand the thermal processing
used for sterilization.
 After filling with food, the pouch is then heated
to 116-121°C for several minutes under high
pressure inside a retort or autoclave machine.
 This process reliably kills all commonly occurring
microorganisms (particularly Clostridium
botulinum), preventing it from spoiling.

10. 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

14. Quality of Retort Food
 Safety - should be free from chemical additives and
preservatives
 High Nutritional value – proteins, fat,
carbohydrate, vitamins, minerals etc.
 GoodTaste
 Food Appeal – is the sum of sensory characteristics:
appearance, flavor, smell and texture.
 Suitability and ConsumerValue: - freshness, shelf
stability, suitability for the intended purpose and
convenience.
 Reasonable price

15. Quality of Retort Food
 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.

18. Vertical Still Retort

19. Malo Cooker/Retort

20. FullWater Immersion Retort

21. Partial Water Immersion Retort

22. Water Spray Retort

23. Steam/Air Retort

24. Hydrostatic Cooker

25. ACB HydrolockContinuousCooker

26. Shaka Retort

29. Pouch Filling
 Opening
 Filling
 2 Part
 Seal Contamination
 Evacuation
 Steam, vacuum
 Sealing
 Impulse, Constant Heat, Ultrasonic
 2 Step
 Cooling

32. Defects
 Abrasion
 Channel Leaker
 Contaminated Seal
 Puncture
 Seal Creep
 Swollen Package
 Wrinkle
 Non‐bonding
 Cut
 Fracture
 Leaker

33. Pouch Integrity Test
 Seal inspection
 X‐ray
 HVLD
 Seal strength & inspection
 Pouch burst strength
 Leak detection
 Dye
 Vacuum
 Pressure Decay
 Ultrasound

34. Soya Pea Curry

36. Major Players
 MTR
 Gits
 ITC
 Bambino
 Kohinoor
 Tasty Bites
 Satnam Overseas

38. Types of Microorganisms Important in
Retorted Foods

39. THANK YOU