PMG Newsletter (Volume 2. Issue 16)- DIGITAL.pdf

DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION
TECH-KNOWLEDGE
FOOD & BEVERAGE
INDUSTRY
ENGINEERING
& DESIGN
SCIENCE &
TECHNOLOGY
Vol .02-Issue .16-April 2023
www.pmg.engineering
A
The Official PMG Engineering Newsletter
PMG
Retort Packaging

CONTENTS
2-6
7-8
9
10-12
1. WHITE PAPER
PMG
2. INDUSTRY BUZZ
3. WEEKS HIGHLIGHT
4. DID YOU KNOW?
A. Retort technology
B. Retort Packaging
Latest Food Industry News Updates
A Look Into The Main Events Of The Week
Fascinating Food Facts To Expand
Knowledge

RETORTING TECHNILOGY
Introduction
READ MORE....
PMG
The major objective of this thermal processing is to
destroy microorganisms and to deactivate the
enzymatic activity which are responsible for
shortage of shelf life and changing of physical and
chemical properties of food. Retort consists of
basket in which packaged food is kept. Then these
food products are exposed to the sterilizing
temperature (121 Deg. C) mainly by the application
of steam and high pressure (15 psi). Compressed
air and water are used for sterilizing and cooling
for the food products respectively. Principally, it
involves seven steps
Operating Principle
a) Preparing the Retorts: Cleaning by washing
and steaming for a short time, checking the
thermometer, pressure gauge, recorder, inlet,
outlet valves etc. before loading the cans
b) Loading: Cans are Jumble stacked for better
steam circulation However, this reduces the retort
capacity by about 25% and care should be taken to
avoid denting.
c) Venting: Removal of air from the retort before
process timing begins.
d) Come-up-time: This is the time required to
bring up the retort to processing temperature after
steam is turned on. Most important thing is to see
that all air is driven out through vents before
processing starts. The vent should be closed when
process time starts.
Retorting is one of the major technique used for
the thermal processing of food products which are
packed either in semi rigid flexible laminates or in
metal or alloy cans. Retort Technology provides the
advantage of processing the food and packaging
together which makes the filled product more
commercial stable. This technique is used for
commercialization of traditional or ethnic dishes
which are important due to their delicacy and are
high in demand. It can be defined as the heating of
low acid food prone to microbiological spoilage in
hermetically sealed container to extend shelf life.
f) Blowing Down: Stopping steam supply and
opening the vents. The retort pressure should be
gradually brought to ‘zero’. Too quick blowing
down may result in buckling of cans. Open the
retort only after pressure reaches zero.
g) Unloading: Unload the cans and cool outside
promptly.

PMG
PLATE HEAT EXCHANGER
10. Water inlet and spreader: It is used for
spraying cold water on the can for cooling after
heat process is over.
11. Crates, baskets and devices: To hold the
cans.
Components of Retort
1. Steam inlet: It is a valve-controlled pipe of
suitable size and the opening through which steam
is admitted to the retort.
2. Steam Spreader: It is a pipe with perforations
for uniform distribution of steam inside the retort.
Perforated steam spreaders shall be maintained to
ensure that they are not blocked during operation.
3. Safety Valve: It is set to open, when the working
pressure has exceeded the safety limit pressure of
the retort.
4. Vent: These are large valve, openings controlled
by gate, plug cock, or other adequate valves used
for the elimination of air during the venting period
Types of Retort
5. Bleeder: It is a small opening used to remove air
entering the retort with the steam and to provide
circulation of steam in the retort and shall be open
during the entire process, including the come-up
time.
6. Drain Valve: It is an opening used to remove
the condensed or cooled steam (water). A non-
clogging, water tight drain valve shall be used;
screens shall be installed over all drain openings.
7. Pressure gauge: is used to maintain correct
processing pressure corresponding to the
temperature to show the pressure inside the retort
at all times.
8. Thermometers: To maintain correct processing
temperature and to show the temperature inside
the retort during heat processing.
9. Rails: In case of horizontal retorts only, used for
pushing the trolley.
1.Batch Retort: It can be either horizontal type or
vertical type. The retort has a lid or door with good
fastening. It has necessary controls for
temperature, pressure and safety devices. They
can also be of circular or rectangular cross section.
In batch systems, the retort is filled with product,
closed and then put through a processing cycle.
2. Continuous sterilizer: There is continuous
container handling and intermittent product
agitation. The retort system is constructed of a
series of cylindrical vessels called shells (typically
1.5 m diameter). To maintain pressure in the
shells, containers enter and exit through self-
sealing inlet and discharge valves. Product
agitation increases rate of heat penetration, allows
use of higher processing temperature (up to
138°C), and improves product uniformity and
quality.
Retort processing still relies on aggressive
application and penetration of heat throughout
foods, recent advancements in process
engineering coupled with evolution of packaging
technology have allowed for overall improvement
of the technology. Retort processing presents the
advantage of increased shelf life with less loss of
nutrients due to which it can be applied to process
ready-to-eat meals, marinades, vegetable curries,
soups and rice.

RETORT PACKAGING
Introduction
READ MORE....
Food packaging has become heart of modern food
industry, which helps to store food and beverages
in hygienic manner. Packaging is enclosure of
products, items or packages in a wrapped pouch,
bag, box, cup, tray, can, tube, bottle or other
container contributing achieve functions such as
containment, protection and /or preservation,
communications and utility or performance.
Ready-to-eat food products have dominated
packaged food Industry. Ready to eat foods (RTE)
are convenience foods, enclosed in metal
container or flexible pouches that only need to be
cut open and heated before being served. RTE food
includes wide range of ethnic food products viz.
vegetarian / non-vegetarian, basic food /
delectable desserts.
PMG
Retorting or In-bottle Sterilization is one of the
major technique used for the thermal processing
of convenient foods which are packed either in
semi rigid flexible laminates or in metal or alloy
cans. Packaging before heat treatment providing
the advantage of both processing the food and
packaging together, making filled product more
commercially stable. This technique involves
heating of food products prone to microbiological
spoilage in hermetically sealed container to extend
shelf life for commercialization of traditional or
ethnic dishes, which are important due to their
delicacy and are of high demand.
Processing techniques differ from product to
product and from package to package, hence,
retort designs and operating procedures vary.
Traditionally, metal cans were used for retort
processing however, over the years we have seen
wide usage of pouches, plastic pots and trays,
allowing more convenience, better product quality
through reduced processing time, reduction in
costs for food manufacturers and better surface to
provide intended marketing information for
consumers.
1.Type of container – Glass is not a good
conductor of heat. Therefore, product in a glass jar
takes more time to heat compared to equivalent
size/shape metal can.
2.Size and shape of the container – A large
container will take longer to heat than a small
container, hence size of container matters.
Efficiency Determining Factor
The materials of packaging must be inert, heat
sealable, dimensionally stable and heat resistant
(usually 115°C–125°C). They should have low
oxygen and water-vapour permeability and be
physically strong to resist penetration by the
foodstuff contained and abuse during handling
and storage.

Vol .01 Newsletter
PMG
Vol .02-Issue .06-February 2023
3. Retort temperature – A higher retort
temperate will result in more rapid heating but
also may lead to more over-processing of product
near the package.
4. Agitation- Agitation of the containers will
increase the heating rate by mixing the contents of
the container, especially with viscous or semi-solid
foods. End over end agitation is better than axial
agitation.
3. Type of product – Different products conduct
heat more or less easily and have different heat
capacities. Some products are more viscous than
others are which can have a particularly significant
effect in agitating retorts.
4. Headspace – insufficient headspace can also
affect the rate of heating, especially in an agitating
retort.
1. Traditional Retort Cans: The market for canned
food products continues to grow which is driven by
its high mechanical strength, the need for
convenience, appealing recyclable properties of
the cans, thermal stability, resistance to pressure
and excellent barrier properties, increase in shelf
life and food safety. Generally, tinplate (Consists
low-carbon, mild steel sheet or strip, 0.50–0.15 mm
thick, coated on both sides with a layer of tin) and
aluminium are used for metal container and
closure construction for food and drink products.
Both are relatively low-cost materials and
nontoxic, having adequate strength and are
capable of being work hardened. Cans are used for
safe preservation of low acidic food such as meat,
seafood, poultry, dairy products etc. They have
high mechanical strength but major disadvantage
associated with them is that they take more time
to transfer heat as compared to retort pouch.
3. Retort Pouch: Retort pouch is a flexible or semi-
rigid package made from heat-resistant laminated
metal - plastic, into which food products are
placed, sealed and sterilized at temperatures up to
121°C. The resulting product is then sterile and
shelf-stable. Retort pouches comes up in various
styles such as three sided seal, four sided seal,
stand up, stand up fitment and pre made form
seal. Retort pouches are used in several countries
for a wide range of processed ready-to-serve shelf-
stable products. Laminate films used for retort
pouch manufacture vary depending upon their
specific application.
Field of Applications
2. Retort Cartons: Retort cartons is a new entry
on this segment with only Tetra Recart developing
world's first retortable carton packaging system
designed for low acid, shelf-stable food products
with particles of almost any size. Tetra Recart
cartons differs from other Tetra Pak cartons as the
paperboard material used for this process are
moisture resistant. Though it resembles in having
six layer construction consisting of primary
polypropylene layer that comes in direct contact
with the product, then a second layer of an
aluminium foil, again a layer of polypropylene,
then comes paperboard (approx. 65% of
composition of packaging), again a layer of
polypropylene and lastly a lacquer protected flexo-
printed graphics that has an appealing effect and
promotes marketing.
Composition of Pouch
Mainly these flexible pouches are constructed with
4-ply laminate consisting of four layers:
1.Polyester: It offers high temperature resistance,
toughness and Printability.
2.Nylon: It acts as puncture and Abrasion
resistance
READ MORE....

Vol .01 Newsletter
PMG
Vol .02-Issue .06-February 2023
3.Aluminium: It acts as a complete barrier to light,
Gases, Microbes, odours, extended shelf life,
stiffness.
4.Food Grade Polypropylene: It can be used as
bonding and sealing layer, which gives strength
and flexibility to the pouch.
There are also disadvantages associated with
retort pouches. One disadvantage is the lack of
strength of the material compared to metal cans.
Retort pouches are much more prone to abrasions
and punctures that ruin package integrity and
potentially the product. More care and expense is
needed when packaging retort pouches. Another
disadvantage of retort pouches in the mode of
retort generally used. Many continuous agitating
retorts currently in use in industry were designed
for compatibility with metal cans, and retort
pouches cannot be processed in the same
equipment. Therefore, retort pouches are
frequently processed in less efficient still batch
retorts resulting in higher operating costs. Batch
operations are less efficient than continuous
operations because of time needed for loading and
unloading between batches.
Retort processing has evolved significantly since its
incorporation into Department of Defence and
NASA food system. While the technology still relies
on aggressive application and penetration of heat
throughout foods, recent advancement in process
engineering coupled with evolution of packaging
technology have allowed for overall improvement
of the technology.Retort processing presents the
advantage of increased shelf life with less loss of
nutrients due to which it can be applied to process
ready to meal, marinades, vegetable curry, soups
and rice.
Quality checks should be carried out on pouches:
1.Visual assessment: to check there are no
defects on the pouches both decorative and that
may have an adverse effect on the process and
shelf-life of the product.
2.Seal strength: to measure the strength of the
seal for processing and storage.
3.Burst testing: to ensure the pack has adequate
seal strength and integrity.
4.Oxygen and water transmission rates: to
measure the barrier properties of the pouch.
5.Bond strength: to ensure the pouch has
sufficient strength to prevent delamination of the
layers.
R
etort Packaging

FOOD INDUSTRY
INDUSTRY BUZZ
FSSAI creates a panel to examine
RAFT kits and applications.
Angel investors help Proost Beer raise
Rs 8.5 crore in equity and debt.
The FSSAI has established a committee to examine the use
of Rapid Analytical Food Testing (RAFT) kits, apparatus,
and procedures.
The Rapid Analytical Food Testing (RAFT) Kit, Equipment,
and Method Applications Review Committee has been
established by FSSAI as part of the RAFT Scheme.
However, before being adopted or put into practice, the
Competent Authority and the Scientific Panel on Methods
of Sampling and Analysis must accept the RAFT
committee's recommendations. The food authority must
ensure that the suggested quick kit, equipment, and
procedure adhere to international standards and meet
the Food Safety and Standard Regulations requirements.
Existing investors Dauble PTE and Dev Punj also participated
in the round, demonstrating their ongoing commitment to
the company and faith in its ability to develop. With the most
recent cash infusion, it plans to increase manufacturing
capacity, explore new markets, and meet its working capital
needs. The business is excited about using these funds to
accelerate its growth trajectory and solidify its position as
India's top brewery.
PMG
Proost Beer, a well-known player in the beer brewing sector
with a Delhi base and a Shark Tank India participant, recently
made an exciting statement on the success of its financing
round. The round, led by Mumbai Angels, Hyderabad Angels,
Speed Fund, GetVantage, Finvolve, and other illustrious angel
investors, saw the company raise Rs 8.5 crore.

Somerdale International introduces
a new line of premium cheese for
the Asia Pacific market.
2022 REVENUE GROWTH FOR CARGILL OF 23% TO $165 BILLION
Chaayos introduces the Chai Frappe,
a light takes on traditional milk tea.
The Chai Frappe, a new summer beverage, was just released
by Chaayos, India's biggest and most popular chain of chai
cafes, along with the equally distinctive and energizing
campaign #AisaBhiHoSaktaHai.
Positive results from the new study point
to the UK and Irish food systems being
decarbonized in 2023.
PMG
At FHA Food & Beverage, Somerdale International, the top
producer of British cheese to more than 50 nations
worldwide, will introduce a new, opulent line of blended
and infused Westminster-branded cheddars.
New research from Tetra Pak shows that businesses and consumers are
resolute in keeping their eyes on net zero objectives, especially those that
may be attained through the decarbonization of food systems, when
pressure on the world's food and energy supply chains is increasing.
The event, held at the Singapore Expo from 25 April to 28
2023, is anticipated to draw more than 40,000 business
travelers from the Asia Pacific region. It will give the
Somerset-based company a significant opportunity to
showcase its new line of products and 'fly the flag' for the
best dairy products produced in the United Kingdom in a
rapidly expanding export market.
Although more than a third (36%) of managers, directors, and business
owners in the food and beverage industry view the development of
sustainable packaging as crucial, new research released today reveals that
41% of these individuals now experience supply chain issues or disruption.
Raw material shortages and price hikes were the two main obstacles
preventing the adoption of sustainable packaging choices at the moment.
Twenty-four percent (24%) of respondents feel sustainability should
continue to be their organization's top priority in 2023 despite the need to
adopt more sustainable practices for food production and consumption
while lowering food waste and loss throughout the system.
It defies the common misconception that chai should only be
served hot by combining the spicy flavor of chai with the
chill, creamy goodness of frappe. The #AisaBhiHoSaktaHai
campaign encourages individuals to think outside of their
comfort zones. It promotes creativity and ingenuity by
dispelling clichés and adding an unexpected spin on what to
expect at Chaayos. A creative take on the conventional chai,
the Chai Frappe offers an incredible and decadent experience
that beats the heat. Three energizing kinds of chai frappe are
offered: caramel, dark chocolate, and magic spice.

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WEEKS
HIGHLIGHT
WORLD ART DAY
World Art Day is celebrated every year on April 15,
to promote the development, diffusion, and
enjoyment of art.
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PMG
15 APRIL
The festival of Baisakhi is celebrated on 14 April.
This festival marks the onset of spring in India and
also the start of Punjabi New Year. The time of
Baisakhi usually signifies the end of the harvest
season, and is an occasion of tremendous joy and
festivity for farmers.
VAISHAKI
14 APRIL
19 APRIL
World liver day is observed on April 19 every year,
to spread awareness about liver-related diseases.
The liver is the second largest and the most
complex organ in the body, except the brain. It is a
key player in the body's digestive system.
WORLD LIER DAY

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Vol .01 Newsletter
DID YOU KNOW?
Fact 1
Fact 2
1/2 2/2
PMG
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Cauliflower naturally comes in multiple colors. Green (also known as
Broccoflower), purple, and orange coloured cauliflower are available. Although it
does not have the same appearance as the popular white cauliflower, it has the
same flavour: mild, sweet, and nutty. Orange and purple cauliflower contain
more antioxidants than white cauliflower.
The winemaking process, particularly the fining process, frequently includes
small amounts of substances that vegetarian and vegan consumers may find
objectionable. Because many of these ingredients are derived from animal
bones, intestines, or other byproducts, not all wines are suitable for vegans or
vegetarians.
1/2 2/2

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Fact 3
PMG
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Consumption of sugary and artificially sweetened beverages has been linked to
cardiometabolic risk factors, which increase the risk of cerebrovascular disease
and dementia. In the study by FHA (Framingham heart study) 2,664 participants
were found to be 1.91 times more likely to develop Alzheimer's disease if they
consumed one to seven servings of sugar-sweetened beverages per week.
1/5 2/5

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Fact 4
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Analysis of herbs and spices is a critical process in
ensuring their quality, safety, and efficacy. There are
several methods used for analyzing herbs and spices,
including sensory evaluation, chemical analysis, and
microbiological analysis. In addition to these
methods, there are also various regulations and
standards that govern the analysis and quality of
herbs and spices.
4/5

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