The document outlines the definition, application, materials, properties, and manufacturing processes of retort pouch packaging. It highlights the advantages of retort pouches over traditional metal cans and glass bottles, including low energy requirements and ambient shelf stability. Additionally, it details the required equipment and operational procedures for effective retort pouch processing.

1. RETORT POUCH PACKAGING
Course Outcomes
1) Definition, Application, Material and Properties required
2) Retort –Types, operating procedure and application
3) Manufacturing process of retort Pouch.
Mr.P.S.Shirahatti (GPM FC)

2. 1.1 Definition: Retort pouch is a flexible packaging which is an
alternative to metal cans and glass bottle which can withstand
thermal processing temperature up to 120 to 130°C and combine
advantage of metal can and the plastic boil-in –bag.
1.2 Application:
It provides High barrier properties, long shelf life, toughness a
puncturing resistance.
Used for packaging low acid products like meat, fish, veg.,
rice products.
 It is a rectangular, flexible, laminated plastic, four-side
hermetically sealed pouch .
Transparent type of Retort pouch Semi Rigid Retort Cups

3. 1.3 Retort pouch- Material and its Function
1. Aluminum-foil –Provide good barrier properties against
oxygen, light, moisture vapor .Those without aluminum foil
are transparent. (Al foil 7–9μm )
2. The outer polyester film -provides strength and toughness and
stable for high temp.
3. While the inner PP provides good heat-sealing properties,
strength, flexibility and compatibility with all foodstuffs. (CPP
at 70–100μm)
4. The additional incorporation of an oriented PA (nylon) -
increases the durability of the pouch, especially where the
individual pouches are not, subsequently, packed individually in
cartons. (PA 15–25μm)

4. 1.4 Retort pouch laminate layers with name of
materials
2 ply
• Nylon or polyester-
polypropylene
3 ply
• Nylon or polyester-aluminum
foil- polypropylene
4 ply
• PET/PA/AL/CPP

5. 1.5 Effective requirement of retort film material :
1. Low oxygen permeability -0CC/m2/24hr/atm.
2. Sterilization temp. stability -0 to 1500C
3. Low water vapor transmission rate- 0gm/m2/24hr
4. Heat sealabilaty-160 to260 0c
5. Thickness tolerance-+-2 micrometer
6. Seal strength 2 to 3.5 kg/10 mm
7. Busting streangh -7.5 kg/cm2
1.6 Examples of Products to be Packed in Retort
pouch.
 Sliced meat in gravy, fish, sauces, soups, vegetables, fruits,
drinks and baked items
 Foil-free pouches have been utilized particularly for vegetables
where high visibility is desirable and a short shelf life from 4
weeks to 6 months is acceptable.

6. 1.Less energy is required to manufacture pouches compared with
cans
2.Light weight of pouches
3.Production and packaging material is cheaper compare to can
4.Filling lines may be automated
5.Rapid heat penetration and faster process results in better
nutrition/flavour
6.Contents are ambient shelf stable – no refrigeration is required
7.Packed pouch is more compact requiring about 10% less shelf
space
8.Low brine or syrup used, pouches are lower in mass and cheaper
to transport
9.Opens easily by tearing or cutting
10.Ideal for single portion packaging and serving size control
11.retort pouch materials are non-corrosive
12.Convenient for outdoor leisure and military rations use.
1.7 Advantages of retort packaging system

7. 2.1 Major equipments required for Retort Packaging System
1) Boiler
2) Refrigerator
3) Retort- Steam and air (Overpressure Retort)
4) Steam jacketed kettle –Cooker
5) Retort Pouch Packaging Machine
6) Material Handling equipments

8. 2.2 Batch Retort:-
Cylindrical shell, may be horizontal or vertically operated.
Uniform heating overall surface for the success of the retorting
Pressure of stream is control as per inside temperature
requirement by automatic sensors
Provided controlling device through micro processed based control
system.

9. 2.3 Heating media:
1) Steam: Saturated or Superheated steam under pressure used.
2) Water: Water under pressure may be spray or full Immersion
system used.
3) Steam and Air: 75% steam and 25% Air under pressure used.
It is useful for glass, flexible retort pouches. In this system steam
maintain internal temperature and air control internal pressure
during processing is called over pressure processing retort.
2.4 Types of batch Retort:
1) Super heater water spray Autoclave
2) Steam water Retort
3) Full Water Immersion Retort
4) Air and Steam Mixture Autoclave with Water cooling
5) Steam Retort.

10. 2.4.1 Steam water Retort
Instrumentation and control valve systems are vitally
important to accurately control and record pressure and
temperature (+1°C to −0.5°C) during the retorting of
pouches.
Automatic process cycle control is preferred.

11. 2.4.2.Air and Steam Mixture
Autoclave with Water cooling
2.4.3.Full Water Immersion Retort
Heating by Steam and Air mixture,
Cooling by circulating cooled water
under pressure
Heating by immersion in
pressurized hot water
Cooling by cooled water

12. 2.4.4 Super heater water spray Autoclave
2.4.5 Tray for loading retort pouch inside to
autoclave
Heating by water spray under
high pressure
Cooling by circulating cooled
water with high pressure

13. 3.1 Retort Operation Cycle :
1. Retort Pouches load in to tray / Cage
2. Cage load in to retort
3. Close the retort door tightly
4. Initially drain valve open to remove internal air
5. Start the operation by injecting / spray pressurized steam and
water in to retort
6. Close the drain valve
7. Pressure rise up to pre set ( Temperature also rise with pressure)
8. Process time is controlled after the come up pressure
9. After heating time , steam is closed and water spray for cooling
under pressure
10. Cooling under air pressure carried out
11. After cooling reduce the internal pressure slowly
12. Open the retort door
13. Remove the cage and surface dry the retort pouch for stand some
time.

14. PRODUCT PREPARATION
WEIGHT AND FILLING INTO
POUCH
SURFACE DRYING AND
SECONDARY PACKAGING
PRE-FORMED RETORT
POUCH
FILLING AND VACUUM SEALING
BY MNUALLY OR AUTOMATIC
RETORTING
3.2.1 PRE-FOMED RETORT POUCH PACKAGING
 Retort Pouches- Pre-fomed
 Filling- Automatic or Manually
 Vacuum- By steam injection and sealing or
vacuum packaging
 Retorting- Heat for 121 deg. C, Hold for 30
minutes and then ,Cool to 35 C

15. RETORT FILM WEB (REEL)
AUTOMATIC BAG MAKING
MACHINE
BAG FILLING BY AUTOMATIC
AND VACUUM SEALING
RETORTING
SURFACE DRY AND
SECONDARY PACKAGING
PRODUCT
PREPARATION
3.2.2 FORM-FILL-SEAL PRTORT POUCH PROCESSING.

16. References
1. Food Packaging Technology –Richard coles
2. A Handbook of Food Packaging- Paine FA and Paine HY
3. Food Packaging Principles and Practice- Gordon L.
Robertson
4. Food Packaging Technology- R Coles, D McDowell, MJ
Kirwan
5. Food processing Technology-P. J. Fellows
6. https://youtu.be/xvnPkR25qaA (Retort Processing of
Food)

17. Thanks