This document discusses retort pouch packaging and aseptic packaging. It describes retort pouches as a type of flexible packaging made from laminated plastic and metal foils. This allows for the sterile packaging of foods through aseptic processing, as an alternative to canning. The document outlines different retort pouch styles, materials, filling and sealing processes, defects to check for, integrity testing methods, and major players in the retort pouch industry. It also lists different types of microorganisms important to control in retorted foods through the thermal processing in retort pouches.

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