Have you ever looked at a curry or pet food pouch and wondered where it came from? There is a demanding step, retort sterilization, where food is cooked in its packaging for safety and durability. This flexible packaging, retort pouches, are made for extreme conditions and are designed specifically for this process. For a retort pouch manufacturer, these are more than just guidelines and regulations; they represent a commitment to do things right for the factory, and for the final product.
Flexible pouches are not all retort pouches. What sets these flexible pouches apart is their ability to endure the extreme conditions of a retort autoclaves, which are designed to contain pressurized steam at temperatures greater than 121 degrees Celsius (250 degrees Fahrenheit) for long periods of time. Such high temperature processing destroys all microorganisms, rendering the product commercially sterile. In order to withstand the conditions, these pouches must be designed perfectly in laminate structure. Such pouches are made of several layers, including an outer polyester layer that provides both protection and printability, a foil layer in the middle that works as a top notch barrier against light, oxygen, and moisture, and an inner polypropylene layer that meets food safety standards, can heat seal, and withstands the temperature without leaching. The adhesives that bond these materials must be selected to withstand the heat and their physical stresses. The seals are the weakest part of the design, so they must be perfect to withstand the quick changes in pressure and the violent movements inside the retort chamber. There can are no mistakes, as they can ruin the entire sterilization.
To make sure that every pouch is made with the highest quality assurance, there are international and local safety and quality control standards that govern the manufacturing and testing of every pouch. These rules are what suppliers of packaging and producers of food rely on to ensure safety. Most important are those that come from the U.S. Food and Drug Administration (FDA) that governs food contact materials, and standards from the International Organization for Standardization (ISO) and of the American Society for Testing and Materials (ASTM). These rules cover everything. They state which materials are approved for food contact and high-temperature processing. They spell out the specific testing required for seal strength, which may be evaluated by the use of a burst test or a tensile test that measures the amount of pull required to separate the seal. They require testing of the overall durability of the pouch, such as a drop test, that simulates a storage and transport environment, and a creep test, that measures the seal strength over time with constant pressure. For brands it is critical to choose a packaging partner who not only understands all of these rules but who also is an expert at using this knowledge.
Obtaining maximum sterility and meeting safety standards is the minimum requirement, what is really valuable is what one superior retort pouch allows. Probably the most important is product quality. The combination of rapid retort heat transfer and high-barrier properties allows food to be cooked in a more evenly and for a much shorter time than traditional metal cans. This leads to a better retention of nutrients, color, and flavor, and texture. Consumers are able to taste a fresher meal. The packaging offers practical benefits as well. Retort pouches are light and take up less room. This allows shipping and trucking to be more economical, and provides a reduction in the company's carbon footprint. Retailers and consumers alike appreciate the convenience with no requirement of a can opener. A printable pouch surface provides prime marketing space, and high quality vivid graphics can be used for better faster consumer connection. Easy peel openings and resealable pouches can also be integrated which enhances functionality. Therefore, pouches that master high temperature standards and have more creative uses than just store of food. They can be used for providing a better brand experience.
The retort packaging world is never at a standstill. It changes with the patterns in consumer behavior and technology. The most prominent motivator is the need for green packaging. The industry is looking for ways to minimize the use of materials, find alternatives to aluminum foil that are recyclable, and create packaging that is easier to recycle. Another prominent move is the trend towards efficiency and smarter systems. This includes the manufacture of new retort equipment that is better at controlling temperatures and pressure for even better quality of the products. In packaging, the use of time-temperature indicators, for visible assurance of freshness, is intelligent. With better processing techniques, the evolving standards will move even faster in meeting safety, performance, and environmental benchmarks. For brands that look to the future and wish to lead the market, the need to partner with a packaging innovator that is fully committed to this sort of R&D is a necessity. This will ensure that their products meet the high standards necessary of the future.
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