A PROJECT REVIEW REPORT

ON

Retort Packaging

Submitted in the partial fulfillment for the award of

Post Graduate Diploma in Packaging (Semester-I)

2021 – 2023

To

Submitted by

Harsh Rana
Roll No. : PG/M/21A/021

Under the guidance of

Dr. Babu Rao Guduri,

HOD: Training & Education Department
Indian Institute of Packaging
E-2, MIDC, Area, Andheri East, Mumbai – 400 093
April, 2022
 INDEX

Chapter Content Page No.

1 Abstract 1

2 Introduction 2

3 Literature Review 3

4 Conclusion 23

5 Reference 24
 ABSTRACT
From 1950 to 2022 the retort packaging had come a long way in the field of
packaging. In the field of packaging, Retort packaging had made its own market along
with tin container, glass container and tetra pack. The pouch is made of 2 - 4
laminates consisting of a combination of layers like PET, Nylon, PP and Al foil.
Various laminates have different characteristics and barrier properties and their
combination provide retort pouches. Steam sterilization of the retort pouches is done
at 121-degree Celsius in autoclave. Retort packaging is mostly used in the food
packaging for MRE and Ready to cook products like idle mix, Gulab jam mix, sauces
etc. Amcor Amlite Heat flex and 3 compartment pouches are the latest innovations in
the retort packaging

All the data in the project report has been collected from various articles,
information videos, websites and pdfs and aggregated together. Global value of retort
packaging is also studied as per the latest data.

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 INTRODUCTION
The packaging industry is always looking for ways to extend shelf-life and preserve
foods. Packaging is a global industry of high diversity. There is growing scientific
interest on packaging that come into contact with food products. As a result of the
growing consumer interest in the consumption of fresh produce with extended shelf
life and maintained quality, producers have to provide advance and safe packaging.
Consumers like to see new products and will buy things if they are more convenient.
The Retort pouch is perfect for the consumer and the producer.

The retort pouch is a very demanding packaging that consists of a three-layer

laminate that may be composed of an outer layer of polyester film, a middle layer of
aluminum foil, and an inner layer of modified polypropylene. A retort pouch is a thin,
lightweight, flexible laminated plastic package used to hold processed foods. The
lightweight packaging also provides cost savings and production efficiencies when it
comes to the sterilization processes. Retort pouches comes with the variety of
features, giving you the opportunity of choose packaging solutions that work well
with your products and most directly meet the needs of your customers. It saves
shelf space and creates an overall attractive product display.

A Retort Pouch as “a flexible package in which prepared food is hermetically sealed

(air tight) for long-term unrefrigerated storage” (1977 Webster). Retort is a process
that uses heat and pressure to cook food in a strong, sealed package. It is most
acceptable form of food preservation in rigid, semi rigid and flexible packaging
system. The material used in retort pouch must also provide superior barrier
properties for long shelf, seal integrity, toughness and puncture resistance. They are
made of heat resistant plastics thus retort at temperature of around 121°C normally
encountered in thermal sterilization of food.

In retort packaging, food is filled into a pouch or metal can, sealed and then heated
to extremely high temperature, rendering the product commercially sterile. Retort
vessel used for distillation of substance that are placed inside and subjected to heat.
This technology allows us to assemble and cook the ingredients within the package.
Therefore, the product become shelf stable for eighteen months. Retort pouch is
better than other forms as it is easy to open “notch” has eliminated the need to use
can openers and reduces the risk of cuts after opening. Labels can be printed into the
laminate, making them permanent. Flexible pouches are easier to distribute and
therefore have lower transportation costs and require less disposal space. Storage
space for empty flexible pouches is also reduced. It is use to cook food ready for
consumption. Retort packaging have lots of advantages and on the other hand it has
some of the limitations.

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 LITERATURE REVIEW
Structure of Retort pouch:

The structure of laminate film depends on the

application, most pouches are either are 3 or
4 ply laminates with an inner layer in contact
with the food of polypropylene a barrier layer
of aluminum EVOH silicon oxide as IOX or
aluminium oxide ALOX a polyamide, nylon
layer on an outer polyester layer.

The polypropylene provides the critical heat,

seal integrity, flexibility, strength & taste and
odour compatibility with a variety of food
products. The inherent characteristics of
polyester and polypropylene enables the
img 2 Layers of Retort Pouch
pouches to be processed at up to 135 oC or
275oF.

The aluminium foil can be laminated using the matte or shiny side exposed to view normally
the matte side is to be outside. Aluminium foil provides a barrier to light and gas for
extended shelf life.

The Nylon layer gives strength and puncture resistance.

The polyester film is used for high temperature resistance, toughness and printability. The
polyester film may be reverse printed that is ink is embedded between the film and foil.

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 Requirements for a pouch film are:

1. Gas permeability less than 15 ml / m2 / 24 / atm.

2. Water Vapor Transmission Rates (WVTR) less than 0.8 g / m2 / 24 / atm.
3. Resistance to temperature from below 32o F to at least 250o F.
4. High hydrophobic properties.
5. Low cost of material and package fabrication.
6. Suitability for food use.
7. Resistance for fats and oils.
8. Heat sealability over wide range of temperatures.
9. Chemical inertness and dimensional stability.
10. Good heat penetrability and capacity to being handled on automatic fabricating
and filling equipment.
11. Physical strength to resist handling abuse.
12. Good durability, printability and consumer appeal.

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Effective requirements of retort films:

 Low oxygen permeability- OCC/m2/24 hr/ atmosphere.

 Sterilization temperature- 0 o c - 150 o c.
 Low water vapour transmission rate- 0 gm/ m2/ 24 hr.
 Heat saleability- 160 o c to 260 o c.
 Thickness tolerance- ±2 micrometre.
 Seal strength- 2 to 3.5 Kg/ 10 mm.
 Bursting strength- 7.5 Kg/ cm2.

img 3 Structure of 4-ply and 3-ply retort pouch

PROPERTIES OF RETORT PACKAGING MATERIAL:

 PROPERTIES OF POLYPROPYLENE:
1. High stiffness/rigidity & high tensile strength.
2. Highest resistance to chemical among poly olefins.
3. Good ESCR.
4. High heat resistance.
5. Integral-Hinging properties.
6. Density: 0.88-0.90 g/cc.
7. Tg: -10o C.
8. Tm: 160o – 170o C
9. WVTR: 590 g µm/m2 day at 37.8oC, 90%RH.
10. Water absorption: 0.01- 0.03%.
11. Tensile Strength: 31-42 MPa.
12. Tear Strength: 50g/25µm.

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 PROPERTIES OF ALUMINIUM FOIL:
1. It has excellent barrier function hence keeps out air, light, micro-organisms,
fats, volatile compound and water vapours to preserve food.
2. It has heat conductivity, hence ideal for defrosting, warming up and cooling
food.
3. Melting point of 660oC and thickness of 200 µm and below is achievable.
4. Non- toxicity.
5. Corrosion resistance.
6. Tasteless and odourless.
7. Good compatibility with food and chemicals.

 PROPERTIES OF NYLON (PA):

1. High Barrier.
2. Aroma retention.
3. Good puncture resistance.
4. High bursting strength.
5. High mechanical properties.
6. Excellent printability.
7. High chemical resistance to oils & fat.
8. Can be bi-axially oriented.

 PROPERTIES OF NYLON 6,6:

1. Density: 1.14 g/cc.
2. Tg :: 60o C.
3. Tm : 255oC.
4. WVTR: 1750-3000 g µm/ m2 day at 37.8oC, 90% RH.
5. Water Absorption: % 24hrs 2.8
6. Tensile Strength: 90MPa.

 PROPERTIES OF NYLON 6:
1. Density: 1.05 g/cc.
2. Tg: 50o C.
3. Tm:
200oC.
4. WVTR: 1750-3900 g µm/vm2 day at 37.8oC, 90% RH.
5. Water absorption: % 24hrs 3.0
6. Tensile Strength: 80MPa.

 PROPERTIES OF POLYSTER:
1. Highly desirable due to its good and easy printing.
2. High yield strength.
3. Low water absorption.
4. Low gas permeability and resistance to chemical attack
5. Can be used with various laminates and films
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PROCESS OF RETORT PACKAGING IN AUTOCLAVE

Previously the lid of the

autoclave machine is
closed with normal
atmospheric conditions.

The door is opened so

as to fill in with retort
pouches container or
pellets

Pallets of Retort
pouches filled with the
food products are
placed in side the
chamber.

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The door is then
locked for the further
process.

Since while feeling

the pellets of retort
pouches air also gets
trapped inside the
space and so as to
remove this air
present steam is
injected into the
space.

For the proper

circulation of steam
fans are rotated so
as to move steam in
each corner of
space and get filled
in.

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As the steam is
filled in the space
then the venting
valve is opened so
as to gush out the
air from the heating
chamber.

After opening the

venting valve, the
chamber is heated
so as to reach
from 100 to 121
degree clecius.

Venting valve is
then closed and
the temperature
and pressure is
maintained for the
sterilization of
product. 100-200
for 30 min is
general
sterilization.

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As the
sterilazation
process is
commenced,
immediate
release of pre-
cooling water is
done in chamber
so as to prevent
the food product
from getting over
heated or over
cooked.

Shower of water
is also performed
so as to dissipate
any extra heating
and to provide
uniform cooling
of the pouches.

Injection of cold
water is then
perfomed by
showering over
the pouches for
completely
rendering any
heat in the
product.

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 Now the pressure
valve is opened so as
to remove the
internal pressure
present during the
process.

The pellets are then

drained of water and
then are ready to e
taken out of chamber
by opening the door.

After removing of one

batch the chamber is
againg prepared for
another batch

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 Retort pouch manufacture containers are loaded into the chamber. The retort lid is
sealed. Venting stage air trapped inside the retort is removed prior processing, if air is
present at a given pressure the temperature inside the retort will be lower that attained by
steam alone, a mixture of air and steam may stratify leading to cool spots where there is air.
This mixture is less efficient heat transfer medium then steam alone. Air in retort cuts down
the heat penetration of steam by insulating the cans and can accelerate external corrosion.
When venting is completed the venting valve closes and pressure begins to build up in
retort. When process temperature is reached the thermometer and pressure gauge reading
must agree pressure range in retort operation. High acid foods pH less than 4.5 are usually
processed at low pressures of around 3-4 Kpa low. Acid foods pH greater than 4.5 are
processed at 73 or 103 Kpa.

The time from when the steam is turned on to when the process temperature is reached is
the come-up time, once this has finished the process begins. Process time is from the end of
the come up time to the commencement of cooling during cooling the overcooking, cooling
there are two methods of cooling for small cans at temperature less than 116 degree Celsius
atmospheric cooling may be used, for large cans with a diameter greater than 6 centimetres
are processed at the pressure around the container is maintained by compressed air during
the addition of water the water addition causes the steam to condense and pressure
outside the package drops suddenly as the internal pressure inside the container does not
drop until the contents cool steam deposition may occur if the external pressure is not kept
high critical factors thermal processing of flexible containers

The major critical factors that affect thermal processing of retort containers are as follows:

 Minimum head space.

 Product consistency.
 Maximum filling or drained weight.
 Initial temperature.
 Processing temperature.
 Temperature distribution.
 Container orientation.
 Residual gas in headspace and in food.
 Processing and racking system.
 Processing machine.
 Saturated steam.
 Water with air pressure for cooling.
img 4 Autoclave Machine
 Steam slash air.
 Overheating air pressure.
 Product heating rates.
 Materials from which pouch is constructed.
 Divider strip hole sizes and spacing.
 Possibly other factors.

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RETORT PACKAGING IN FOOD
The main reason for the spoilage of the food is due to the action of microorganism. The
thermal processing can easily destroy the harmful microorganism. The main aim of the
thermal processing of the food is to kill all the microorganism and make the food
“commercially sterile”.

Retort packaging are defined by ASTM “Those capable to withstanding specified thermal
processing in a closed retort at temperature over 100-degree Celsius”. Retort package is used
to describe a flexible or semirigid package into which food products are placed, sealed and
sterilized at temperature more than 100-degree Celsius. Usually, food with pH above 4.5 is
packaged by this process. They are sterile and shelf-stable.

Retortable packaging maintains the product’s integrity as well as their required barrier
properties for the designated product during package handling, thermal processing and
transport abuse. For the food products need to be stable it must have extended barrier
properties against such effects as light, moisture, oxygen, microbial penetration etc.

The selection of the polymer and combination is based on the requirement of barrier
properties. Retort package are available in the form of flexible pouches of co-extruded and /
or laminated films of PET, PP, and PC with aluminum foil, thermoformed when it comes to
trays and containers by injection blow moulding process. It has the advantage of combining
shelf stability of canned food with texture and nutritive value of frozen food.

Retort packaging is the multilayer plastic films with or without aluminum foil. These pouches
are the heat resistant flexible packaging which can withstand the rigors of handling and
distribution with desired shelf life.

The typical retort pouch materials currently used are:

1) 9 to 25 microns polyester / 9 to 25 microns aluminum foil / 50 to 85 microns

polypropylene

2) 15 to 30 microns polyamide / 50 to 75 microns cast polypropylene

3) 12 microns polyester / 9 microns aluminum foil /15 microns-oriented polyamide (nylon 6) /

50 microns polypropylene.

The 3-ply laminate consisting of PET/ Al foil / PP is the most commonly used in
retort pouches and the only type which is used in India at present. PET is the outer layer of
about 12 microns, which gives required strength to the pouch. PET with its excellent glossy
surface and printability, is reverse printed so that inks are embedded between the outer layer
and the next inner layer to give striking graphics. Aluminum foil used in the thickness of 9 to
25 microns serves as the barrier layer, which is responsible for the shelf life of more than one
year obtained for the product. Polypropylene used as the inner layer usually in the thickness
of about 75 microns provides the critical seal integrity, strength and taste and odor
compatibility with a variety of food products.

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Other materials commonly used in retort pouch structures include nylon, silica coated nylon,
ethylene vinyl alcohol (EVOH) and polyvinylidene chloride (PVDC). Nylon has limited
barrier properties and in combination with PP, it is used for products that do not require more
than 3-6 months shelf life.

These pouches are designed such that they can withstand retort temperature and pressure.
During retorting, pouches are carefully laid on racks to maximize heat transfer and minimize
potential damage to seal or foil structure within the retort; this is usually, but not always
accomplished by water immersion. Retorting heat-sealed pouches is a delicate balance
between effecting heat penetration and avoiding fusion heat seal bursting. Retort pressure is
controlled very carefully to counter steam pressure developed within the pouch from the
heating internal steam pressure during cooling portion of the cycle.

The basic requirement of the retort film are as follows:

 Low gas (oxygen) permeability

 Low water vapor transmission rate

 Resistance to temperature from 0 – 121o C to cover storage condition exposures and the
minimum sterilization level for low acid products.

 Inertness in terms of resistance to penetration by food components and low migration

of the film components in conformance with food and drug regulations.

 Heat seal ability and capability of being handled on automatic fabricating and
filling equipment.

 Good ageing properties.

 Physical strength to resist any handling abuse during manufacturing and

during distribution cycles.

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 Semirigid Retortable Thermoformed Container

img 5 Layers in Retort Container

These semi-rigid plastic containers are a tray or tub with a supporting body and a
peelable lid. Thermoforming, cold impact forming and co-extrusion have recently
advanced the state-of-the-art of retort packaging. Originally, the trays were made of
aluminium foil, laminated with CPP as the exterior layer. Recently, high barrier
plastics have replaced this in order to be micro-oven able. Two plastics that are being
used are PVDC (saran) and EVOH. The lidding material generally comprises of a
laminate of PET/Al foil/CPP. The primary structure of these containers is PET/EVOH
or PVDC/CPP sandwiched with appropriate tie layers and fillers. The RTF (rotary
thermoformed) process co-extrudes multiple layer sheeting directly on to a rotary
drum where it is thermoformed into multi-cavities whilst the sheet is still above the
melt temperature of polypropylene. Cooling occurs during thermoforming and the
formed sheet passes directly to a filling and lidding station prior to being severed into
individual containers. The structure may contain 2 – 8 layers in thickness from 6 – 80
milli (0.006 – 0.080) inches. A typical RTF container has seven layers: Polypropylene
/ regrind / adhesive tie-layer / EVOH / adhesive tie layer / regrind / polypropylene.

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Various Shapes of Retort Pouches

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Processing of Food in Retort Packaging

1) Printing: The first step in manufacture of laminate for pouches

involves printing the polyester film.

2) Filling: Filling the pouches with raw material is the first step in the process.

3) Air Removal: Removal of air from the filled pouch is done to remove the bulk
of the air from retort pouches before they are sealed.

4) Sealing: By impulse sealing.

5) Traying: After the pouches are sealed, it is transferred to a retort rack or tray
on which each pouch is accommodated in a separate compartment or slot.

6) Processing: The pouches are then autoclaved.

img 6 Example of MRE (Meals Ready to Eat) Retort Package

The convenience food could be basically classified into two categories

A. Shelf - stable convenience food

B. Frozen convenience food

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 Shelf-stable convenience food is further classified as:

i) Ready to Eat (RTE) and Ready to Serve (RTS) food -e.g., Idlis, dosas, pav bhaji,
meat products like precooked sausages, jam, chicken products, curries, chapattis,
rice, vegetables like aloo-chole, navaratna kurma, chana masala etc.

ii) Ready to Cook food _ e.g., Instant mixes like cake mixes, Gulab jamun mix,
Falooda mix, ice-cream mix, jelly mix, pudding mix etc. Pasta products like noodles,
macaroni, vermicelli etc.

Why Ready to Eat Foods???

 Globalization of Indian food and its culture are the core factors for popularization
of ready to eat foods. Main motivation for these ready to eat foods is fast
growing foreign market.

 Retail outlet culture is now growing rapidly in India. Shelf life of these foods are
at least 12-18 months, quality, taste, and flavors of these foods remains as good as
fresh up to the expiry date.

 Women wanting to spend more time out of the kitchen.

 Cost effective in comparison to the Indian cuisine served by the restaurants in

foreign countries

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MARKET STUDY
Global Retort Packaging Market is segmented based on Packaging Type, Material,
Application and Region. Based on Packaging Type, the global market has been
segmented into pouches, trays, cartons, and others. In 2018 the overall market share
of of pouches was around 52.86% of the world, with a market value of USD
16,873.29 million. It is predicted to grow at 6.9% CAGR during the upcoming
period. Based on Material, the global market has been segmented into paper &
paperboard, aluminium foil, polypropylene, polyester, and others.

Global Retort Packaging market by Regions, 2018

img 7 Retort Packaging used world wide

Europe covers the UK, Germany, France, Spain, and the rest of Europe. All the
regions mentioned above covers the largest share of the retort packaging. Several
largest companies like Mondi Group, Clondalkin Group, and Austria, which supports
the growth of the retort packaging as per the need of the developing regions. Europe
is one of the largest regions with 36.36% worldwide where retort packaging is mostly
preferred, owing to factors such as increased investment by the companies in the
packaging of food and beverage and pharmaceutical products. The retort packaging
market in Asia-Pacific is expected to have a steady growth, due to the high demand
for fast-moving consumer goods (FMCG). FDI (Foreign Direct Instance) in retail has
further widened the scope for packaging, which attracts foreign players to establish
their facilities in the region. The increasing demand backs the growth of the retort
packaging market in the region for packaged food and beverage items in growing

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countries such as China and India, primarily due to the increasing per capita
disposable income.

The growth of the market share always depends on the companies those are investing
in market, market environment, and regulations. Thus, these companies should
continue to consider enhancing their offerings and expanding their presence. Amcor
PLC (Australia), Mondi (Austria), Sonoco Products Company (US), Sealed Air
Corporation (US), and Winpak Ltd (Canada) held nearly 41.00% of the market share
in 2018. PROAMPAC (US), Constantia Flexibles (US), Clondalkin Group
(Netherlands), Coveris Group (Austria), and Clifton Packaging Group Limited (UK)
are some of the other key players operating and increasing in the global retort
packaging market share. Statistics Bureau of Japan, the retort packaging market is
expected to reach USD 1.76 billion by 2023.The increasing consumption of the baked
food is also influencing the market. According to the report by US department of
agriculture, the consumption of these food has been increasing in India up to 3.07
million metric tons in 2019. The demand of the processed food products in India is
growing at the rate of 22-25% per annum as per the data of the Packaging Industry
Association of India (PIAI). India has 32% of the country’s total process food product
market. Due to the COVID-!9 outbreak had affected the jute mill production, thereby
disrupting the production of the jute bags. Hence it is supporting the growth of the
retort pouches within the country.

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Advantages of Retort Packaging:
Retort pouches combine the advantage of metal can with the frozen, boiled in the bag.

The attributes of flexible containers offer benefits for the consumer retailer and many
factors like-

1. The thin profile of the pouch or container provides rapid heat transfer for both
preparation and sterilization during processing. A 30- 40 % reduction in processing
time is possible with energy saving.
2. Reduced heat exposures result in improvement in the colour, flavour there are also
fever nutrient losses.
3. Preparation of product that need to be heated to serving temperature can be
accomplished in 3 to 5 mins by immersing pouch in boiling water or container
in microwave oven.
4. Storage space of retort pouch or container in a paperboard carboard is not larger
than for cans, disposal space is also less equivalent to that of foods in metal cans.
5. Shelf life of retort pouch product is equivalent to that of foods in metal can.
6. Refrigeration or freezing is not required by packers, retailer, or consumer.
7. Pouches or containers do not corrode externally and there is min of
product container interaction.
8. Opening pouch requires only tearing pouch across the top of the notch in side
seam or by using scissors. The container lid may be peeled open by using knife.
9. The flexible container is safer as the consumer could not be cut as in case of metal
can, or be faced with broken glasses with glass jars.
10. Empty retort pouches and nesting containers offer processes of reduction in storage
space and lighter weight compared with empty cans and an equal number of retort
pouches use 85% less space and are significantly lighter.
11. Advantages for the retailer include savings and shelf space and the shape makes
it easier for the retailer to handle and display the product.
12. The use of a flat carton or an over wrap to hold one or two pouches provide for
better product identification on the shelf than cans. The pouch also offers the
opportunity to market multipacks.
E.g.: Entrée in one pouch and accomplishment such as rice in another.
13. Energy requirement for container construction is less than that for cans.

Disadvantages of Retort Packaging:

1. Thermal processing of flexible container is more complex have to be established
for each product in the particular type and size of container
2. The filling & sealing equipment and thermal processing systems for flexible
pouches are generally more expensive than for cans.
3. Filling is slower and more complex.
4. There are limitations in size of containers that can be handled and processed.
5. Retort pouches at present require over wrapping such as a carton and may be
required for semi grid containers.
6. Since the pouch is a flexible container, the detection of leakage is more difficult than
with conventional type container.
7. Pouches and semi rigid containers may be punctured.
8. Products in the pouches may lose their shapes

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CONCLUSION

 The entry of Retort packaging is highly flourishing with its benefits

far compared to that over the can and other rigid or semi-rigid
packaging.

 Retort pouches and containers are proving to be a tough competitor to the

previously established can and glass packaging due to its high flexibility
and easy storage also with ease in transportation.

 Retort packages can also be recycled now as per the research conducted
in Netherland, overcoming its previous drawback.

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REFERENCE

1. http://ecoursesonline.iasri.res.in/mod/page/view.php?id=147994#:~:text=Retort%2
0is%20a%20cooking%20process,C%20to%20130%C2%B0C.
2. http://ecoursesonline.iasri.res.in/mod/page/view.php?id=6219
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liquor?gclid=CjwKCAiAhbeCBhBcEiwAkv2cY4xKt4b_I2rUA5GA-
IALnbcHQQhDUFvtNFIp6o_1vJZlFgbkSq8fdxoCUiEQAvD_BwE
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chavan?from_m_app=android
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chavan?from_m_app=android
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products?from_m_app=android
8. https://en.wikipedia.org/wiki/Meal,_Ready-to-Eat
9. https://en.wikipedia.org/wiki/Retort_pouch#Origin
10. https://images.app.goo.gl/6eaZab7XBNAVnsje8
11. https://images.app.goo.gl/6eaZab7XBNAVnsje8
12. https://images.app.goo.gl/axfgwsDpB4uwLH9f7
13. https://images.app.goo.gl/rQaQnYwmWErdhQNU6
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packaging+milk+products&qst=ib#
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19. https://www.globenewswire.com/news-release/2021/01/08/2155624/0/en/Global-
Retort-Pouch-Packaging-Market-2020-to-2025-Growth-Trends-and-Forecasts.

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