BENEFITS OF RETORT TECHNOLOGY

Retort: The Legacy

 200 Year Old Invention
 Conventional retort practices using
pressurized high temperature water,
steam or air
 Nicolas Appert started first commercial
canning operations in 1804.
 Can opener was invented after
100yrs although we don’t need it
anymore!
 What Is Retort Sterilization?
 Sterilization of product by heating above 100C, typically at 121C
 Exact sterilization temperature and time (holding) depends on
- Type of product: pH, microbial load, heat sensitivity
• Used for Low Acid food with pH above 4.2
- Efficiency of heat penetration in the product
- Package Shape & Size
- Efficiency of retort for heat uniformity and heating rate
Types of Retort
By mode of Heating By mode of Agitation
 Steam & Air  Static
• Steam NO circulation  Rotary (along shaft)
• Steam with circulation
 Oscillation (along shaft)
 Water Cascade
 Oscillation (horizontal)
 Water Spray
 Shaking (horizontal) – high frequency
 Water Immersion
 Steps Involved In Retort Processing

 Product preparation
- Need to adjust precooking to compensate for cooking during sterilization
- Select ingredient to minimize heat damage
 Filling & sealing
- Select speed suitable to pack for one batch load in less than 45mins
• Cold fill, Ambient fill, Hot fill
 Retort Sterilization
- Heat, Hold, Cool while controlling OVER / COUNTER PRESSURE
Retort Sterilization: Heating

 Vessel is heated from ambient to sterilization temperature (usually 121C)

 Product lags vessel temperature as heat slowly penetrates into the product
 Pressure inside the package lags pressure inside the vessel
 Heating can be designed in multiple steps to minimize temperature lag,
optimize heat penetration, cook uniformly, reduce cycle time
- Consider phase change temperature as pressure changes rapidly
 Retort Sterilization: Holding
 HOLD mode is started once vessel sterilization temperature (usually 121C)
is achieved
- Still heating is required as product absorbs heat from the vessel
 Duration of HOLD mode is determined by time required to achieve required
sterility (Fo) of the product
 Overpressure is maintained in the HOLD mode
 Retort Sterilization: Cooling
 Once desired sterility (Fo) is achieved, cooling is started
 Vessel is cooled from sterilization temperature (usually 121C) to ambient or
lower temperature
 Product temperature is higher than vessel temperature as heat is slowly removed
from the product
 Pressure inside the package is higher than pressure inside the vessel
 Cooling can be designed in multiple steps to minimize temperature lag, optimize
heat removal, minimize product thermal damage, reduce cycle time
- Consider phase change temperature as pressure changes rapidly
Where is the Cold Spot?
How to find the Cold Spot & Validate?

www.ellab.com
www.tmi-orion.com
 Selection of Thermal Processing Conditions
 To be sure of commercial sterility the Fo value at the thermal centre of the retort
& container, must be sufficient to kill all Clostridium botulinum and
 Reduce survival probabilities for other more heat resistant bacteria to an
acceptable level.
 “Worst case” scenario on which product safety must be based
• Highest fill weight in the package
• Largest particle of highest microbial load food ingredient
• Cold spot in the package at the Cold spot in the retort

Sterilizing Symbols (D, z, F): http://www.fda.gov/ICECI/Inspections/InspectionGuides/ucm070835.htm

CANNING PRINCIPLES: http://www.fao.org/docrep/003/r6918e/r6918e02.htm
Products from Retort Sterilization Process
Products from Retort Sterilization Process
RTE Export Market Stats

MOFPI (foodprocessingindia.gov.in)
 Benefits of Retort Technology
• Retort packaged items don't require
refrigeration.
 Benefits of Retort Technology
• Retort packaged items don't require
refrigeration.
• Free from chemical additives and
preservatives.
 Benefits of Retort Technology
• Retort packaged items don't require
refrigeration.
• Free from chemical additives and
preservatives.
• Shelf Appeal and Handy portion
packs.
 Benefits of Retort Technology
• Retort packaged items don't require
refrigeration.
• Free from chemical additives and
preservatives.
• Shelf Appeal and Handy portion
packs.
• Can place product across the globe
 Benefits of Retort Technology

• Retort sterilization is a must if one has to

export RTE/ RTC food.
• Widely accepted by US, EU, JPN and other
regulatory bodies.
• Long Shelf life (ranging 6 to 18 months)
creates opportunities for exports.
 Benefits of Retort Technology

• Retort sterilization is a must if one has to

export RTE/ RTC food.
• Widely accepted by US, EU, JPN and other
regulatory bodies.
• Long Shelf life (ranging 6 to 18 months)
creates opportunities for exports.
• Food for the front line workers in challenging
situation.
 Benefits of Retort Technology
• Retort sterilization is a must if one has to
export RTE/ RTC food.
• Widely accepted by US, EU, JPN and other
regulatory bodies.
• Long Shelf life (ranging 6 to 18 months)
creates opportunities for exports.
• Food for the front line workers in challenging
situation.
• Packed food helpful during the disaster.
 Benefits of Retort Technology
• Retort sterilization is a must if one has to
export RTE/ RTC food.
• Widely accepted by US, EU, JPN and other
regulatory bodies.
• Long Shelf life (ranging 6 to 18 months)
creates opportunities for exports.
• Food for the front line workers in challenging
situation.
• Packed food helpful during the disaster.
• Single serve packs in trains/ flights.
 Thank
You
Contact Info
india@eka-global.com
info@eka-global.com
www.eka-global.com