Retort pouch

Last updated
A Meal, Ready-to-Eat (MRE), a field ration that uses a retort pouch as packaging FEMA - 37706 - MRE (Meals Ready to Eat) package held by a resident in Louisiana.jpg
A Meal, Ready-to-Eat (MRE), a field ration that uses a retort pouch as packaging

A retort pouch or retortable pouch is a 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. Retort pouches are used in baby and toddler food, camping food, field rations, fish products, [1] instant noodles, space food [2] sports nutrition and brands such as Capri-Sun and Tasty Bite.

Contents

Some varieties have a bottom gusset and are known as stand-up pouches.

History

In 1968 Otsuka Foods Company of Japan became the first company in the world to commercialize a retort food product. The product was a Japanese curry called "Bon Curry". Curry became a food that could be stored for long periods of time and like instant noodles, could be eaten after being cooked for three minutes. [3] [4] Since detailed technical information on the retort pouch, which was a military technology, was not publicly available, Otsuka Foods Company developed it in cooperation with a Group company that developed intravenous drugs using high-temperature sterilization technology. [4]

The current form of the retort pouch was invented by the United States Army Natick Soldier Research, Development and Engineering Center, Reynolds Metals Company, and Continental Flexible Packaging, who jointly received the Food Technology Industrial Achievement Award for its invention in 1978. [5]

Construction

A retort pouch is constructed from a flexible metal-plastic laminate that is able to withstand the thermal processing used for sterilization. The food is first prepared, either raw or cooked, and then sealed into the retort pouch. The pouch is then heated to 240-250 °F (116-121 °C) for several minutes under high pressure inside a retort or autoclave machine. The food inside is cooked in a similar way to pressure cooking. This process reliably kills all commonly occurring microorganisms (particularly Clostridium botulinum ), preventing it from spoiling. The packaging process is very similar to canning, except that the package itself is flexible. The lamination structure does not allow permeation of gases from outside into the pouch. The retort pouch construction varies from one application to another, as a liquid product needs different barrier properties than a dry product, and similarly an acidic product needs different chemical resistance than a basic product. Some different layers used in retort pouches include:

This multi-layer structure prevents the retort pouch from being recycled into other retort pouches or food packaging. However, the material can be recycled into an aluminized resin or up-cycled into textile materials. [6] The weight of a pouch is less than regular cans or bottles, and the energy required to produce each pouch is less than competing packaging from metals, paper, and glass.

Reception

In the consumer market, retort pouches have gained great popularity outside of the United States, particularly in the Pacific Rim region. However, American consumers have evidently demonstrated reluctance regarding the packaging technology and adoption has been slow. As a result, many retort packages sold in the United States are packaged in cartons to give them an appearance more familiar to consumers. Tasty Bite products are an example of a retort pouch product packaged in a carton. Several American food distributors have begun manufacturing foods in retort pouches without cartons, notably tuna canning companies as Chicken of the Sea and Bumble Bee and baby/toddler food companies as Plum Organics.

See also

Related Research Articles

<span class="mw-page-title-main">Smoked salmon</span> Preparation of salmon

Smoked salmon is a preparation of salmon, typically a fillet that has been cured and hot or cold smoked.

<span class="mw-page-title-main">Flexible electronics</span> Mounting of electronic devices on flexible plastic substrates

Flexible electronics, also known as flex circuits, is a technology for assembling electronic circuits by mounting electronic devices on flexible plastic substrates, such as polyimide, PEEK or transparent conductive polyester film. Additionally, flex circuits can be screen printed silver circuits on polyester. Flexible electronic assemblies may be manufactured using identical components used for rigid printed circuit boards, allowing the board to conform to a desired shape, or to flex during its use.

<span class="mw-page-title-main">Packaging</span> Enclosure or protection of products for distribution, storage, and sale

Packaging is the science, art and technology of enclosing or protecting products for distribution, storage, sale, and use. Packaging also refers to the process of designing, evaluating, and producing packages. Packaging can be described as a coordinated system of preparing goods for transport, warehousing, logistics, sale, and end use. Packaging contains, protects, preserves, transports, informs, and sells. In many countries it is fully integrated into government, business, institutional, industrial, and for personal use.

<span class="mw-page-title-main">Carton</span> Type of domestic container

A carton is a box or container usually made of liquid packaging board, paperboard and sometimes of corrugated fiberboard. Many types of cartons are used in packaging. Sometimes a carton is also called a box.

<span class="mw-page-title-main">Plastic bag</span> Type of container made of thin, flexible, plastic film, nonwoven fabric, or plastic textile

A plastic bag, poly bag, or pouch is a type of container made of thin, flexible, plastic film, nonwoven fabric, or plastic textile. Plastic bags are used for containing and transporting goods such as foods, produce, powders, ice, magazines, chemicals, and waste. It is a common form of packaging.

<span class="mw-page-title-main">Japanese curry</span> Japanese-style curry dish

Japanese curry is commonly served in three main forms: curry over rice, curry udon, and curry bread. It is one of the most popular dishes in Japan. The very common "curry rice" is most often referred to simply as "curry".

<span class="mw-page-title-main">Shelf-stable food</span> Foods that can be stored at room temperature

Shelf-stable food is food of a type that can be safely stored at room temperature in a sealed container. This includes foods that would normally be stored refrigerated, but which have been processed so that they can be safely stored at room or ambient temperature for a usefully long shelf life.

<span class="mw-page-title-main">Food packaging</span> Enclosure and protection of nutritional substances for distribution and sale

Food packaging is a packaging system specifically designed for food and represents one of the most important aspects among the processes involved in the food industry, as it provides protection from chemical, biological and physical alterations. The main goal of food packaging is to provide a practical means of protecting and delivering food goods at a reasonable cost while meeting the needs and expectations of both consumers and industries. Additionally, current trends like sustainability, environmental impact reduction, and shelf-life extension have gradually become among the most important aspects in designing a packaging system.

Tasty Bite is an Indian-American preserved food manufacturer, producing ready-to-eat Indian and pan-Asian food products. The products require no refrigeration.

<span class="mw-page-title-main">Folding carton</span> Type of paperboard packaging

The folding carton created the packaging industry as it is known today, beginning in the late 19th century. The process involves folding carton made of paperboard that is printed, laminated, cut, then folded and glued. The cartons are shipped flat to a packager, which has its own machinery to fold the carton into its final shape as a container for a product. Some styles of folding cartons can be made of E-flute or micro-flute corrugated fiberboard.

Aseptic processing is a processing technique wherein commercially thermally sterilized liquid products are packaged into previously sterilized containers under sterile conditions to produce shelf-stable products that do not need refrigeration. Aseptic processing has almost completely replaced in-container sterilization of liquid foods, including milk, fruit juices and concentrates, cream, yogurt, salad dressing, liquid egg, and ice cream mix. There has been an increasing popularity for foods that contain small discrete particles, such as cottage cheese, baby foods, tomato products, fruit and vegetables, soups, and rice desserts.

<span class="mw-page-title-main">Vertical form fill sealing machine</span> System to create and fill plastic bags and pouches

A vertical form fill sealing machine is a type of automated assembly-line product packaging system, commonly used in the packaging industry for food and many other products. Walter Zwoyer, the inventor of the technology, patented his idea for the VFFS machine in 1936 while working with the Henry Heide Candy Company. The machine constructs plastic bags and stand-up pouches out of a flat roll of film, fills them with product, and seals them. Both solids and liquids can be bagged.

<span class="mw-page-title-main">Stand-up pouch</span> Type of self-standing packaging

A stand-up pouch or doypack is a type of flexible packaging that is able to stand erect on its bottom for display, storage, and convenience. It has characteristics of plastic bags, water bottles, and retort pouches. The bottom part of a stand-up pouch is gusseted to provide support for display or use.

Ecologic Brands Inc. is a United States company that specializes in creating eco-friendly packaging for consumer products. The products are made from sustainable materials and are designed to be recyclable or compostable. The company also provides branding and marketing services to help companies promote their environmentally conscious products.

<span class="mw-page-title-main">Malabar matthi curry</span> Indian dish

Malabar matthi curry, also known as fish curry, is a traditional Kerala dish. It is usually prepared with fish semi-stewed in a Kerala-style sauce that typically includes a blend of spices and assorted vegetables, such as okra or onions. While sardines are commonly used, the dish can be prepared with a variety of fish, such as mackerel, kingfish, or pomfret. It is usually served with rice or tapioca. The dish is most popular in Kerala, Goa, and Sri Lanka, where rice and fish are staple foods. Other variations may include adding tamarind juice or coconut milk.

The Brazilian packaging market is the fifth-largest in the world, having realized US$35 billion in sales in 2014, with Brazil being the seventh largest economy in the world by nominal GDP. The packaging market includes manufacturing of packaging materials from raw materials, distribution of packaging materials to producers, packaging design as well as recycling processes. The packaging sector has strong ties to environmental organizations and tries to adapt to the demands of environmentally friendly production with more sustainable packaging.

<span class="mw-page-title-main">Boil-in-bag</span> Packaged food product

Boil-in-bags are a form of packaged food products in which bagged food is heated or cooked in boiling water. Plastic bags can be solid and impermeable for holding frozen foods; alternatively, bags can be porous or perforated to allow boiling water into the bag.

<span class="mw-page-title-main">Pasta processing</span> Process of making pasta

Pasta processing is the process in which wheat semolina or flour is mixed with water and the dough is extruded to a specific shape, dried and packaged.

Huhtamaki PPL Limited or HPPL is an Indian multinational company specializing in flexible packaging and packaging solutions, founded in 1935 in Lahore. In 1999, the company became part of Huhtamäki Oyj, Finland. It has been involved in the field of packaging for over 80 years.

References

  1. Manju, S (2004). "Heat penetration characteristics and shelf life studies of seer fish moilee packed in retort pouch" (PDF). Fishery Technology. 41 (1): 37–44. Archived from the original (PDF) on December 1, 2018. Retrieved December 1, 2018.
  2. Catauro, P M (2012). "Assessment of the long‐term stability of retort pouch foods to support extended duration spaceflight". Journal of Food Science. 71 (1): S29–S39. CiteSeerX   10.1.1.666.7247 . doi:10.1111/j.1750-3841.2011.02445.x. PMID   22260129.
  3. "Japan's Bon Curry certified as world's longest-selling retort pouch curry brand". Mainichi Shimbun. 12 January 2023. Archived from the original on 12 February 2023. Retrieved 20 February 2024.
  4. 1 2 House Foods (2019). Sekai no Karē Zukan (The World's Curry Picture Book), p.111. Mynavi Publishing Corporation. ISBN   978-4839970130
  5. (Food & Drug Packaging) Retort pouches build up steam: big food companies are taking advantage of technical advances to bring out retorted products in flexible material - Technology: retort packaging
  6. "Why Flexible Packaging | Maco PKG". Maco PKG. 2015-06-29. Retrieved 2016-11-03.

Further reading