Retort Pouch Packaging Solutions

  • Retort Pouch Packaging Solutions
  • Retort Pouch Packaging Solutions
  • Retort Pouch Packaging Solutions
  • Retort Pouch Packaging Solutions
  • Retort Pouch Packaging Solutions
  • Retort Pouch Packaging Solutions
  • Retort Pouch Packaging Solutions
  • Retort Pouch Packaging Solutions
  • Retort Pouch Packaging Solutions
  • Retort Pouch Packaging Solutions
Retort Pouch Packaging Solutions
  • LD PACK
  • China
  • Mono PE / Mono PP
  • Pure milk, yogurt, milkshake, juice, wine,cooking oil
  • We have enough machinery and equipment for production to reach 350 tons per week.
  • 100,000 PCS
  • 30 days lead time

Retort pouch are the alternative packaging for cans or any other type of food container.
Unlike conventional packaging, these retort packaging provide enhanced cooking convenience while incorporating recyclable elements, contributing to environmental sustainability.
They are designed with film structures through the lamination of various materials so as to give the packaging effect that is desired.
Several layers of the materials are laminated together, and they protect the products from oxygen, moisture, vapor, and other contaminants.
Some edible products that require retort stand up pouches include:
Pet wet food/Pet food /Organic products/Soup/Fresh food etc...

retort pouch


Retort Pouch

Retort pouch is a kind of laminated plastic film pouch that can be heated. It takes into account of the advantages of both canned containers and boiling water resistant plastic pouch. The food can be kept wholly intact in the pouch and heated by high temperature sterilization (generally in 120~135℃). Once taken out, it  can be served. Retort pouch is not only convenient, hygienic and practical, but also greatly maintains the original flavour of the food. It is favoured by consumers.

  • Retort pouch is a type of packaging suited to food that need to be heated and sterilized, regarded as a lightweight and economical alternative to industrial canning methods. 

  • With heat seal and vacuum seal, retort pouch is usually used for both hot and cold food packaging.

  • Retort pouch has high barrier properties, including good oxygen and water vapor barriers, light and corrosion prevention.

LD PACK offers exceptional packaging solution that withstands aggressive retort conditions and excellent barrier properties.


    Up to our high quality standard

        √FDA approved food grade material

        √ISO & QS quality grade

        √Excellent printing

        √Recyclable

retort packaging

Advantages & Benefits


It can stop microbial growth and make various enzyme inactive during retorting, ensuring shelf stability of the product. Plus, It can ensure to remain the maximum nutritional value, taste, aroma and flavor by shortening processing time.

     √ Including hot and cold forging processes

     √ High performance forging process

     √ Extremely durable

     √ Quiet running

     √ Compensates misalignment and deflections

stand up pouch


Market Trend


retort pouch


The key drivers of Retort Pouch Market

  • Benefits of retort pouch in food and beverages industry and increase in demand for lightweight as well as sustainable packaging are the key factors boosting the Retort Pouch market growth.

    Increase in E-commerce activities and food delivery services in the main driver of Retort Pouch market.

  • The rise in public awareness about health issues is one of the factors propelling the Retort Pouch market throughout the forecast period. Increase in use of sterilizing solutions as a result of the coronavirus epidemic is also driving the demand for the overall industry.

  • The rise in demand for retort pouch in pharmaceutical, and cosmetics drives the demand for retort pouch, owing to the fact that they help in easing the process of packaging and transit.


Application

Meat, soy products, leisure halogen products, pet food, baby food, pre-made food, sauce, food for special medical purpose.

retort packagingstand up pouchretort pouch

Tips

  • Retortable 125℃, 30 min 

  • There are clear retort pouch and aluminized retort pouch.

  • Because the heat transfer of the clear retort pouch is slow during sterilization, so it's suitable for small packages of less than 300g; For contents over 500g, it's suggested to use aluminized retort pouch. 

retort packaging

Sterilization Classification


1. Classified by temperature & time conditions:

ClassClass ConditionComment

Water Boiling

Sterilized by 100℃ boiling water

Sterilizing time 30min

Medium temperature Retorting

Retorting sterilization below 121℃(121℃ included)Sterilizing time 40min

High temperature Retorting

High temperature sterilization below 135℃(135℃ included)

Sterilizing time 30min

2. Classified by FDA standards:

ClassTime Condition

Shelf Life of Contents

121℃ Retort PouchBelow 121℃,  20-60min

Over 6 months

135℃ Retort Pouch

135℃,  about 20min

1~2 years
140℃ Retort Pouch

Below 140℃,  usually 2~5min

Microwave heating sterilization Within 2 years


Structure Design


stand up pouchretort pouch


Structure Comparison


retort packaging

Items

Performance

Mono-PP Retort Pouch

Standard Retort Pouch

Recycling

x

High Barrie

Cost Advantage

x


Mono-PP Retort Pouch

     Mono- PP Used in Retort Pouch.

      Facts:

  • ≥95% PP  Based packaging

  • High barrier PP film

  • No metallic aluminum 

  • OTR≤0.5

  • Hot fill or pasteurization

  • Retortable 125℃

  • Comply with FDA EU regulations

      Applications range:

  • Pet food \Rice \Tuna \Sauce

stand up pouch

      Characteristic:

retort pouch

  • Surface layer used heat-resistant OPP material, which has better temperature resistance and low shrinkage rate, Pouch with better flatness suitable for high-speed automatic filling equipment. 

  • Middle layer has high barrier OPP, using special  process and coating, the barrier performance is more stable before & after retort.




OTRWVTR
Before retort0.42-0.45-0.550.65-0.80
After retort0.35-0.45-0.480.72-0.85
OTR: cc\m2.24h.0.1Mpa;   WVTR: g\m2.24h


retort packaging

  • Low temperature heat sealing RCPP film ensures the heat sealing effect , good heat sealing strength and smooth heat sealed appearance.

stand up pouch
retort pouch

Stand-up Retort Pouch 

Facts:

● ≥95% PP Based packaging

● High barrier PP film

● No metallic aluminum, OTR≤0.5

● Hot fill or pasteurization  

● Retortable 125℃

Applications: 

● Tuna, sauce, wet pet food

retort packaging

Spouted Retort Pouch

Facts:

● ≥96% PP Based packaging

● High barrier PP film OTR≤0.5

● Retort above 125℃

● PP material spout and cap

● Good recyclable in PP recycling

 Applications: 

● Fruit puree, protein, baby food, wet pet food

* All the data listed are typical values for your reference.

  The above information is strictly confidential.

Customization

stand up pouch

Here at LD PACK, as a leading producer of flexible packing, we can help you get ready to meet the new legislation. And our R&D team is working hard on sustainable packing solutions meeting design for recyclability requirements. Even for challenging product applications like fresh meat or heat treated retort packaging, we have solutions.

Get in touch with us today to discuss your sustainable packaging requirements!

1.Comparison Between Retort Pouches and Cans
.
FeatureRetort PouchCans
Processing MethodFood is processed inside pouch under high temperature and pressure.Food is heated and sterilized inside sealed metal cans.
Packaging MaterialMultilayer composite materials, often including plastic and metal layers.Metal cans.
Shelf LifeLong, maintains food quality and freshness.Long, can last for several years.
Food Quality PreservationPreserves food quality, texture, and nutritional value.Preserves food quality, texture, and nutritional value.
PortabilityLightweight, easy to carry and store.Relatively heavy, less suitable for portability.
Opening and UsageEasy to open and use, no can opener required.Requires a can opener to open cans.
Environmental ImpactCan use recyclable or biodegradable materials, reducing environmental impact.Cans are often difficult to recycle, although they can be reusable.
Packaging VarietyCustomizable in various shapes and sizes to accommodate different product types.Usually fixed can sizes and shapes.
Heating MethodSuitable for microwave, boiling water, or steam heating.Typically needs to be transferred to another container for heating.
Storage RequirementStore at room temperature, no need for refrigeration or freezing.Store at room temperature, no need for refrigeration or freezing.
TransparencyTransparent or semi-transparent, allowing consumers to see the food.Opaque, consumers cannot see the food inside.
ApplicabilitySuitable for frozen foods, ready-to-eat meals, soups, etc.Suitable for general canned foods like vegetables, fruits, meats, etc.

This table summarizes some key differences between retort pouches and cans, including processing methods, packaging materials, portability, environmental impact, heating methods, and applicability. The choice of packaging method depends on the type of product, market demands, and consumer preferences.

2.Choosing the Right Retort Pouch:
Comparison of Common Structures and Parameters
StructureShelf LifeSterilization TemperatureSterilization Time
Three-Layer Structure (Examples)///
- Polyethylene/Aluminum Foil/Polypropylene (PE/Al/PP)6-12 months121°C15-30 minutes
- Polypropylene/Nylon/Polypropylene (PP/Nylon/PP)12-24 months135°C20-45 minutes
Four-Layer Structure (Examples)///
- Polyester/Aluminum Foil/Polyethylene/Polypropylene (PET/Al/PE/PP)12-24 months127°C20-45 minutes
- Polyester/Nylon/Aluminum Foil/Polyethylene (PET/Nylon/Al/PE)12-24 months135°C20-45 minutes
Single Material Structure (Examples)///
- Oriented Polypropylene/High Barrier OPP/Retortable CPP (OPP/HBOPP/RCPP)12-24 months121°C15-30 minutes

Note: The values in the table are examples. Actual sterilization temperature and time should be adjusted based on the specific type and specifications of the packaged food, as well as the performance of the production equipment. Experimental testing should be conducted to ensure the quality and safety of the food during the cooking and packaging processes.

3.Classification of High-Temperature Retort Pouches
Structured Classification
Retort Pouch ClassificationStructureWater Vapor Permeability (g/(m2·24h))Oxygen Permeability (ml/(m2·24h·0.1MPa))
Class APA/CPP, PET/CPP≤15≤120
Class BPA/AL/CPP, PET/AL/CPP≤0.5≤0.5
Class CPET/PA/AL/CPP, PET/AL/PA/CPP≤0.5≤0.5
Classification by Sterilization Temperature (30~45 minutes)
SterilizationTemperature (°C)SterilizationTime (Minutes)RelativePressure (kPa)ShelfLife (Months)Main Characteristics
11530-45
100-1306-12Suitable for mild or gentle heating
121110-14012-18Universal sterilization temperature; suitable for various foods
126120-15018-24Suitable for foods requiring higher temperatures
135130-16024-36High-temperature sterilization; suitable for stricter products

Note: The values in the table are indicative and can vary based on specific requirements and food types. The shelf life and characteristics are approximate and can be adjusted according to the actual needs of the packaged products.

4.Why Choose Retort Pouches:

1.Extended Shelf Life: Retort pouches' high-temperature, high-pressure processing effectively kills microorganisms, extending the food's shelf life. This reduces food spoilage and waste while providing longer shelf display time. 

2.Maintaining Food Quality: Retort pouches maintain food quality, texture, and nutritional value. Foods are often cooked in their juices, enhancing flavor and retaining moisture, preventing dryness. 

3.Convenience: Retort pouches offer a convenient way for consumers to prepare food. Users simply need to place the food inside, seal the pouch, and heat it, saving time and effort without requiring additional cooking utensils. 

4.Packaging Variety: Retort pouches can be customized into various shapes and sizes, accommodating different food types, including frozen foods, ready-to-eat meals, soups, meats, seafood, etc. This flexibility makes them ideal for diverse market demands. 

5.Compatibility with Various Heating Methods: Retort pouch foods can be heated using microwaves, boiling water, or steam, enhancing their convenience both in home kitchens and convenience stores or restaurants. 

6.Environmental Friendliness: Retort pouches can use recyclable or biodegradable materials, reducing the environmental impact. Some pouches are lightweight, reducing the overall packaging material usage. 

7.Visibility: Retort pouches are usually transparent or semi-transparent, allowing consumers to see the food's appearance and quality, increasing their purchasing confidence. 

8.Innovation: The design and structure of retort pouches can be continuously innovated to adapt to market changes. Manufacturers can highlight their brands through custom designs, attracting more consumers.

5.Advantages of Retort Pouches:

1.Convenience: Retort pouches offer great convenience to consumers. No additional cooking utensils are required; one just needs to place the food inside the pouch and heat it under appropriate conditions.

2.Freshness: Retort pouches, with their high-temperature and high-pressure processing capabilities, effectively kill microorganisms, prolonging the freshness of the enclosed food. This reduces the risk of food spoilage and waste. 

3.Food Quality: Retort pouches maintain the food's moisture, aiding in retaining a good texture and quality. Food is typically cooked in its own juices, enhancing the flavor. 

4.Packaging Variety: Retort pouches can be customized based on food type and packaging requirements. They can be produced in different shapes and sizes to accommodate various products like frozen foods, canned goods, instant noodles, etc.

6.Foods Suitable for Retort Pouches:

Retort pouches are suitable for a variety of foods that require cooking, steaming, or heating, such as frozen vegetables, meats, seafood, instant noodles, canned goods, soups, and ready-to-eat meals.

7.Structure of Retort Pouches:

1.Outer Layer: Typically made of polyethylene (PE) or polypropylene (PP), providing packaging strength and appearance.

2.Sealing Layer: Used to seal the pouch opening, usually the same material as the outer layer.

3.High-Temperature, High-Pressure Layer: Typically made of materials resistant to high temperature and pressure, used to withstand the retort or heating process.

4.Moisture Barrier Layer: Prevents moisture infiltration, preserving food quality.

5.Gas Barrier Layer: Prevents oxygen from entering the pouch, extending the food's shelf life.

8.Factors Affecting Retort Pouches in Manufacturing:

Several factors impact the production of retort pouches, ensuring their quality, safety, and suitability for high-temperature processing. According to the requirements of the U.S. Food and Drug Administration (FDA), the tolerance of adhesives under high-temperature conditions is crucial. Materials such as modified polypropylene (mPP) and aliphatic polyurethane (PU) are commonly used to ensure compliance with standards. These factors are elaborated below:

1.Adhesive Selection:

Modified Polypropylene (mPP): mPP adhesives are widely used in retort pouches due to their excellent heat resistance and adherence to various substrates. They provide strong bonding under high-temperature and high-pressure conditions. 

Aliphatic Polyurethane (PU): PU adhesives are known for their high-temperature resistance, making them suitable for retort applications. They offer excellent bonding strength and flexibility, ensuring the pouch's integrity during the retort process.

2.Film Materials:Polyester (PET): PET films are commonly used in retort pouches due to their high-temperature resistance, durability, and ability to maintain the pouch's shape during processing. 

Nylon (PA): Nylon films provide excellent puncture resistance and are suitable for packaging products with sharp edges or corners. 

Aluminum Foil: Aluminum foil layers act as a barrier against light, oxygen, and moisture, preserving the food's freshness and extending shelf life.

3.Quality Control:Strict quality control measures are essential throughout the manufacturing process. Automated systems are employed to monitor pouch formation, sealing, and integrity. Quality control checks include seal strength testing, visual inspection for defects, and sample testing to ensure the pouches meet the required standards.

4.Innovative Designs:Continuous research and development lead to innovative pouch designs that enhance functionality, convenience, and visual appeal. Manufacturers explore new materials and structures to improve the overall performance of retort pouches. 

5.Regulatory Compliance:Manufacturers must adhere to regulations and standards set by regulatory authorities such as the FDA. Compliance ensures that retort pouches are safe for consumers and suitable for various food products.

In summary, adhesive selection, film materials, stringent quality control, innovative designs, and regulatory compliance are critical factors in the manufacturing of retort pouches. By addressing these factors, manufacturers can produce high-quality, safe, and innovative retort pouches that meet consumer demands and regulatory requirements.

9.Problems and Solutions in Sterilization of High-Temperature Retort Pouches after Filling:

1.Sealing Issues: Proper sealing of the retort pouch is crucial to ensure effective sterilization. Incomplete sealing or leakage can result in incomplete sterilization, impacting the quality and safety of the product. 

Solution: Use high-quality sealing equipment and materials. Strictly control sealing temperature and pressure. Regularly inspect equipment to ensure good sealing performance.

2.Bubble Formation: During sterilization, bubbles might form inside the pouch, leading to uneven temperature and pressure in certain areas, affecting sterilization effectiveness. 

Solution: Minimize bubble formation during the filling process. Utilize appropriate gas discharge equipment or techniques to address bubble issues.

3.Packaging Material Selection: Different packaging materials have varying tolerance to high-temperature and high-pressure sterilization. Inappropriate materials can lead to deformation, leakage, or other problems. 

Solution: Ensure selected packaging materials meet the requirements of high-temperature and high-pressure sterilization. Use suitable composite structures and adhesives.

4.Sterilization Time and Temperature: Improper settings of sterilization time and temperature can result in inadequate sterilization. Too short or too long sterilization time, as well as incorrect temperature settings, can affect product quality and safety. 

Solution: Set the correct sterilization time and temperature according to product specifications and process requirements. Regularly monitor and record the sterilization process to ensure consistency.

5.Post-Sterilization Packaging Issues: After sterilization, the pouch might experience pressure and temperature variations. Insufficiently stable packaging materials could lead to ruptures or deformities.Solution: Use packaging materials with high-temperature and high-pressure stability. Implement appropriate measures during cooling and storage after sterilization to reduce packaging stress.

6.Product Stratification: During sterilization, ingredients within the product might stratify, affecting uniformity and quality. 

Solution: Use suitable stirring equipment or techniques to ensure product uniformity during sterilization.

These are potential issues that may arise during the filling and sterilization processes of high-temperature retort pouches, along with possible solutions. Strict adherence to food production and safety standards, coupled with proper equipment maintenance and quality control, can help minimize these problems.

10.Color Bleed and Delamination in High-Temperature Retort Pouches:

1.Solutions Color Bleed: 

Explanation: Color bleed refers to the migration of colors (typically printing inks or dyes) from packaging materials into food products during high-temperature and high-pressure retort processes, causing color changes or staining on the food's surface or around it. 

Color bleed can occur due to one of the following reasons:Inks or dyes used do not comply with food safety standards, leading to color migration. Material structure is unsuitable for high-temperature and high-pressure retort, increasing the permeability of packaging materials. Improper sterilization conditions, such as excessively high temperature or prolonged duration, causing color bleed. 

To prevent color bleed, the following measures should be taken: Use inks and dyes that comply with food safety standards.Ensure packaging materials have adequate barrier properties to prevent color migration.

Strictly control the temperature and duration of the retort process to prevent color bleed during sterilization.

2.Delamination: 

Explanation: Delamination refers to the separation or layering of the multiple layers in a retort pouch during high-temperature and high-pressure retort processes, leading to packaging failure. 

Delamination can occur due to one of the following reasons:Inappropriate selection of packaging materials, such as adhesives unsuitable for high-temperature and high-pressure conditions. Insufficient bonding between packaging materials. Expansion of packaging materials under high-temperature and high-pressure conditions, leading to delamination. 

To prevent delamination, the following measures should be taken: Use packaging materials and adhesives with high-temperature and high-pressure stability.Ensure quality bonding between packaging materials, including appropriate adhesives and bonding processes. Control the temperature and pressure during sterilization to minimize the expansion of packaging materials.Addressing color bleed and delamination issues requires appropriate selection of packaging materials, quality control, and strict adherence to production processes.

These problems can negatively impact the appearance, quality, and safety of the product; therefore, special attention and suitable preventive measures should be implemented during the production process.


FAQ


retort pouch

Are you a manufacturer?

Yes, we have more than 25 years experience in flexible packaging from 1990.Including Packaging bags, Plastic bag / Stand up Pouch/Spout bags/Ziplock bags/ Food Packaging Pouch/Stand up Pouch with spout/ Plastic pouch/Black ziplock Pouch/Cookie bag/Popsicle Packaging/Ziplock bags


retort pouch

What information should I let you know if I want to get a quotation?

- Bag shape 

- Dimension: Length x width (+ bottom/side gusset)

- Material structure and thickness, surface handling 


retort pouch

If you are not sure, please let me know the effect you want and we will suggest.

- Printing colors, please also provide the artwork if possible

- Quantity


retort pouch

When we create the artwork, what kind of format is available for printing?

- AI, PSD, CORELDRAW, PDF

retort packaging



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