Retort pouch packaging

Retort packaging - Definition, advantages, material and its properties required, retort-working and types, retort packaging system.

1. Retort pouch packaging Course Outcomes Definition, Application, Material and Properties required Retort –Types, operating procedure and application Manufacturing process of retort Pouch. Mr.P.S.Shirahatti (GPM FC)

2. 1.1 Definition: Retort pouch is a flexible packaging which is an alternative to metal cans and glass bottle which can withstand thermal processing temperature up to 120 to 130°C and combine advantage of metal can and the plastic boil-in –bag. 1.2 Application: It provides High barrier properties, long shelf life, toughness a puncturing resistance. Used for packaging low acid products like meat, fish, veg., rice products. It is a rectangular, flexible, laminated plastic, four-side hermetically sealed pouch . Transparent type of Retort pouch Semi Rigid Retort Cups

3. 1.3 Retort pouch- Material and its Function Aluminum-foil –Provide good barrier properties against oxygen, light, moisture vapor .Those without aluminum foil are transparent. ( Al foil 7 – 9μm ) The outer polyester film - provides strength and toughness and stable for high temp. While the inner PP provides good heat-sealing properties , strength, flexibility and compatibility with all foodstuffs. ( CPP at 70 – 100μm) The additional incorporation of an oriented PA (nylon) - increases the durability of the pouch, especially where the individual pouches are not, subsequently, packed individually in cartons. ( PA 15 – 25μm)

4. 1.4 Retort pouch laminate layers with name of materials

5. 1.5 Effective requirement of retort film material : Low oxygen permeability -0CC/m 2 /24hr/atm. Sterilization temp. stability -0 to 150 C Low water vapor transmission rate- 0gm/m 2 /24hr Heat sealabilaty-160 to260 c Thickness tolerance-+-2 micrometer Seal strength 2 to 3.5 kg/10 mm Busting streangh -7.5 kg/cm2 1.6 Examples of Products to be Packed in Retort pouch. Sliced meat in gravy, fish, sauces, soups, vegetables, fruits, drinks and baked items Foil-free pouches have been utilized particularly for vegetables where high visibility is desirable and a short shelf life from 4 weeks to 6 months is acceptable.

6. Less energy is required to manufacture pouches compared with cans Light weight of pouches Production and packaging material is cheaper compare to can Filling lines may be automated Rapid heat penetration and faster process results in better nutrition/ flavour Contents are ambient shelf stable – no refrigeration is required Packed pouch is more compact requiring about 10% less shelf space Low brine or syrup used, pouches are lower in mass and cheaper to transport Opens easily by tearing or cutting Ideal for single portion packaging and serving size control retort pouch materials are non-corrosive Convenient for outdoor leisure and military rations use. 1.7 Advantages of retort packaging system

7. 2.1 Major equipments required for Retort Packaging System 1) Boiler 2) Refrigerator 3) Retort- Steam and air (Overpressure Retort) 4) Steam jacketed kettle –Cooker 5) Retort Pouch Packaging Machine 6) Material Handling equipments

8. 2.2 Batch Retort : - Cylindrical shell, may be horizontal or vertically operated. Uniform heating overall surface for the success of the retorting Pressure of stream is control as per inside temperature requirement by automatic sensors Provided controlling device through micro processed based control system .

9. 2.3 Heating media: 1) Steam : Saturated or Superheated steam under pressure used. 2) Water: Water under pressure may be spray or full Immersion system used. 3) Steam and Air: 75% steam and 25% Air under pressure used. It is useful for glass, flexible retort pouches. In this system steam maintain internal temperature and air control internal pressure during processing is called over pressure processing retort . 2.4 Types of batch Retort: 1) Super heater water spray Autoclave 2) Steam water Retort 3) Full Water Immersion Retort 4) Air and Steam Mixture Autoclave with Water cooling 5) Steam Retort.

10. 2.4.1 Steam water Retort Instrumentation and control valve systems are vitally important to accurately control and record pressure and temperature (+1°C to −0.5°C) during the retorting of pouches. Automatic process cycle control is preferred .

11. 2.4.2.Air and Steam Mixture Autoclave with Water cooling 2.4.3.Full Water Immersion Retort Heating by Steam and Air mixture, Cooling by circulating cooled water under pressure Heating by immersion in pressurized hot water Cooling by cooled water

12. 2.4.4 Super heater water spray Autoclave 2.4.5 Tray for loading retort pouch inside to autoclave Heating by water spray under high pressure Cooling by circulating cooled water with high pressure

13. 3.1 Retort Operation Cycle : Retort Pouches load in to tray / Cage Cage load in to retort Close the retort door tightly Initially drain valve open to remove internal air Start the operation by injecting / spray pressurized steam and water in to retort Close the drain valve Pressure rise up to pre set ( Temperature also rise with pressure) Process time is controlled after the come up pressure After heating time , steam is closed and water spray for cooling under pressure Cooling under air pressure carried out After cooling reduce the internal pressure slowly Open the retort door Remove the cage and surface dry the retort pouch for stand some time.

14. PRODUCT PREPARATION WEIGHT AND FILLING INTO POUCH SURFACE DRYING AND SECONDARY PACKAGING PRE-FORMED RETORT POUCH FILLING AND VACUUM SEALING BY MNUALLY OR AUTOMATIC RETORTING 3.2.1 PRE-FOMED RETORT POUCH PACKAGING Retort Pouches- Pre- fomed Filling- Automatic or Manually Vacuum- By steam injection and sealing or vacuum packaging Retorting- Heat for 121 deg. C, Hold for 30 minutes and then ,Cool to 35 C

15. RETORT FILM WEB (REEL) AUTOMATIC BAG MAKING MACHINE BAG FILLING BY AUTOMATIC AND VACUUM SEALING RETORTING SURFACE DRY AND SECONDARY PACKAGING PRODUCT PREPARATION 3.2.2 FORM-FILL-SEAL PRTORT POUCH PROCESSING.

16. References Food Packaging Technology –Richard coles A Handbook of Food Packaging- Paine FA and Paine HY Food Packaging Principles and Practice- Gordon L. Robertson Food Packaging Technology- R Coles, D McDowell, MJ Kirwan Food processing Technology-P. J. Fellows https://youtu.be/xvnPkR25qaA (Retort Processing of Food)

17. Thanks