What is retort
& should I use it?
Why use retort?
As food producers, we often want our products to remain shelf stable as long as possible to reduce waste and keep costs lower. Retort packaging is a popular way to preserve food and beverages, especially when they need a long shelf life or products are being transported over long distances.
The retort process involves high temperatures and pressures to sterilize the products. Retort sterilization is an ideal choice for a wide range of products, including ready-to-eat meals, seafoods, fruits, vegetables, meat, dairy, pet food, and baby food.
How does the retort process work?
The retort process involves filling the container (can, glass jar, or retort pouch) with product, sealing it, and then subjecting it to high temperature and pressure in an autoclave or retort machine. Increasing the pressure allows the product to be heated above the boiling point of water, up to 116-130°C.
The high temperatures and pressures help to kill any bacteria or other microorganisms present in the product, ensuring that it remains safe for consumption for a longer period and prevents food from spoiling. This is how many food producers achieve shelf-stable products that would normally need to be refrigerated.
The packaging required for retort is specialized and highly durable to withstand these harsh conditions.
What packaging do you need for retort?
While the retort process often uses cans or glass jars, retort packaging can also use a flexible retort pouch.
These pouches are made from a combination of layers of different materials that are designed to provide specific properties, such as barrier protection, puncture resistance, and heat resistance. The layers are typically made from materials like polyester, nylon, aluminum, polypropylene, and polyethylene.
What are the advantages or flexible retort packaging?
Extended shelf life
Retort packaging preserves food products and allows it to stay at room temperature for an extended period. This eliminates the need for refrigeration and allows the product to last longer, avoiding product waste.
Microwavable and heat resistant
Retort pouches can be made to be put right into the microwave, or they can allow your product to be placed directly into hot water, which means customers can easily reheat the product without extra hassle. These pouches can be used for user convenience even when the product doesn’t undergo retort sterilization.
Cost-effective
Flexible packaging is a cost-effective solution to traditional packaging, and the lightweight nature allows for lower shipping costs and easy storage compared to bulky glass cars or cans.
Retains nutritional value
Retort packaging uses a high-temperature sterilization process that helps retain the nutritional value, flavor, and texture of the food products. It ensures that the packaged items maintain their quality over a long period.
Versatility & convenience
Retort packaging is widely used in the food and beverage industry for items such as ready-to-eat meals, soups, sauces, meats, seafood, and produce. This packaging can also be fully printed and customized with the added convenience of being lightweight and easy to handle, catering to the needs of both manufacturers and consumers.
Safety
Retort packaging undergoes a rigorous sterilization process that eliminates harmful microorganisms, ensuring food safety. The air-tight seal on the pouches prevent contamination and protect against external factors like oxygen and moisture, and an aluminum layer protects products from light.
It’s important to keep in mind that not all foods are suitable for retort. It’s a good idea to work with a food scientist or consult a food lab to see if retort sterilization can be used for your products and applications.
To wrap up, retort packaging is used to preserve a wide range of food and beverage products. It can be achieved through the use of a flexible retort pouch, which is designed to withstand high temperatures and pressures during the sterilization process. Retort packaging offers several benefits, including extended shelf life, cost-effectiveness, and flexibility, and is an excellent choice for companies looking to protect their products during transportation and storage.
Want to know what options are available for retort packaging?
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