Retort Pouch

12/20/2012
Department of Food, Nutrition, and Packaging Sciences
Department of Food, Nutrition, and Packaging Sciences
Retort Pouch: Processing Requirements and Package Integrity
Presented at:
FIRST IFTPS SOUTH EAST ASIA TECHNICAL OUTREACH SEMINAR
THERMAL PROCESSING: Basics and Beyond
November 27, 2012 Bangkok, Thailand
Scott Whiteside, Ph.D.
Associate Professor
Clemson University, Clemson, SC (USA)
Agenda
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Brief history
Retort pouch formats
Retort pouch formats
Processing requirements
Pouch handling
Pouch integrity
Videos
Department of Food, Nutrition, and Packaging Sciences
Department of Food, Nutrition, and Packaging Sciences
Retort Pouch History
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Post WWII
Italy
US Military
Asia
US Retail (1979‐ present)
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Continental Kitchens Entrees Kraft A la Carte Entrees
Pet Food
Tuna
Retort Pouch Styles
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3‐side seal
4‐side seal
St d
Stand‐up
Stand‐up & fitment
Pre‐made, form‐fill‐seal
Department of Food, Nutrition, and Packaging Sciences
Processing Requirements
Pouch Filling
• Opening
• Filling
– 2 part
– Seal contamination
Seal contamination
• Evacuation
– Steam, vacuum, mechanical, hot filling, flushing
• Sealing
Department of Food, Nutrition, and Packaging Sciences
Processing Requirements
Pouch Handling
• Manual systems
– Flexibility
– Pouch loadingg
– Rack movement
– Crate movement
– Impulse, Constant heat, Ultrasonic
– 2 step
• Cooling
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12/20/2012
Department of Food, Nutrition, and Packaging Sciences
Department of Food, Nutrition, and Packaging Sciences
Processing Requirements
Pouch Handling
• Automated systems
– Loading
– Racks
– Conveying system
Processing Requirements
Retort Racks
• Metal
– Automation
• Plastic
– Manual
– Material selection
• Design of even flow of pouches
• Synchronize line speeds
• Seamless conveyors & smooth conveyor surfaces
• Rack Design
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Compartments
Rack Depth
Smoothness/Edges
Rack quantity (3x)
Department of Food, Nutrition, and Packaging Sciences
Processing Requirements
Department of Food, Nutrition, and Packaging Sciences
Processing Requirements
Retort Racks
Retort Racks
• Hazards
– Oxidation
– Edges
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– Damaged
– Deterioration
Department of Food, Nutrition, and Packaging Sciences
Processing Requirements
Retort Overpressure
• Pouch expansion
– Heating
– Coolingg
• Compensation
Department of Food, Nutrition, and Packaging Sciences
Retort Pouch Integrity
• Material selection
• Defects
– Various: minor to major • Seal Strength
– Capability of pouch seal to withstand separation
• Leak Detection
– Physical opening in pouch
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12/20/2012
Department of Food, Nutrition, and Packaging Sciences
Department of Food, Nutrition, and Packaging Sciences
Retort Pouch Defects
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Abrasion
Channel Leaker
Contaminated Seal
Cut
Fracture
Leaker
Non‐bonding
Retort Pouch Defects
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Puncture
Seal Creep
Swollen Package
Wrinkle
Department of Food, Nutrition, and Packaging Sciences
Department of Food, Nutrition, and Packaging Sciences
Retort Pouch Integrity
Retort Pouch Integrity
Online Testing
Offline Test Methods
• Seal inspection
• Seal strength & inspection
• Pouch burst strength
• Leak detection
– X‐ray
– HVLD
– Dye
– Vacuum
– Pressure Decay
– Ultrasound
Department of Food, Nutrition, and Packaging Sciences
Thank you!
Questions?
Dr. Scott Whiteside
wwhtsd@clemson.edu
www.clemson.edu/cafls/departments/fnps/
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