Flexible Retort Packaging
Cooking prepackaged products under high pressure and heat sterilises the contents, maintains freshness and increases shelf life. This process is called retorting. Flexible retort packaging is manufactured using heat-resistant plastics, glues and inks. Nowadays, retort pouches are used for a wide range of products, including pet food, ready-to-eat meals, soups and sauces.
The Retort Process
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Retort systems use steam or superheated water to cook food in its own package. |
| The temperature in the sterilization chamber is raised to approximately 120 °C and kept there for a specified period of time. |
| Food packaged in a conventional metal can must be cooked approximately twice as long as food contained in a retort pouch. |
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The Retort Process
As metal cannot be used in microwaves, silicon-based coating is used to replace the barrier characteristics of foil in microwaveable retort pouches. To manufacture silicon-coated films, the food industry has borrowed technology from the microchip industry, using plasma deposition to apply silica to required surfaces. Contact Helion for further information about our silicon oxide (SiO2) films.
Design Features
- Standup or flat pouches
- Reel stock
- Resealable zipper
- Printed or plain
Retort Grades |
Temperature |
Cooking Grade |
| Low |
100 – 110 °C |
High Temp Boiling |
| Middle |
121 – 124 °C |
Retort |
| High |
125 – 135 °C |
High Retort |
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Materials Used
| Polyester (PET) |
Protects barrier layers and provides tensile strength high heat resistance (up to 235 °C) |
| Aluminum (AL) | Major barrier provider against UV, O2, H2O, CO2 |
| Nylon (NY) |
Barrier layer heat resistant up to 190 °C |
| Retortable Cast PP (RCPP) |
Innermost layer provides heat seal function, heat-resistant up to 160 °C |
| Retortable PE (RPE) | Innermost layer provides heat seal function |
| Silicon Oxide | Coating layer which can be added to improve shelf life |
