Retort pouch

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Military MRE: bean and rice burrito

A retort pouch or retortable pouch is a type of food packaging made from a laminate of flexible plastic and metal foils. It allows the sterile packaging of a wide variety of food and drink handled by aseptic processing, and is used as an alternative to traditional industrial canning methods. Packaged foods range from water to fully cooked, thermo-stabilized (heat-treated) high-caloric (1,300 kcal on average) meals such as Meals, Ready-to-Eat (MREs) which can be eaten cold, warmed by submersing in hot water, or through the use of a flameless ration heater, a meal component introduced by the military in 1992. Retort pouches are used in field rations, space food, fish products, camping food, instant noodles, and brands such as Capri Sun and Tasty Bite.

Some varieties have a bottom gusset and are known as stand-up pouches.

What is a retort pouch?

KNOWLEDGE ARTICLE

A retort pouch is commonly defined as a flexible pouch for low-acid foods that are thermally processed in a pressure vessel, often called a "retort." The pouch is made of layered polyester, aluminum foil, and polypropylene. Commercial sterilization occurs at temperatures greater than 212 °F (100 °C), typically 240 to 250 °F (115. to 121 °C). The retort packaging is shelf stable at room temperature.

What is the history of aseptic packaging?

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Aseptic packaging is a beverage system first developed in Europe in cooperation with the World Health Organization to provide beverages such as milk and water to people involved in disasters. It was introduced to the United States in the early 1980's.

What's the difference between retort and aseptic packaging?

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In retort packaging, food is filled into a pouch or metal can, sealed, and then heated to extremely high temperatures, rendering the product commercially sterile. In aseptic packaging, the food or beverage is sterilized by quick exposure to ultra-high heat, rapidly cooled to an ambient temperature, and filled into sterilized containers that are then sealed in a commercially sterile environment. However, the assembled aseptic package is not further processed like retort products.

What is aseptic packaging?

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Aseptic packaging is the process by which microorganisms are prevented from entering a package during and after packaging. During aseptic processing, a sterilized package is filled with a commercially sterile food product and sealed within the confines of a hygienic environment.

What are the advantages of the retort pouch?

KNOWLEDGE ARTICLE

The retort pouch has several advantages. It weighs less than a metal can. It is flexible, meaning that it can handle a lot of abuse when taken away from home or on military maneuvers. Because it is flat, it takes up little space, making it easier to carry in a backpack or pocket. The flat shape also gives the pouch an advantage during processing. In the plant, the pouch is filled with food, sealed, and then retorted at temperatures of 240 to 250 °F to commercially sterilize the contents. Because a pouch is flat, it takes much less time than a metal can does to heat the contents to the point of commercial sterilization. That can result in a better tasting product.