What are the benefits of a retort pouch?

Retort pouch packaging is still a fast growing segment globally. This is mainly due to the advantages in the field of logistics (empty pouches take up less space than cans or jars), the increasing need for convenience packaging and the amount of design options that allow products to stand out on the shelf.

How to automate a retort pouch process?

(Pet) food producers who opt for retort pouches have to deal with filling machines, retorts and packaging machines. But the focus of a fully automated production line is undoubtely a smooth transport of the pouches to and from the retort. These so-called pouch handling systems ensure high efficiency and predictability in your production environment. Taking topics such as food safety, energy efficiency and ergonomics into account.

What kind of retort pouches exist?

Most known pouch types are the stand-up pouch, the pillow pouch and the spouted pouch. Each type of pouch has its own points of attention in the handling process, such as the proper drying of the product.

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What is a retort pouch?

A retort pouch, also known as retortable pouch, is a flexible or semi-rigid food package that can withstand thermal processing, like sterilisation up to 121 °C. The result? A product that is sterile and ready for long-term unrefrigerated storage. Retort pouches are used for a wide range of products, including soups, sauces, meat packs, ready meals, wet pet food and baby snacks.

Why producing retort pouches? 3 big benefits

Flexible retort pouch packaging is still a fast growing segment globally. Consumers see the convenience of the user-friendly pouch packages, for example while traveling. At the same time, the demand for sustainable, recyclable packaging is increasing. A retort pouch must therefore meet high expectations.

Compared to cans and jars, pouches can be produced with much less packaging material - up to 80% - and unfilled pouches take up less space, reducing transport costs.
As the number of single-person households and the aging population increases, the target group of pouch users becomes larger. Pouches are suitable packaging for on-the-go and convenience meals.
Stand-up pouches offer you various design options and sizes ensure that your product stands out on the shelf.

More info: pouch handling solution

#1 - Variation in product size

Following the market trends, you might be thinking about a variation in Stock Keeping Units (SKU’s). More and more we see that there is a specific product type for each type of consumer. That is why we specialise in configuring quick and easy exchange systems to ensure flexibility in your production line. Our special reversable tray, for example, can be used for loading both large and small pouches.

In this case we handled the following SKU’s within one pouch handling system: 225g, 500g, 550g and 2000g. But our handling systems are also equipped for the more smaller pet food packaging, like 50, 80 or 100 grams.

#2 - Drying your pouches

After completing the sterilisation process and unloading the retorts, the following challenge appears. Getting the pouches as dry as possible, so they can be immediately packed. What you may not know is that you do not need a complex transport system for this. Pillow pouches, stand-up pouch (with often a harder to dry gusset!) and spouted pouches: they all have their own points of attention when it comes to drying. Thanks to our extensive experience, we have developed an inline dryer.

How it works? The inline dryer dries your pouches directly in the robot head. Your advantage: a small footprint solution without shifted products and mis-picks. Results of only 0.04g of residual water per product can be achieved.

#3 - Climb that sustainability ladder

By choosing pouch as your packaging type, you contribute to combating food waste. Pouches have the great advantage of resealability, so that no product has to be thrown away unnecessarily. But how about the sustainability of your pouch packaging itself? This depends on the amount and types of plastics used. Do you have green ambitions with regards to pouch packaging? DeeDee Pouch Professionals will help you climb the sustainability ladder!

Stand-up pouches

Catch attention on the shelf! Many lay-out options. We have built handling systems for soups, sauces and ready meals that need to be pasteurised or sterilised.