Retort pouch

Benefit from our experience with various shapes and materials pouches

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.

  • arrow-checkmarkCompared 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.
  • arrow-checkmarkAs 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.
  • arrow-checkmarkStand-up pouches offer you various design options and sizes ensure that your product stands out on the shelf.
Pouch handling
More info: pouch handling solution

What challenges you need to tackle when producing retort pouches?

#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.

Pouch Sustainability ladder - Dee Dee

#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!

We have experience with the handling of...


Pouch handling at PPF

Our collaboration with PPF from the Czech Republic goes back years.

 

Started with one pouch production line. Now a fully automated factory. During the installation of the first pouch handling production line at Partner in Pet Food, we were confronted with various challenges (limited space, specific pouch supply, desired quality control features).

Pouch handling at HAK

We are proud of our contribution to the production process of this well-known traditional Dutch brand.

 

At HAK, the in-house production of stand-up pouches was completely new. That is why our engineers took the project leaders of HAK step by step into the arguments for certain choices. And that was necessary, given the limited space and high degree of desired flexibility (4 different pouch sizes!).


How can we help you?

Feel free to contact us