Exploring the Variety: Understanding Different Types of Retort Pouches
Are you troubled by choosing steamable bag packaging for your brand? For coffee roasters, specialty food producers, and other brands, the technical nuances of retort pouch packaging—from balancing structural flexibility to meeting strict temperature thresholds—often turn selection into a complex, multi-layered puzzle.
The following packaging guide from MTPAK systematically examines four key dimensions to simplify the selection process of steamable bag packaging: structure, temperature resistance requirements, material selection, and functionality, enabling your brand to make clear decisions and choices based on technical requirements and brand value.
Learn how MTPAK's advanced packaging expertise can help you choose the perfect retort bag solution, ensuring product freshness while meeting the expectations of modern consumers.
What Is Retort Pouch Packaging?
Retort pouch packaging is actually a flexible and heat-resistant packaging method designed specifically for the sterilization process of steaming and boiling. This process mainly involves heating the sealed bag to 115-135 ° C (239-275 ° F) under pressure to disinfect its contents. This can achieve shelf stability without the need for refrigeration.
Retort pouch is different from the traditional canned bag packaging. It is a more comprehensive upgrade, providing a lighter, more space-saving and sustainable packaging choice. On this basis, the flavor and nutritional value of the products in the bag can be better maintained.
For brands, choosing retort pouch packaging is also of great benefit, which can help to reduce the cost of product transportation and reduce the carbon footprint to some extent. More importantly, it can provide consumers with a better product experience.
What Are the Different Types of Retort Pouches?
Selecting the right retort pouch requires a systematic framework. At MTPAK, based on our practical experience of collaborating with global coffee roasters and food brands, etc., we classify poached bags according to four core dimensions: structure, temperature resistance, material and style. Understanding these classifications is key for you to make informed decisions for your brand and ensure product safety and quality.
1. By Structure
The structure of a cooking bag is actually the combination of its laminated materials, which directly determines the barrier performance and protective level of the cooking bag. The most common classification is based on the number of layers and the materials used.
Transparent High-Barrier Structure
For example, PET/PA/CPP or PET/EVOH/CPP. This structure is free of aluminum foil and can provide excellent oxygen barrier performance (especially when EVOH is used), while also allowing consumers to see the products inside the bag. It is commonly used in the packaging of ideal delicacies, such as those that require microwave heating, high-end sauces, and coffee beans, where visibility is ideal. Its light transmittance is an inherent feature.
Foil-Based High-Barrier Structure
That is PET/AL/PA/CPP, which is the structure with the highest performance. The middle aluminum foil layer (AL) provides an almost absolute barrier for the products inside the bag, preventing moisture, oxygen and light, and extending the shelf life to 24 months or longer. It is the gold standard for products highly sensitive to oxidation, such as coffee, pet food, meat products, and ready-to-eat meals (MREs).
Metalized High-Barrier Structure
For example, PET/MET/PA/CPP. This structure uses metallized film (MET) instead of aluminum foil, achieving a balance between transparent and all-foil structures. It offers better barrier performance than transparent structures, can partially block light, and is usually microwave-safe, making it a popular compromis
In fact, a standard "three-layer" retort bag (such as PET/AL/CPP) is not composed of just three layers of film, but is made by layering three functional layers, each with a different use:
Outer Layer (Substrate)
Typical PET or NY/PA. The outer layer provides mechanical strength and wear resistance, serving as the surface for packaging printing, undertaking initial heat resistance and protective functions.
Middle Barrier Layer
Typical ones are aluminum foil (AL), metallized film (MET) or EVOH. This can be called the "heart" of the bag, mainly responsible for blocking oxygen, moisture and light, and thus it is the core layer that determines the shelf life of the product.
Inner Sealant Layer
Almost all are CPP (cast polypropylene). This layer is to come into direct contact with food and must comply with food contact regulations (such as FDA 21 CFR and EU 10/2011). It has heat-sealing performance and can ensure the integrity of the seal during high-temperature reforming and subsequent storage.
2. By Temperature Resistance
Different products require different sterilization intensities (F0 values), which determine that the retard bags must withstand specific temperature and time cycles.
Low-Temperature Retort Pouches
Can withstand around 115℃. For highly acidic products and those with relatively low sterilization requirements, for instance, certain fruit products or sauces, which are usually products with a shorter shelf life, such retort bags can be applied.
Mid-Temperature Retort Pouches
It can withstand temperatures around 121℃. It is suitable for most meats, vegetables and pet foods, etc., and can provide a shelf life of about 12 to 18 months.
High-Temperature Retort Pouches
It can withstand temperatures ranging from 125℃ to 135℃ and is often used in products that require extremely strong sterilization conditions. Specifically, it can be used for low-acid products to achieve a longer shelf life, that is, more than 24 months.
3. By Pouch Style
Once technical parameters are determined, the choice of pouch style relates to user experience and shelf presence.
Stand-Up Pouch
This type of bag has a vertical display panel at the bottom, which provides the best shelf visibility and brand area.
Spout Pouch
Based on the vertical bag, a screw cap or nozzle is added to facilitate the pouring of liquids and powders, making it suitable for products such as liquid seasonings and beverage mixtures.
Flat Pouch / Pillow Pouch
In summary, this type of retort bag has a simple structure, high cost performance and high space utilization. It is widely used in military rations (MREs), single-cup coffee grounds and is an important product for reducing transportation volume.
Four-Side Seal Pouch
The front and back bag films are of the same size and sealed on all four sides, providing a flatter and more refined printing surface. It is more commonly used in high-end tea, gift packaging or occasions where double-sided printing is required.
How to Choose the Right Retort Pouch for Your Brand?
At the very beginning, it was mentioned that choosing the best and most suitable retort pouches is a strategic decision for a brand. Because it affects product quality, shelf life, sustainability certificates, and brand perception.
In addition to technical specifications, the packaging also needs to be consistent with the unique requirements of the product and the core values of the brand. Based on MTPAK's successful experience in developing solutions for coffee and food brands, it is recommended to follow the following decision-making framework:
Step 1: Define Your Product's Primary Challenge
The first step is a scientific assessment of what you need to protect your product from. This will directly dictate the required barrier structure.
• Oxygen ( leading to oxidation and staleness)
This is the top concern for coffee, nuts, oils, and many prepared foods. Your choice hinges on the required level of protection.
￮ >12-month shelf life / Maximum protection: Choose an aluminum foil barrier (PET/AL/CPP). This is the gold standard for absolute oxygen and light blockage.
￮ 6-12 month shelf life / Product visibility: Opt for a transparent high-barrier structure with EVOH. This provides excellent oxygen resistance while allowing consumers to see the product.
• Moisture ( leading to clumping or texture loss)
It is a key factor for products such as powders (such as coffee or beverage mixtures), biscuits and dry snacks. However, all the retort bags offer excellent moisture-proof barriers, and the foil structure provides the highest level of protection.
• Light ( which can accelerate oxidation and degrade vitamins)
If your product is light-sensitive, an aluminum foil or metalized layer is the most effective solution. Transparent barriers offer no protection against light.
Step 2: Align with Your Brand Values
Turn to environmental protection packaging to achieve the purpose of strengthening brand value. The first scheme that can be considered is to use a single recyclable material such as PP. Although its barrier property is different from that of aluminum foil, it can solve the problem of traditional packaging recycling. Or consider another direction, that is, explore FSC paper or bio-based plastics.
The brand should also consider the consumer experience. Therefore, for liquids, sauces or multi-purpose products, nozzle bags with resealable zippers can provide great convenience.
Step 3: Consider Practical Logistics and Compliance
The final step involves operational and regulatory realities.
• Distribution Channels
Are your products sold online or offline? For online sales, durability and puncture resistance have a significant impact on the survival of products during transportation. For offline hours, the emphasis is placed on standing ability and the influence of the shelves.
• Fill Volume and Machinery
Ensure the pouch size and style are compatible with your filling equipment. The choice of flat vs. A stand-up pouch can affect line efficiency and storage space.
• Regulatory Compliance
It is necessary to confirm that the supplier has provided the FDA (21 CFR) and EU (10/2011) declaration of conformity for all materials, especially the inner sealing layer (CPP) in contact with food. MTPAK has always provided these files as standards.
Conclusion
When choosing retort bag packaging to protect your brand products, it should be consistent with your brand values and also be attractive to consumers. This is actually not a one-size-fits-all solution, but a strategic choice made based on the technical requirements and brand development goals of each brand.
At MTPAK, combining technical expertise with practical experience, we offer high-performance and eco-friendly custom cooking bag solutions for a wide range of coffee and food brands.
Contact MTPAK immediately to obtain samples, material inquiries or tailor-made quotations based on your needs. Please send mail to account@mtpak.com or visit https://mtpak.com/contact-mtpak.
FAQ
1. What is retort pouch packaging?
A flexible package that can withstand high-temperature disinfection can keep the product safe, prolong the shelf life and does not need refrigeration.
2. How does retort pouch packaging work?
The filled bag is placed in a pressurized container, and the inside of the package is disinfected by heating at high temperature-killing microorganisms and ensuring safety.
3. Is the packaging in retort pouch safe?
Yes Usually, packaging bags are made of food-grade materials and meet strict international standards.
4. What is retort pouch used for?
It is mainly used for packaging food and beverage with storage resistance. Common products include whole ground coffee, ready-to-eat meals (MREs), pet food and other products that need long shelf life.