PACKAGING INNOVATIONS THE HISTORY OF RETORT CANS AND POUCHES
The retort process was developed in the mid-19th century, enabling the safe preservation of food in cans.
Building on the invention of tin cans and their functionality, a technique needed to be developed to preserve perishable goods in tinplate cans without damaging the soldered seams. Applying direct heat treatments was destructive to the integrity of the seal, leaving little room to explore advanced applications. Employing the method of soldering, itself, could lead to contamination and limited the usage of the cans for certain products.
To counteract this limitation, a process was developed that involved placing sealed cans in high-pressure steam vessels called retorts and subjecting them to heat treatment. The intense heat and pressure ensured that the contents of the cans were thoroughly sterilized, eliminating harmful bacteria and extending shelf life.
The development of the retort process led to large-scale commercial production of canned goods. It also led manufacturers to use cans made of thicker metal, which could withstand the pressure and heat of the process. To streamline the process further, continuous upgradation and improvements of the canning machinery and automated production lines were also observed.
Soon, retort pouches, which are flexible, lightweight and often more convenient, emerged as an alternative to rigid retort cans. These pouches are made of multi-layer laminated materials, including plastic films and aluminum foil.
After flexible packaging materials gained popularity as an alternative to rigid containers like cans and bottles in the early 1950s, agencies such as NASA and their big-budget research departments focused their resources and energies on the development of packaging materials, especially for space missions. This was due to the many advantages, such as lightweight, easy handling, and space efficiency, offered by flexible packaging.
In the 1960s, NASA sought packaging solutions that would be lightweight, compact, and capable of preserving food for a long period of time without refrigeration. The resulting innovation paved the way for the retort pouch.
In the 1970s, retort pouches were first commercialized in Japan by a packaging company called Toyo Seikan. Toyo Seikan introduced a pouch made of laminated films with excellent barrier properties to protect the contents from oxygen, moisture, and light. These packs also offered the benefits of quick heating and product visibility.
Today, retort pouches are used for packaging various food items, including sauces, gravies, pet foods, baby foods, seafood, vegetables, and even beverages like coffee and juices. Innovations include features such as resealable zippers, spouts for pouring, tear notches for easy opening, and microwave-safe designs.
Retort packaging continues to evolve, with innovations in materials, opening mechanisms, and heat distribution techniques to ensure food safety and quality.
