food product development ideas | food research lab

INTRODUCTION • The demand for ready-to-eat processed food is skyrocketing in emerging nations like India due to changing lifestyles, rising job demands, and nuclear families. • Thermal processing is one of the most important methods for producing packaged, shelf-stable food goods. • Food preservation through canning has advanced to include the retort processing of foods in semi-rigid, flexible laminates. It is a thermal procedure that gives products a longer shelf life while maintaining appropriate nutritional and sensory properties [1]. Figure 1: The increasing popularity of packaged food has led to advancements in food preservation technologies www.foodresearchlab.com |Info@foodresearchlab.com A Unit of Guires © 2023 |

Types of Retort  The three fundamental retort processes are • Steam • Total Immersion. • Falling Water • Each category has further subcategories for steam/air, steam spray, water spray, and partial immersion. • When choosing a particular packaging medium, it is evident that some principles of heat transmission to sealed containers have benefits over others [2]. www.foodresearchlab.com |Info@foodresearchlab.com A Unit of Guires © 2023 |

Steam Retort • The first technique for in-container sterilisation is the saturated steam process. • The technique requires the retort vessel to be saturated with steam since air is considered an insulating medium. • It is necessary for the procedure that all air be let out of the retort by filling the vessel with steam and opening vent valves. • Since air is not allowed to enter the vessel at any point during any sterilisation stage, there is no overpressure during the sterilisation steps of this procedure. • Air overpressure may be supplied throughout the cooling process to avoid container deformation [3]. Figure 2: Saturated steam retorts [3] www.foodresearchlab.com |Info@foodresearchlab.com A Unit of Guires © 2023 |

Water Immersion Retort • The water immersion technology is the overpressure technology most frequently used to sterilise products. • The product is completely shielded from any impact of cooling air during the water immersion process, similar to a saturated steam process in which the product is completely submerged in water. • In contrast to saturated steam, air can be injected into the vessel during sterilisation, adding air (or steam) on top of the water creates overpressure. • In some cases, the steam is heated by the addition of air; the hot air pressurises the processing load and stirs the water as it rises to the surface [4]. Figure 3: Water immersion retort [4] www.foodresearchlab.com |Info@foodresearchlab.com A Unit of Guires © 2023 |

Water Spray Retort  • Like water immersion, the water spray method likewise uses overpressure, but the product is subjected to the effects of overpressure air. • In water spray retorts, steam is the driving force for getting to the centre of the load, and it is comparable to the saturated steam process. • Air can enter the vessel during sterilisation with the Water Spray method, unlike saturated steam, which cannot. • By injecting air (or steam) into the retort, overpressure is created. The spray nozzles vaporise the steam and combine it with the air to overcome the insulating properties of the air [5]. Figure 4: Water spray retorts [5] www.foodresearchlab.com |Info@foodresearchlab.com A Unit of Guires © 2023 |

Retort Pouches • The Reynolds Metals Company, Continental Flexible Packaging, and the United States Army Natick R&D Command developed the retort pouch. • A retort pouch is made of laminated plastic and metal foil with three or four wide seals typically produced through aseptic processing. This makes it possible to package a wide range of beverages in a sterile manner, including everything from water to fully prepared, thermostabilised meals like ready-to-eat meals. • Using this method, cooked or raw food is first prepared and then sealed in a retort pouch. • The pouch is heated inside retort or autoclave machines to 240–250°F (116–121°C) for several minutes under high pressure. This method reliably eliminates all typically present microorganisms, especially Clostridium botulinum, preventing spoilage [6]. • Propylene, the first layer, is a heat-seal surface and offers strength and flexibility. • The nylon layer, which is the following layer, provides abrasion protection. • The aluminium coating enhances the product's shelf life and shields it from light, gases, and odour. • Excellent strength is provided by the last polyester layer, which is also extremely simple to print on. In addition, FDA- approved materials are used for packaging retort pouches, and sterilisation procedures boost the packaging's tensile strength [7]. www.foodresearchlab.com |Info@foodresearchlab.com A Unit of Guires © 2023 |

Advantages Disadvantages • Different sizes and shapes • Not as durable as cans, • Improved graphics capabilities; • Higher packing costs lower processing line • 85% reduction in empty weight and space; lower cost per speed; pouch; • Higher investment cost; • Easy, safe, and less expensive transportation; • The possibility of rodent and insect assault • Shelf life equal to or better than cans; and challenging leakage detection [7]. • No refrigeration or freezing; • Easy opening facility; • Environmental safety; • Destruction by incineration; • Easy reheating before consumption; • No refrigeration or freezing www.foodresearchlab.com |Info@foodresearchlab.com A Unit of Guires © 2023 |

REFERENCES • https://www.researchgate.net/publication/257798204_Retort_process_modelling_for_Indian_traditional_foods • https://www.retorts.com/white-papers/retort-sterilization-process/ • https://www.retorts.com/white-papers/steam-retorts/ • https://www.manage.gov.in/publications/eBooks/seafood%20industrial%20practices.pdf • https://www.retorts.com/white-papers/water-immersion-retorts/ • https://www.sciencedirect.com/science/article/pii/B9780128017739000467 • https://www.mdpi.com/2304-8158/10/5/940 www.foodresearchlab.com |Info@foodresearchlab.com A Unit of Guires © 2023 |

food product development ideas | food research lab

food product development ideas | food research lab

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