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2. Retort Processing ​ New Technologies Report Date:13th April , 2023​ www.foodresearchlab.com |Info@foodresearchlab.com        A Unit of Guires © 2023 |

3. 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]. ​ www.foodresearchlab.com |Info@foodresearchlab.com        A Unit of Guires © 2023 | • Figure 1: The increasing popularity of packaged food has led to advancements in food preservation technologies

4. 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 |

5. 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].​ www.foodresearchlab.com |Info@foodresearchlab.com        A Unit of Guires © 2023 | Figure 2: Saturated steam retorts [3]​

6. 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].​ www.foodresearchlab.com |Info@foodresearchlab.com        A Unit of Guires © 2023 | Figure 3: Water immersion retort [4]​

7. 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]. ​ www.foodresearchlab.com |Info@foodresearchlab.com        A Unit of Guires © 2023 | Figure 4: Water spray retorts[5]​

8. 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 |

9. www.foodresearchlab.com |Info@foodresearchlab.com        A Unit of Guires © 2023 | Figure 5 : Schematic diagram of a retort pouch [7]​

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

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12. 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 |

13. THANK YOU M1. 20% www.foodresearchlab.com |Info@foodresearchlab.com        A Unit of Guires © 2023 |