WHY CHOOSE A CONTINUOUS RETORT? - Retort Basics

13 Jan.,2025

 

WHY CHOOSE A CONTINUOUS RETORT? - Retort Basics

There are multiple solutions available to meet food sterilization requirements. Both Batch Retort and Continuous Retort systems offer mature, well proven methods for this application. So why choose a Continuous Retort process?

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Sterilization is critical for a significant amount of the food we humans consume or feed to our trusted pet companions. Sterilization time and temperature is designed to extend product shelf life and to neutralize Clostridium botulinum, a potent bacterium that can cause death in humans and animals.

Thermal Process Advantage

With a Continuous Retort, interior containers are not nested between outer containers, eliminating the container master-slave heat transfer relationship common to Batch Retort processing.  The STOCK Hydrolock Continuous Retort integrated loader forms a single file array of containers that enter the sterilization chamber in a non-nested format, allowing instantaneous heat penetration to each individual container.

Unlike the Batch Retort, a Continuous Retort requires no Come Up time.  Come Up time is defined as the time it takes all points of the sterilizer to be equal to or greater than the filed process temperature.  By eliminating differential temperature seen by the nested load of a Batch Retort, the STOCK Hydrolock Continuous Retort provides a shorter, more uniform thermal process.

Energy Efficiency

In comparison, a Continuous Retort provides better energy efficiency over an equivalent Batch Retort system. 

The STOCK Hydrolock Continuous Retort can be held at process temperature for as long as there is a need for production.  Unlike a Batch Retort, the Continuous Retort requires no cycling between Come Up, Sterilize and Cooling.  These process phases are maintained in a steady state control loop with indirect heat exchangers, eliminating high demand energy usage needed to heat and cool the metal of the shell.

Layout Consideration

A Continuous Retort requires less floorspace than the equivalent Batch Retort system. 

The STOCK Hydrolock Continuous Retort not only includes the shell for the sterilization process, a fully integrated loading and unloading system is also included within a single frame.  This consolidates overall footprint and facilitates ease of installation.

Batch Retort applications not only require multiple shells for the sterilization process to achieve the same volume as a Continuous Retort, but the Batch Retort system also requires multiple pieces of equipment for container handling including sperate loader, shuttle, unloader, and basket transfer conveyance.

Flexibility and Maintenance

Both the Continuous Retort and Batch Retort offer flexibility when it comes to the types of packaging and products that can be handled and sterilized.  This includes metal cans, glass, pouches, and plastic trays, as well as others. 

A Continuous Retort is usually designed around a specific set of container geometries and has the most benefit in high volume applications.  Batch Retort systems can generally process any container geometry but may require sperate material handling systems for each.

A Continuous Retort requires less maintenance, fewer replacement parts, and less labor to operate than the equivalent Batch Retort system.

Conclusion

The STOCK Hydrolock Continuous Retort is a great fit when your needs are focused on high volume processing in a dedicated set of similar container geometries and your desire is to be as energy efficient as possible, with minimal operational labor, and lower cost of overall maintenance.

Are you interested in learning more about retort manufacturing? Contact us today to secure an expert consultation!

If your requirements demand the need for an array of different container geometries and product processing, the flexibility of a STOCK Batch Retort system may be a better fit.

Why Retortable Pouches are Better Than Cans

A change is taking the supermarkets by storm. Products that used to come in cans are now finding their home in a new packaging medium &#; the retortable stand up pouch.

There has never been a time when we witnessed so many innovations in packaging in such a short span of time. Pet food manufacturers, seafood manufacturers, and other food manufacturers have started to consider this new method of custom food packaging to make their products more appealing to consumers. Retortable pouches offer several advantages over their traditional rival &#; the tin can. Here is a short list of some of these advantages:

(1) Retortable stand up bags are made using special materials, and through the use of a new technology which allows manufacturers to pre-cook food in these packages. They use super-heated water or steam to cook food inside these pouches. Pre-cooking makes the pouches more appealing to consumers as the food requires almost no preparation before eating. The less the cooking, the more the consumers are going to like them.

(2) Retortable stand up pouches are resealable, so consumers do not have to look for a place to store their remaining tuna. These pouches come with a handy zip lock which eliminates the need to buy more storage mediums.

(3) Food in retortable pouches cooks better. Retort packaging offer a large surface area, over which the food is spread out uniformly. This results in faster and more even cooking. In cans, it is not uncommon to find overcooked food near the walls and undercooked food around the center.

(4) Retortable pouches give your brand an increased visibility. These pouches offer a large surface area in front and at the back. Manufacturers can utilize this surface area to create graphic designs to attract consumers' attention. Additionally, these pouches are made using the latest techniques, so they are friendlier towards newer printing methods than traditional packaging mediums.

(5) Supermarkets can place retort packaging on store shelves, or hang them in a peg display. This versatility gives manufactures more visibility.

(6) It is easier and more convenient to store retortable pouches before they have been filled. These packages pack flat, so transport and storage is easier.

(7) Retortable pouches are made from several high quality layers. These layers make the package durable. This durability is comparable to tin cans. And you do not have to worry about any dents either.

(8) Finally, there are no sharp edges. These pouches are many times safer than tin cans because of a complete absence of sharp edges.

These eight reasons clearly demonstrate that standup pouches are better than tin cans. Make your choice wisely.

If you want to learn more, please visit our website customized flexible retort pouch packaging.