Retort Pouch

Thin and lightweight pouches for ready meals to be heated in the microwave and are suitable for sterilisation.

The packaging of products like ready meals, sauces, soups, olives, chestnuts, and beets requires the ability to undergo sterilisation in pressurised tanks at temperatures of up to 131°C before being packaged. Retort flexible films and pre-made pouches emerge as the ideal packaging solutions for this product category.

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Aropack Retort Pouch

Key Benefits of Retort Bags

In contrast to cans, they reduce retort time and offer convenience in terms of portability and usability. Our retort films and pouches can be crafted with two to four layers with recyclable options upon request.

Product window

Re-sealable Zipper

Laser scoring

Tear notches

Perfect for hot-fill

Rounded corners

Gloss or matte finishes

High barrier films

Withstand temperatures up to 131°C

Two to four layers with recyclable options

Features of Retort Pouches

Explore the complete range of features built into our retort pouches. From advanced barrier protection to custom finishes, each element is designed to enhance performance, product life, and shelf impact.

Sizes

Available in sizes ranging from 20g to 5kg.

Finish Type

Matt, gloss, paper touch, de-metalized, unprinted and spot finish.

Film Properties

Available with oxygen, moisture, light and puncture barriers.

Filling & Sealing

Heat sealable and suitable for hot and cold filling.

Materials

Recyclable mono materials or multi-layer laminates.

Printing

Flexo and gravure print up to 9 colours.

Custom Features for Maximum Impact

Each retort pouch can be customised with:

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Sealing Options

Zipper, Peel Seal, Top Sliders, Child-Resistant, Aplix

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Laser Scoring

Effortless opening, ideal for sturdy & thicker materials

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Rounded Corners

Enhance shelf appeal, improve safety, and ease handling

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Handles

Easy to Carry: side handles, top handles, euro-slots

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Perforations

Allows airflow while maintaining breathability

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Windows

Clear or frosted windows

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High Barrier Films

Extends shelf life and keeps product safe

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Tear Notch

Easy-to-open for convenient consumption

Common Applications for Retort Pouch Packaging

Our retort bags are designed to meet the unique needs of industries, from ready meal and pet food to baby food and more.

Ready Meal

With decades of experience and expertise, we deliver high-temperature flexible packaging solutions tailored for ready-meal products.

Pet Food

Ensuring the nutritional integrity of items like kibble, treats, and supplements, pet owners rely on quality to provide their pets with balanced meals for well-being.

Soup & Dressing

Perfect for hot fill applications and are the ideal solution for packaging ready made soups, sauces, condiments, and dressings.

Baby Food

Designed to preserve the freshness of baby food, by prioritising the health and well-being of your little ones.

Meat & Seafood

Packaging for any type of cooked or uncooked meat & seafood products. Suitable for vacuum processes.

Got questions about retort pouch packaging?

Here are some of the most common queries we get about our retort pouch packaging.

Products like cooked rice, pasta sauces, curries, soups, wet pet food, baby food, and ready-to-eat meals often use retort pouches for extended shelf life without refrigeration.

They undergo thermal processing in a pressure vessel (retort) where high temperature and pressure kill pathogens. This process allows the pouch to achieve similar food safety as canned products.

Typical structures include PET/ALU/CPP or high-barrier PET/EVOH/CPP laminates — designed to resist delamination, maintain seal integrity, and withstand retort conditions.

Retort pouches are designed for commercial sterilisation in pressurised retort chambers. Boilable pouches are typically for home use or low-temp pasteurisation, and cannot handle the same pressure or heat.

Retort pouches can offer a shelf life of 12–24 months without refrigeration, depending on the food type, barrier structure, and processing parameters.

Yes. We supply retort-compatible pouches suitable for form-fill-seal systems or pre-made pouch lines, designed with tolerances to handle high-heat conditions.

Absolutely. Proper headspace is essential to prevent over-expansion during the retort process. It also allows steam and heat to circulate evenly inside the pouch for thorough sterilisation.

Yes, vacuum sealing is required to remove oxygen before thermal processing. It helps minimise pouch expansion during the retort cycle and improves heat penetration for more efficient sterilisation.

Swelling can occur due to insufficient vacuum, overfilling, or incorrect headspace. Inadequate seal strength or poor lamination structure may also lead to pouch bursting under pressure and heat.