Retort pouches are the solution for all products that require thermal treatment after filling. Whether sterilization in an autoclave (retort process) or pasteurization – heat, pressure, and time place the highest demands on the material, seal, and pouch integrity.
As a manufacturer, we develop and produce series-ready retort pouches and retort pouches for food, convenience products, baby food, pet food, and industrial applications. Our solutions are designed for real production conditions – not for laboratory conditions.
Our CASTELLI monomaterial retort pouches combine proven shelf life performance, stable seal seams, and industrial series production with a recycling-oriented material concept.
For high-performance packaging solutions in demanding retort and pasteurization processes.
Our retort pouches are suitable for all products that undergo heat treatment after filling. It doesn't matter whether they are food, specialty products, or pet food—the decisive factor is process reliability after heat and pressure exposure.
Typical areas of application for our retort pouches:
Retortable packaging is essential wherever products are sterilized or pasteurized in pouches.
There is a lot of talk in the market about recycle-ready and sustainable concepts. But in the retort sector, what counts are robust solutions. Our CASTELLI retort pouches made of monomaterial are not only technically developed, but also industrially mature.
For you, this means:
This reduces the risk associated with material changes and enables safe scaling from test runs to large-scale production.
The EU Packaging and Packaging Waste Regulation (PPWR) significantly increases the requirements for recyclability, material efficiency, and design for recycling.
This poses a particular challenge for retort-compatible packaging. Thermal processes require highly resilient material structures – at the same time, material composites should be reduced and recycling-oriented solutions preferred.
Classic aluminum or complex multilayer composites often meet the technical requirements, but their recyclability in existing recycling structures is limited.
Modern monomaterial concepts based on polymers offer an alternative approach here:
They reduce material complexity and support design for recycling – without compromising the necessary process reliability in the autoclave.
The technical design is crucial here: only when these factors are taken into account can a solution be created that reconciles regulatory requirements and product protection.
Thermal processes are uncompromising. During sterilization, high temperatures and overpressure act on the packaging. At the same time, product properties change due to fat content, acidity, or salt content.
Typical challenges in the retort process:
Our retort pouches are specifically designed to withstand these stresses. The seal remains stable, the pouch shape controllable, and packaging integrity guaranteed—even after demanding autoclave profiles.
The acid and salt content in vegetable products place special demands on the material and seam stability. At the same time, long shelf lives are required. Our retort pouches guarantee stable barrier properties and reliable performance even under high process loads.
Rice dishes, pasta, or stews often contain chunks, fat, and sauces. This combination places a particularly heavy strain on the seal. Our retort pouches are designed for these mechanical and thermal requirements and ensure stable series production.
Pressure, temperature, and product fat all act on the packaging at the same time. Here, integrity after the process is crucial. Our solutions ensure reliable tightness and product protection.
Even with milder pasteurization processes, packaging is crucial. Our pasteurizable bags offer secure seams, a clean appearance, and consistent quality.
Would you like to optimize your existing packaging, switch from aluminum composite to monomaterial, or develop a new retortable product line? Whether you are looking to change materials, switch to recyclable packaging, introduce new packaging formats, or optimize existing packaging, we will advise you personally and provide you with a customized quote on request.
tbs-pack GmbHOtto-Hahn-Allee 1 D - 50374 Erftstadt
CEO: Benedikt Schröder, Thomas Stumpp
Telephone: 02235 - 47048 - 0Fax: 02235 - 47048 - 21Technical service - packaging machines: +492235-47048-99E-Mail: info(at)tbs-pack.de
Website: www.tbs-pack.de Online Shop: www.tbs-pack.de/shop
Filling & Capping Machines for Bags
Our machines fill and seal stand-up pouches such as Doypacks reliably and efficiently – ideal for food, pet food or cosmetics.
Pillow Bag Machine Stick-Pack
Our stick-pack machine reliably packs powders, granulates and liquids into slim single portions – compact, hygienic and efficient.
Sleeve-Labeling Machines
Our sleeve-labeling machines apply shrink sleeves precisely to products of any shape, such as tubes, cans and bottles. The PLC control and pneumatic guidance ensure fast format changes and high process reliability. Perfectly compatible with our sleeve shrink tunnels.
Sleeve-Shrink-Tunnels
Our sleeve-shrink-tunnels offer precise shrink wrapping of sleeves for perfect labelling – quickly and reliably.
Sleeve-Steam-Tunnels
Our sleeve-steam-tunnels enable precise shrinking of heat-shrinkable film sleeves on almost all container shapes and film types. Made of stainless steel, they are waterproof, easy to clean and equipped with viewing windows for process monitoring.
Stretch Wrapping Machines & Cobot Palletiser
Our stretch wrappers and cobot palletisers automate packaging and logistics – precisely, safely and perfectly integrated into existing production lines.
A retort pouch is a flexible packaging designed for thermal sterilization in an autoclave (retort process) or for pasteurization processes. It can withstand high temperatures, pressure loads, and defined process times while ensuring tightness and product safety. We are happy to advise you—just write to us info_at_tbs-pack.de
Sterilization in the retort process takes place at higher temperatures and over longer process times in order to completely kill microorganisms and achieve a long shelf life. Pasteurization is a milder thermal process that reduces germs but involves lower temperatures and pressure loads. However, both processes require process-safe, heat-resistant packaging.
Retort pouches are suitable for all products that undergo heat treatment after filling, e.g.:
Yes. Modern mono-material structures can be designed to be retortable, depending on their design. The decisive factors are the material composition, sealing technology, and adaptation to the individual process profile. Our CASTELLI retort pouches are designed for industrial autoclave processes and have been tested in series production.
Depending on their structure, retort pouches are designed for temperatures of up to 121°C or 134°C in autoclaves. The specific design depends on the product, filling weight, and process profile. Inquire now: info_at_tbs-pack.de
In many applications, a changeover is possible. Barrier requirements, process parameters, and desired shelf life must be taken into account. We support material changeovers with samples, tests, and clearly defined approval criteria. Send us an email at info_at_tbs-pack.de.
+49 2235 470480
+49 2235 794796
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