STD - Tc.-Flexible Retort Pouch Defects PDF

FLEXIBLE RETORT POUCH DEFECTS
Identification and Classification Manual

Chapter Page
Foreword 1
Flexible Retort Pouch Defects Status Date

Identification and Classification New 31/05/2002
FOREWORD
An important element in the production of any safe, wholesome and good

quality pouched product, is that each pouch meets recognised standards.
This flexible retort pouch defect identification and classification
manual has been prepared in order to:
1. clarify current regulatory requirements for classification of

flexible pouch defects;
2. provide information to assist in the communication of issues

associated with the integrity of hermetically sealed flexible retort
pouches, testing procedures for seal strength and integrity; and
3. provide a standard terminology and description for industry and

government inspectors.
This manual provides for standardised classification criteria as well as

uniform terminology for the assessment of flexible retort pouches. It
also provides details of the various tests, against which a flexible
retort pouch may be assessed. It is important to understand that not all
of the tests are required to be performed by the processor as part of
their quality control system.
31/05/2002
Flexible Retort Pouch Defects

Identification and Classification
Table of Contents
1. INTRODUCTION
2. GENERAL
2.1 Background
2.2 Pouch Material Characteristics and Specifications

2.1.1 Basis Weight of the Laminate
2.2.2 Laminate Tensile Strength
2.3 Pouch Laminates
2.4 Types of Pouches

2.4.1 Pre-formed Pouches
2.4.2 In-line Formed Pouches
2.5 Container Terminology
3. INTEGRITY FACTORS
3.1 Pouch Filling
3.2 Exhausting the Filled Pouch
3.3 Seal Formation

3.3.1 Hot Bar Sealer
3.3.2 Impulse Sealer
3.4 Handling of Closed Pouches
3.5 Post-process Pouch Handling

3.5.1 Pouch Drying
3.5.2 Outer Wrapping
3.5.3 Transit Packaging
31/05/2002
Flexible Retort Pouch Defects

Identification and Classification
Table of Contents
4. EXAMINATION AND EVALUATION PROCEDURES
4.1 Container Examination and Tests

4.1.1 Visual Examination
4.1.2 Static Load Burst Test
4.1.3 Internal Burst Test
4.1.4 Tensile Testing
4.1.5 Residual Air Test - Destructive Test
4.1.6 Residual Air Test - Non-Destructive Test
4.1.7 Dye Test
4.1.8 Incubation Test
4.1.9 Gas Leak Detection
4.2 Inspection of Sealed Retort Pouches
5. DEFECT SEVERITY CLASSIFICATION
5.1 Serious Defect
5.2 Minor Defect
6. INDEX/GLOSSARY
7. DEFECT CATEGORIES
8. BIBLIOGRAPHY
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CHAPTER 1
INTRODUCTION
This is a compliance manual for flexible pouch defect identification and

classification. It is intended as a reference manual for use by quality
control and inspection personnel tasked to evaluate the integrity of
flexible retort pouches. Container integrity is the ability of an
hermetically sealed container to deliver safe wholesome food to the
consumer. Container integrity may be compromised by a wide variety of
defects. These defects may arise throughout the various stages of
container manufacturing, filling, sealing, processing, and handling,
before the container reaches the consumer.
The material in this manual will:
1. provide a basis for assessment of container integrity, by using

standard criteria;
2. assist in communicating specific defect conditions, by using

standardised terminology; and
3. provide a severity classification of the various defect types, by

using standard criteria.
These defect classification standards are applicable to both domestic and

imported product.
This manual also provides some general information on flexible pouch

manufacturing (including factors on pouch integrity and thermal
processing) and testing procedures, of which inspectors and pouch
processors should be aware. The information contained in Chapters 2, 3,
and 4 is included for reference purposes; specific compliance standards
for processing and thermal processing may be found in the CFIA Facilities
Inspection Manual.
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CHAPTER 2
GENERAL
2.1 BACKGROUND
The retort pouch is a flexible laminated food package that can withstand
thermal processing. It has the advantage of offering the shelf stability
of metal cans, coupled with the texture and nutrient value associated
with frozen foods. The retort pouch has been considered the most
significant advance in food packaging since the metal can, and has the
potential to become a feasible alternative to the metal can and glass
jar.16
The U.S. Army promoted the concept of flexible retortable pouches for use
in combat rations in the 1950's. The idea was to have a lightweight,
easy-to-pack, shelf-stable food container in order to eliminate the
heavier traditional can. Research continued through the 1960's. In 1965
the first commercial retort pouches were produced in Italy. In Japan,
retort pouch technology has been widely accepted16 and there are many
varied products on the shelf, ranging from sukiyaki to soup.
Examples of some retort pouches are shown in figure 2.1. The retort pouch
has a number of advantages compared to a metal can.
1. The thin profile permits a reduced heating time and thus less of a
chance to overcook the product while producing better color, firmer
texture and less nutrient loss. The manufacturer has reduced energy
requirements for pouch production as compared to that for metal
cans.14 The pouch (because of its thinner profile) transfers heat
faster to its critical point. During processing, this permits the
required amount of heat for proper sterilisation to reach the
critical point with minimal overcooking of the product near the
peripheral container areas. Thus, for those food commodities subject
to quality loss from excessive heating during the process cycle, the
flexible container offers the benefit of higher quality together
with better retention of the heat-sensitive nutrients.
2. Some pouches have an easy to open notch that eliminates the
requirements for can openers and reduces the risk of cuts.
3. Labels can be printed into the laminate, making them permanent.
4. Flexible pouches are easier to distribute and therefore have lower
transportation costs and require less disposal space.
5. Storage space for empty flexible pouches is also reduced. A 45 ft.
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trailer holds 200,000 8 oz cans or 2.3 million retort pouches.
The retort pouch system has disadvantages in processing.
1. The first obstacle is that processors often require a large capital

investment for the unique machinery. Filling is slower and more
complex compared to metal can lines.
2. The thermal process is complex due to the number of critical
processing parameters which must be monitored (e.g., residual air,
pouch thickness, steam/air mixture). Also, special racking systems
may need to be set up in order to provide optimal heating media flow
and prevent pouch to pouch contact.
3. Since pouches are more easily punctured they may require over-
wrapping for distribution.
4. Specialised equipment such as a burst tester, or a tensile tester is
required for leak detection and container integrity evaluation.
Figure 2.1 Examples of Retort Pouches

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2.2 POUCH MATERIAL CHARACTERISTICS AND SPECIFICATIONS
The choice of materials for the manufacture of retort pouches is very

important. The package must protect against light degradation, moisture
changes, microbial invasion, and oxygen ingress and package interactions.
The material must have sound structural integrity and be able to
withstand retort temperatures as well as normal handling abuse. It must
also comply with regulatory requirements. There are approximately 16
basic laminating materials with 100 different possible combinations.
Characteristics essential to a satisfactory retort pouch are:
Low gas permeability (oxygen)

Low moisture permeability
Low hydrophilic properties
Heat sealable and sterilisable
Constructed of appropriate material (material must be approved by
the Canadian Food Inspection Agency (CFIA))
Resistant to penetration by fats, oils and other food components
Physical strength to resist physical abuse during packing,
retorting, storage and distribution (i.e., tearing, pin-holing,
fatigue, impact and abrasion)
Absence of solvent residues. Chemically inert polypropylene films
require manufacturing catalysts, which must be removed with solvents
before the film can be used for foods.
Bonding materials for the laminates must not migrate into the foods.
High light barrier.
A processor may purchase pouches in a number of different forms. The

flexible pouches can be a pre-formed three-side sealed pouch or formed as
an in-line operation with the filling and sealing combined in a pouch
packager. There are several retort pouch filling and sealing systems
commercially available. One design is shown in figure 2.3, where the
retort pouches are formed from roll stock by folding a single roll along
its centerline and heat sealing the sides together. The tubular material
is automatically cut to length and the bottom is sealed just prior to the
product filling operation.
Control of the laminate quality begins with the component material. Close
control of each raw material used in the manufacture of the retort pouch
must be ensured by establishing the specifications which the final
laminated pouch must meet, and by establishing an effective monitoring
program. Two important properties which need to be monitored during
laminate fabrication are the basis weight of the laminate and the
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laminate tensile strength

.
2.2.1 Basis Weight of the Laminate
The basis weight of the laminate is determined by the use of a laboratory

balance. A sample of the pouch material is cut from the pouch material
and weighed. The equivalent weight of the sample in grams is then
converted into pounds per ream.
Note: 1 ream equals 516 sheets of paper.
2.2.2 Laminate Tensile Strength
The laminate tensile strength is measured using an Instron or similar

tensile tester. The bond strengths of polyester film to foil, and
polypropylene film to film are measured to ensure that the retort pouch
material complies with the manufacturer's specifications.
Processors generally choose the pre-formed pouches. These have three

seals already formed, thus requiring a single heat bar for closing.
Pouches are usually transported to the plant in master cartons of 1000 or
more units.
Processors inspect empty flexible pouches prior to use for: pouch

dimensions, pouch shape, correct material, and manufacturer defects
(i.e., delamination, abrasions, tear notch anomalies). These observations
should be recorded and those pouches not meeting the manufacturer
parameters must be culled out as the hermetic integrity of the pouch may
be compromised.
2.3 POUCH LAMINATES
As shown in figure 2.2, most retort pouches are constructed with a 4-ply
laminate consisting of a polyester outside layer, a nylon 2nd layer, an
aluminum foil 3rd layer, and a polypropylene inside layer. The aluminum
foil can be laminated with either the matte or the shiny side exposed to
view. Normally the matte side is to the outside. Some pouch material has
polyvinylidene chloride (PVDC or SARAN®), ethylene vinyl alcohol (EVOH)
or nylon instead of the aluminum foils in the middle layer. The
components of the laminate are held together with adhesive, which are
usually modified polyolefilms such as ethylene vinyl acetate (EVA).
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Each component performs a specific function that is critical to product

shelf life stability and container integrity.
In some cases a clear layer, to permit viewing of the product, replaces

the foil layer. The materials of choice are generally SARAN® (PVDC),
EVOH or nylon. While these plastics are good barriers to oxygen
molecules, they are not complete barriers, and therefore the shelf life
of the container is reduced substantially.
Figure 2.2 Pouch Laminations
2.4 TYPES OF POUCHES
2.4.1 Pre-formed Pouches
The pre-formed retort pouch, which is the type most commonly used by the
food processor, has three sides already sealed by the retort pouch
manufacturer.
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2.4.2 In-line Formed Pouches
As shown in figure 2.3, roll stock laminate is fed through a tensioning

device to ensure that the flexible pouch is smooth. A plow assembly then
folds the laminate along the centerline, exposing the polypropylene
surfaces to each other. (Some roll stock machines bring two separate
rolls of laminate together.) The seals are formed using a heat-sealing
device and the formed pouches are cut off.
One style of filler, for a liquid product, uses equipment that forms the
pouch, fills and heat seals on a production-line basis. After exiting the
sealer, the web of formed pouches is cut by a roller knife to separate
the individual pouches.
Figure 2.3 Flow Chart of Bartlett Intermittent Motion Flexible Pouch Packager
(From Lopez, 1987, "Retortable Flexible Containers" in "A Complete
Course in Canning and Related Processes - Book II")14
2.5 CONTAINER TERMINOLOGY
Any discussion or description of container defects requires standard

terminology relating to the container components. See figures 2.4 and 2.5
for further details on pouch terminology.
Body - the area of the pouch located within the sealed area. The body of
the pouch will vary in dimensions.
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Coding - lettering or numbering that is permanently marked onto the

flexible pouch. Coding applied by the processor indicates the name of
the processing establishment and the day, month and year of processing.
The coding may be in indelible ink or in any other type of permanent
marking (i.e., embossing the cosmetic seal) that is appropriate to the
container.
Cosmetic seal - a seal applied by the processor. Its function is to

provide an embossing surface or to prevent contamination of the area
directly outside of the seal (refer to figure 2.4).
Laminate - the multi-layered construction characteristic of retort

pouches. In retort pouches there are generally 4 layers that are held
together with adhesive layers. Each layer of the laminate contributes in
some manner to the container integrity.
Manufacturer's seal - the seals applied by the pouch manufacturer. In

pre-formed pouches these generally occur on 3 sides of the pouch.
Processor's seal - the primary seal applied by the processor. This is

intended to complete the flexible pouch's hermetic properties (refer to
figure 2.4).
Roll stock - laminate used by the processor in the production of an

entire pouch.
Seal - the hermetic closing of the container that needs to be secure

against entry of microorganisms. The hermetic seal is achieved by the
fusion of two heat-sealable layers of the laminate material (i.e.,
polypropylene).
Seal tensile strength - maximum force required to tear apart the pouch
seal. Results are expressed in kg per linear mm of seal tested
(pounds per linear inch of seal). Also called the bond strength of a
seal.
Seal width - distance across the bonded area of the pouch seal.
Tear notch - the small cut-away portion of the manufacturer's side seal
that allows the container to be torn open with relative ease (refer to
figure 2.5).
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Figure 2.4 Retort Pouch

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Example of "V" notch design
Example of "U" notch design
Example of "C" notch design
Figure 2.5 Notch Designs

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CHAPTER 3
INTEGRITY FACTORS
Contamination of the processor's seal area is a major problem that

affects the hermetic seal of the flexible pouch. Incorrect vacuum or
improper pouch handling causes this problem. For liquid products, too
high a vacuum could suck product into the seal area just before heat
sealing which could affect the integrity of the seal. Also, improper
handling of empty pouches on-line could result in contamination of the
seal during filling (i.e., post-fill drip from an overhead filler spout).
Two of the major causes of pouch failure are improper filling and
sealing. Sealing with a high order of reliability must be of primary
concern to the processor. Fat and water contamination of seal areas
seriously reduces seal strength reliability.
Incorrect handling of pouches during processing and post process could

cause physical damage to the pouch and seal, which could weaken the seal
or compromise the pouch hermeticity.
Thus, flexible pouch integrity factors are concentrated in three main

areas of the process and are outlined in the following sections of this
manual:
1. Improper filling can cause contamination of the seal area
post-fill drip on seal from filler spout

incorrect vacuum
overfilling
2. Improper sealing will compromise the integrity of the pouch
3. Improper handling during processing or post process can cause damage

to pouch and seal.
3.1 POUCH FILLING
Filling pouches is a critical stage in the operation, since it is

essential that the pouch be filled to the proper level with product and
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that the product never contacts the seal area. Overfilling the pouch must
be avoided because it not only increases the potential of seal
contamination and seal failure, but also could lead to underprocessing
due to the greater thickness.
Product dripping from the filler nozzle after the pouch has been filled
is a potential seal contamination problem that must be prevented. The use
of positive cut-off pumps, the removal of product drips from dispensing
nozzles by blow-off or vacuum suck-back systems, and the use of moveable
protective shields, which greatly reduce the chances of fouling the seal
areas, are essential when fibrous foods or sauces containing particles
are being packed.
In the seafood industry, smoked salmon and other fishery products are
commonly hand filled into preformed pouches through a filling shield,
which serves to prevent seal area contamination.
As each product has its own flow and particle size characteristics,
detailed filler specifications aimed at eliminating seal area
contamination are difficult to define. The following steps can be used
as guidelines to minimise seal area contamination:
1. Fillers should be matched to product characteristics through actual

filling tests. For example, although cake dough may resemble
chicken loaf mix in apparent consistency, comparative tests showed
that an auger filler with a sliding-tube nozzle worked better for
the chicken loaf, while a gear pump (Creamy Package stuffer) with a
rotary valve nozzle performed better for cake dough.
2. Nozzles should be designed with such features as:

circumferential suction holes on nozzle tips to suck back
dripping product;
external suction rings; or
sheet-metal guards to physically prevent drippings from
contaminating seal surfaces.
3. Bottom-to-top filling and no filling within a specified distance

(e.g., 3.8-cm) of the top of the pouch should be specified.
4. Control over the configuration of the pouch opening should be

assured by means of:
conveyor clamps on both leading and trailing pouch edges;
air-jet assistance to initiate opening; and
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external suction cups and/or spoonbill internal forming

devices.
5. Controlled handling of filled pouches during and between operations

will prevent contamination of the seal area.
6. Measures should be in place for the removal of residual package air

to prevent splashing, especially with viscous products prone to air
occlusion (i.e., sugar syrup and gravy). These measures include
obvious care to avoid occluded air, control over the rate of air
removal, and control over product fill temperature to prevent
flashing.
As shown in figure 3.1, winged or formed guards that swing into the
package opening can be used at the moment of filling to physically
protect the inner seal from contamination.
Formed guard placed

into retort pouch Close control
during filling to over
Winged guards protect the inner seal configuration
swing down into area. of pouch
retort pouch opening.
Figure 3.1 Two Styles of Guards for Filling Retort Pouches

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3.2 EXHAUSTING THE FILLED POUCH
The control of the "air content" in the filled pouch, which includes any
inert non-condensable gases such as carbon dioxide, is important. The
residual air content in the sealed pouch could lead to excessive
stressing of the seals during the thermal processing and could
significantly affect the rate of heat transfer.
In some products the "air content" is purposely entrapped in the fill

material for product texture development (i.e., bakery products). In
solid products (such as unblanched meats) large amounts of gas are
trapped in the tissues; also cold-filled sauces or liquids could release
high volumes of non-condensable gases during the thermal process.
A producer may also backflush with an inert gas such as nitrogen. In the
backflush procedure, the headspace gas must be controlled in order to
remove oxygen, which will:
extend shelf life

protect package integrity, and
promote uniform and predictable heat transfer.
The control of "air content" in retortable pouches must be defined as a

critical process factor by the processor, if it will affect the scheduled
thermal process. This is specified in the scheduled process as being the
residual gas.
The product type will determine whether a vacuum sealer should be used.
Some processors use steam tunnel atmosphere to complete the open, fill
and seal operations. Whatever method is used, the processor must consider
the factors that will result in a satisfactory final finished product.
Rapid evacuation of the pouch could result in a failure to allow
sufficient time for proper air removal. Rapid evacuation in a vacuum
sealer will increase the chance of the seal area becoming contaminated,
in products that are hot filled.
3.3 SEAL FORMATION
A hermetic seal is achieved in retortable pouches by the fusion of two

heat-sealable layers (such as polypropylene) to each other. Types of
sealing methods include:
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Contact sealer (hot bar or impulse)

Induction (molecules become excited and heating is by conduction)
Ultrasonic (sound waves excite the polymers to produce heat); and
Dielectric (dielectric waves cause the polymers to re-align).
The most commonly used method is the contact sealer, either with the
impulse sealer or the hot bar. The processor's seal is generally applied
using one of these sealing devices, either within a vacuum chamber, or
without a vacuum chamber, using steam injection to remove headspace air.
There are a number of prerequisites for achieving a good seal:
1. properly formed and undamaged pouches;
2. the absence of foreign materials in the sealing area of the pouch

(e.g., product, oil);
3. the proper placement of the pouches within the jaws of the sealing
machine;
4. flat, smooth and parallel sealing surfaces;
5. miscellaneous factors that can affect the hermetic seal such as:
the temperature of fusion;

the pressure created by the sealing tool holding the pieces
together;
the dwell time of the sealing tool holding the pieces together;
sealing material compatibility; and
seal area contamination and the condition of the sealing
surface.12
Heat-sealing temperatures must fall within the specifications provided by

the laminate manufacturer. If the sealing surface is too hot, the
polyester may delaminate from the foil12. Different polymers will melt
and seal at different temperatures depending on the polymer's molecular
weight and elemental constitution. The most desirable polymer is one
with a wide temperature range. Sealing temperature can be affected by
the thermal conductivity of the sealing jaws, air or gas in the container
head space, and the presence or lack of a container head space. A lower
temperature of sealing may sometimes be compensated for by increasing
pressure and dwell time at the sealing jaws.12 Other factors which might
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be taken into consideration in forming a proper seal are the room and
pouch temperature and the humidity.
An acceptable seal is one where it is impossible to distinguish the

individual surfaces after tensioning a welded seal to the point of
failure. The bond between the sealing layers should be stronger than the
bond between the layers of the laminates. The opposing surfaces must
form a total weld. A performance standard on weld strength must be
established for every type of package13.
The presence of contaminants like moisture, oil or other food particles

can contaminate the seal area and seriously affect the seal weld. The
presence of foreign material can cause voids or blisters to form within
the seal as heat is applied, forming a visible depression as the seal
cools. Voids or food particles may also form channels that permit the
inclusion of bacteria. One proactive approach that has been devised to
address some of these problems is to have sealing bars with curved
surfaces that squeeze out some potential contaminants as they clamp onto
the pouch.
Sealing surfaces must also be smooth, flat and parallel. Contamination

of the sealing bar surface can create convolutions (refer to Chapter 7 -
Contaminated Seal) or impressions on the outside surface of the sealed
pouch. Seal width (as shown in figure 2.4) is an important factor.
3.3.1 Hot Bar Sealer
The "hot bar" has two sealing jaws that clamp down with pressure onto the
pouch. These bars remain hot at all times and as a result it is
sometimes hard to get even heating. It is advisable that a thermocouple
be placed in the sealing bar, to independently measure the temperature at
the sealing point.
It should be noted that the thermocouple reading (read from the control
panel) might differ slightly from the actual temperature on the surface
of the sealing bar. There can be a temperature gradient of several
degrees between the thermocouple reading and the actual temperature on
the sealing bar surface. The temperature on the sealing bar surface can
be checked with a pyrometer and compared to the thermocouple reading on
the control panel.
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It is very important that the food processor knows exactly what the
sealing bar surface temperature is and that this temperature is attained
continually during production.
The processor should have specifications from the pouch supplier for
sealing bar temperature, pressure and dwell time necessary to obtain a
good seal. Using these specifications, it is important that the
processor first validate the heat sealer by running several filled
pouches through the sealer, followed by burst testing. During production,
monitoring the sealing bar temperature, pressure and dwell-time and
carrying out burst testing on a regular basis will demonstrate that the
specifications are achieved on a continuous basis.
3.3.2 Impulse Sealer
The "impulse" sealer has two cold bars that come together under pressure.
An electrical current is sent through the bar producing heat. The
impulse sealer mechanism has many adjustable variables including dwell
time and pressure.
Figure 3.2 Design Criteria for Eliminating Top Seal Wrinkles

(From Lampi, 1976, "Performance and Integrity of Retort Pouch Seals")13
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3.4 HANDLING OF CLOSED POUCHES
Original research has been carried out at various centres for retort
pouches demonstrating the potential for re-contamination as a result of
manual handling of the retort pouches17. Manual handling has been
demonstrated to expose retort pouches to a food-poisoning hazard, in
addition to a commercial spoilage risk. The processor must minimize
manual handling as much as possible, recognising that the risk of re-
contamination could result from either punctured or defective laminate or
as a result of the seal failure. The Quality Management Program controls
the sanitation procedures used by the processor during production. All
equipment and surfaces contacting the pouches must not result in damage
or abrasion to the pouch material.
Pouches should not be overlapped or touching while in the retort, or in

other parts of the process. There is a high probability that pouch-to-
pouch contact will create container defects, as the edges of the pouches
are quite rigid and sharp. In the retort, pouches should be held in
separate compartments that will restrain them and prevent incidental
contact and the overlapping of the individual pouches, called
"shingling". If the processor’s practice is to overlap the loose edges of
the pouches during basket loading, the processor needs to be concerned
that the product inside the pouches does not overlap, as this would
impact on the maximum pouch thickness specified in the thermal process.
Special dividers need to be provided, which would ensure that the
specified pouch thickness could not be exceeded.
Retorts should also be kept clean of rust and scale. Rust and scale may
drop onto the pouches and could cause container defects such as pin-holes
and scratches.
3.5 POST-PROCESS POUCH HANDLING
The safe preservation of food in retort pouches is dependent on the

ability of the sealed pouch to prevent re-infection by microorganisms
leaking through the seals or the pouch body after the product has been
heat processed. To minimise microbial contamination of the pouch's
external surfaces, the processor should follow recognised sanitation
requirements, dry the pouches and enclose them as quickly as possible in
a protective outer-wrap.
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3.5.1 Pouch Drying
Retort pouches should be properly dried after the thermal process to

prevent re-infection by microorganisms leaking through the seals or pouch
body. Minimizing the possibility of microbial contamination of the
pouch's external surfaces can be accomplished through post-process
control procedures, adequate drying of the individual retort pouches and
enclosing the pouches in a protective outer-wrap as quickly as possible.
Water left on the retort pouch presents a possibility that the water
could reduce the strength of the permeable outer-wrap and leave
watermarks or staining.
The product center temperature should be checked on a sample of pouches

taken from various locations throughout the retort baskets. At the time
the pouches are removed from the retort for subsequent handling/drying,
the pouch temperature should be cooled to an internal temperature of 110-
140 0F23 for subsequent air cooling and drying. This temperature is at the
low end of the thermophilic range and thus reduces the possibility of
spoilage by heat-resistant organisms.
Pouch drying is accomplished by utilising a combination of residual heat

to promote evaporation, wetting agents in the retort cooling water, and
mechanical dryers, air blowers or air knives to drive off the adhering
water from the pouches.
3.5.2 Outer Wrapping
The retort pouch is punctured easily by sharp objects and is susceptible

to flex cracking when subjected to repeated flexing and folding. Excess
flexing of the pouches will fracture the foil film and pin-holes will
allow oxygen to enter the container. Excessive vibration or movement of
liquid during shipping can also cause flexing. Both of these problems can
be minimised by the use of appropriate filling, sealing and handling
equipment in the packing plant and by the use of a correctly-sized
envelope or carton for over-packing each unit.
Proper over-packaging techniques must be assessed for each product and

evaluated for durability and shipping exposure. Over-packing the
flexible pouch in a rigid board container so that the container gives
maximum support to all surfaces of the pouch gives good protection to the
seal areas from impact, especially if the case is dropped.
Individual outer-wrap on each pouch is not considered essential for

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distribution of retail size retort pouches. Institutional sizes are

normally packed in a high-quality protective carton that will properly
restrain the pouch during distribution. Prior to packing in the carton
each pouch should receive a final inspection. A product label should be
affixed to the pouch.
It is recommended that final protective packaging be done at the primary

processing plant. If final packaging is done elsewhere, extreme care
should be taken in transportation of the pouches to the final packaging
location. Personnel at the final packaging location should be adequately
trained to inspect the pouches prior to packaging.
3.5.3 Transit Packaging
For retort pouches, various methods of transport and final distribution

procedures are used. Specific requirements for the transit packaging will
vary depending on the conditions that may be encountered. The following
points are normally considered in the specification of the transit
package:
1. The transit packaging should be able to provide protection to the

individual retort pouch. It can be the protective carton as the
outer case or a combination of the over-packing and the outer case.
The transit packaging should be capable of supporting the weight of
stacking and protecting the pouches from any handling abuse.
2. The heights for palletisation and stacking of the cases should be

specified to minimise the risk of compressing the pouch contents and
thereby stressing the seals.
The retort pouches should not be subjected to temperature extremes during

storage and transportation. At low temperatures there may be a danger of
reduced flex-crack resistance and at higher temperatures there may be a
danger of growth of thermophilic organisms which may have survived the
thermal process. High humidity conditions may reduce the strength of the
outer case.
Chapter Page
4 1

CHAPTER 4
EXAMINATION AND EVALUATION PROCEDURES
There are a number of unique container integrity tests that can be

performed on retort pouches. Appropriate methods should be obtained from
the manufacturers of the containers or materials. Unfilled containers
must be tested for bond strength. Filled containers, after thermal
processing, must also be tested on a regular basis and results recorded.
Fusion is necessary for a good seal and exists when the opposing seal
surfaces form a total weld. Such a weld is characterised by the
inability to visually distinguish either opposing seal surface at the
inner seal junction or after seal tensioning beyond the point of failure.
On tensile failure (which can be produced by manual pulling), fusion
exists when fracture of one inner ply at the seal junction occurs and
there is delamination of one ply. If the seal peels away so that the
inner seal surfaces are identifiable, fusion does not exist and the seals
should be rejected.
Seals examined at the time of production may meet tensile and burst test
criteria even though the seals do not have proper fusion. After a short
(24-hour-plus) storage period, such seals may fail when subjected to
handling tests such as vibration and drop cycles. Any processor producing
flexible retort pouches should research the topic thoroughly to ensure
that the production equipment and procedures will result in a fusion seal
which will meet the seal specifications of the pouch material supplier.
Destructive and non-destructive tests for assessing seals for fusion are
described in the following sections.
4.1 CONTAINER EXAMINATION AND TESTS
The examination of retort pouches consists of a number of activities that

will provide both quantitative and qualitative information:
1. visual inspection and external seal measurements to provide an

initial assessment of seal integrity (this includes manufacturer's
seals and tear notch area);
2. burst test to assess seal strength;

Chapter Page
4 2

3. tensile test to verify seal weld (the laminate structure should fail
before the welded seal fails).
4.1.1 Visual Examination
A careful external visual examination of containers and their seals is

the primary means of detecting container defects. This involves:
1. removing the label from the container;
2. carefully examining the edges of each seal for any evidence of

product in the seal area. No product (oil, etc.) should be visible;
3. measuring the width of the seals (manufacturer's and processor's) at

a number of locations along the seal to ensure that they meet
sealing machine specifications and the required minimum width of
3 mm; and
4. examining the seals by grasping the unsealed area of the laminate

and exerting a steady pressure. Observe the package and pouch seals
for signs of seal creep or delamination.
Visual examinations should be done at start up and every 30 minutes with

one unit from each sealing head being tested and the results recorded21,9.
A visual exam should also be done on the pouches slated for burst
testing. Visual defects of concern include misaligned seals, flex
cracking, product contamination of the seal, non-bonding, seal creep,
delamination, and scratches.
Visual examinations should also be done after retorting since container

damage could occur during the retorting, unloading, storage and packaging
stages due to shingling of the pouches, rust in the retort and rough
handling. Culls should be documented for defect type in order to assess
the sealing operation.
Figure 4.1 illustrates a normal fusion seal formed by a hot bar sealer
and an impulse sealer. The heat seals can be either flat or profiled.
Regardless of the physical shape of the sealing jaw or bar, the quality
of the fused seal depends upon:
1. the temperature of the sealing surface materials;

2. the sealing jaw pressure;
3. the sealing dwell time;
Chapter Page
4 3

4. the compatibility of the sealing materials;

5. the absence of seal area contaminants; and
6. the physical condition of the sealing surfaces.
Hot-Bar - normal seal
Thermal Impulse - normal
Figure 4.1 Closure Seal - Visual Inspection Criteria
4.1.2 Static Load Burst Test
A static load burst test (also called a compression test) may be used to
determine the burst strength of a pouch as an indication of correct heat
sealing conditions. A filled and sealed pouch of product, water or other
non-compressible fluid is placed horizontally between two horizontal
parallel plates connected to a load cell and indicating dial gauge. A
standard weight is placed on the top plate for a set period of time.
Pouches must withstand a force of 7.5 kg for 15 mm of internal seal
length applied for 15 seconds13.
Chapter Page
4 4

Figure 4.2 illustrates a static load being applied across the faces of
the pouch. The operator records either the force at which the pouch seal
fails or, if a preset maximum force is applied, the time for which the
pouch is held at that force.
Figure 4.2 Static-Load Burst Test

(From Lampi, 1976, "Performance and Integrity of
Retort Pouch Seals")13
When conducting a static load burst test the following points should be
noted8:
1. The fail force of any pouch specification is related to the

thickness of the filled pouch between the plates at the time of
bursting. Since this thickness is determined by pouch internal
dimensions and filled volume, the placement of the closing seal and
product placement should be carefully controlled.
2. Product temperature can have a significant effect on the results of

the test. Owing to heat transfer between the pouch contents and the
pouch seals, a warm product or warm water can have a weakening
effect on the seal. The degree of weakening depends on the pouch
specification. As an example, a change in seal temperature from
30 0C to 40 0C may reduce the static load test result by as
much as 35 %.
3. The seal damage caused by the static load test is generally less
than that caused by the internal burst test because the force
applied to the seals is from hydraulic pressure and it is relaxed as
Chapter Page
4 5

soon as the pouch bursts. Thus the static load burst test is useful
in locating and diagnosing seal faults. Also, the results of the
static load burst test are generally more variable than those of the
internal burst test, probably owing to the factors mentioned in
points 1 and 2 above.
4. If the test is conducted with actual product in the pouch, the

product must be capable of transmitting a hydraulic pressure to the
seals; thus solid packs cannot be used for filled pouch burst
testing.
5. After any burst test, intact test pouches of product must never be
returned to production.
4.1.3 Internal Burst Test
The internal burst test is used as a good overall test for an hermetic
seal including an indication of correct heat sealing conditions and a
measure of the ability of a package to withstand transportation and
handling. Internal pressure, applied by inflation with air, is used to
stress the seals and the container's response is recorded.
Internal burst testing procedures involve the application of air pressure

at a steady rate of 10 kPa/second (1 psig/second). Three internal burst
testing procedures are as follows1:
1. The dynamic burst test, where inflation continues until the pouch
bursts. The internal pressure at bursting is recorded. This test
is used on fusion type seals.
2. The static burst test, in which inflation is stopped at a specified

pressure and is held at that pressure for 30 seconds. Pass or fail
is recorded. This test is used on fusion type seals.
3. The indexed burst test, in which inflation is stopped at a specified

pressure such as 5 psig and held for 30 seconds, then inflated an
additional .5 psig and held for 30 seconds, with inflation and
holding periods continuing until the pouch bursts. The record
includes the internal pressure at bursting and observations of seal
separation. This test is used for peelable seals.
The internal burst test is to be completed before the tensile strength

test.9 It is generally recommended that internal burst tests be done
Chapter Page
4 6

before and after thermal processing as retorting and storage will reduce
seal strength. Lampi13 found that after sealing, pouches passed 240 kPa
(35 psig) for 30 seconds, while after retorting and storage, the pouches
passed 140 kPa (20 psig) for 30 seconds.
The internal burst testing standard, as outlined in CAN/CGSB-32.302-M87

Use of Flexible Laminated Pouches for Thermally Processed Foods7 is 105
kPa (15 psig), held for 30 seconds with no evidence of seal rupture.
Final seal width should be 3 mm or greater.8 Note that pouches after
retorting must meet these criteria, therefore, pouches prior to retorting
will need to meet a higher criteria such as 140 kPa (20 psig) or
greater.
There are two design types of internal burst testers.
1. Four-sided tester: a needle is inserted into a filled pouch and air

is applied through the needle, as illustrated in figure 4.3;
2. Three-side-seal burst tester: an empty or emptied pouch is placed

over an air source, the jaws are clamped to seal the pouch around
the air source as illustrated in figure 4.4
In each case the pouch should be restrained. Restraint limits the angle
of the seal which would otherwise increase with inflation. By limiting
the angle of the seal, packages with strong seals fail at a higher
pressure than when restraint is not used. This results in a noticeable
difference in pressure at bursting between packages with strong seals
versus weak seals.1
For pouches where the maximum thickness is less than 13 mm (½ in.), a

heavy metal plate restrains the pouch thickness so the confining space
will be no greater than 13 mm (½ in.). For all other pouches the
confining space will be 10 % greater than the thickness of the
container.14
Chapter Page
4 7

Figure 4.3 Internal Burst Test Equipment - 4-sided tester

Pouches are restrained between two plates, shown in the open
position (top picture)
Chapter Page
4 8

3-sided seal tester

showing the open end
of the pouch being
connected to the air
source. The top plate
is shown open.
Pouch open end in

position over the
air source. Open end
is sealed between
seal-bars, which clamp
together around the air
source during the test.
Figure 4.4 Internal Burst Test Equipment - 3-sided tester

Chapter Page
4 9

4.1.4 Tensile Testing
Tensile tests are used as a quality assurance tool for assessing the
inherent sealing qualities of flexible packaging films and are employed
as an optional test. Regardless of the specifics of the technique (sample
widths, equipment, and variable crosshead or jaw separation speeds), the
tensile test can best be used for surveillance of the sealability of
materials and as a spot check on sealing conditions and equipment
operation.13
Prior to carrying out the tensile testing, it is recommended that the

heat sealed specimens be conditioned using 23 ± 2 0C (73.4 ± 3.6 0F) and
50 ± 5 % relative humidity as the standard conditioning atmosphere3. A
minimum of 40 hours conditioning is recommended, although some materials
may require longer conditioning times. Judgment should be exercised in
the selection of conditioning times and procedures, which may be
necessary to meet specific test objectives.
Figure 4.5 Measurement Locations for Seal Strength Test

Chapter Page
4 10

Test strips which are 25.4 mm (1 in.) wide and at least 75 mm (3 in.)
long are removed from the pouch seal as shown in figure 4.5. The edges
must be clean-cut and perpendicular to the direction of the pouch seal.3
Each leg of the test strip is then clamped in the tensile testing device
(as shown in figure 4.6). The sealed area of the test strip should be
equidistant between the clamps and the recommended distance between the
clamps is 25 to 50 mm (1 to 2 in.). The test strip must be aligned in the
clamps so that the pouch seal line is perpendicular to the direction of
pull. The seal must not be stressed prior to the initiation of the
tensile test procedure.3
The seam is slowly pulled apart. The rate of loading should be between
250 and 300 mm/min (10 and 12 in/min).3 The force required to pull the
seal apart is recorded in newtons/metre of width (pounds-force per linear
inch). At least three adjacent samples should be taken from each seal
being tested and average of the sample is compared to manufacturer's
specifications.21
Sample Test Strip

Positioned in Clamps
Figure 4.6 Tensile Test Equipment Showing Sample being Tested

Chapter Page
4 11

Note that the tensile test measures the total force required to cause
failure over the total width of each sample strip. The detection of
channels or stress points and the effect of occluded particles or other
small weak areas within the seal obscured by the adjacent high-strength
areas.
Observe the appearance of the tear at the seal. In a properly formed

seal, the inner ply from each side of the pouch are fused or welded
completely such that when the seal area is pulled apart, the seal does
not peel apart at the original surfaces. Instead, delamination should
occur such that the foil and part of the laminated layer from one side of
the pouch tears off, and adheres to the seal area on the other side of
the pouch. The seal should tear evenly and will appear rough and
marbleised21,13 as shown in figure 4.7.
Typical Failure of Acceptable Seals (with Fusion)
Typical Failure of Unacceptable Seals (Lack of Fusion)
Figure 4.7 Tensile Test Closure Seal Visual Criteria

Chapter Page
4 12

The tensile test report should include the following:
identification of materials being tested;

seal width being tested;
test conditions (temperature and humidity);
type of failure observed (delamination, peel or film break);
maximum force required to cause seal failure for each test strip
(expressed in N/m of test strip width, or lb/in of test strip
width); and
other pertinent information (e.g., statistical calculations, percent
elongation before failure).
4.1.5 Residual Air Test - Destructive Test
The quantity of residual air can be measured during the tear down
examination. The amount of allowable residual air is recorded as a part
of the registered process (generally the maximum is 10 cc26,12, but it may
vary as long as this critical factor is specified in the thermal
process). Too much residual air can exert excessive pressure on the seal
during retorting or result in a product cold spot. Too little residual
air can result in flex cracks forming around the edges of solid product
as the pouch puckers upon cooling.
The test is performed by holding the pouch under water under a funnel
attached to a graduated cylinder filled with water. A corner of the pouch
is cut open under the funnel and the air is squeezed out. The amount of
residual air in the pouch is measured as the water displacement in the
cylinder (as shown in figure 4.8).
The volumetric measurements of air may be corrected to atmospheric

pressure by Boyle's law:
V1 = (Pa - Wh)Vm
Pa
where:
V1 = Volume of air at atmospheric pressure (mL)

Pa = Atmospheric pressure (inches of mercury)
Wh = Pressure of water level in graduated cylinder (inches of
mercury)
Vm = Volume of measured air (mL)
Chapter Page
4 13

Figure 4.8 Residual Air Test Equipment
4.1.6 Residual Air Test - Non-Destructive Test
The non-destructive test involves the principle of natural buoyancy,

where the volume of gas is determined by entering measured values into an
equation derived from Archimedes' principle, Boyle's law, and the
combined gas law. A non-destructive method to determine the volume of
air in hermetically sealed flexible packages has been studied for its
applicability as an acceptance test in specifications. The general
principle of this method involves weighing the package while it is
suspended in water and then reducing the environmental pressure until the
gases in the flexible package expand sufficiently so that the package is
in a state of neutral buoyancy (as shown in figure 4.9).
Processors routinely using the non-destructive testing procedure need to

validate the results of the following non-destructive residual air test
calculations, with destructive residual air test results.
The equation used to determine the volume of air in a flexible package is

as follows:
Chapter Page
4 14

V1 = P2 (D)
P1 - P2
where:
V1 = Volume of air (gas) in package at pressure P1 (mL)

P1 = Atmospheric pressure at the time of the test (in. of mercury)
P2 = Pressure at time package is in a state of neutral buoyancy in
water (in. of mercury)
D = Weight of package in water at pressure P1 (g)
Note: the temperature is kept constant and the density of water is

assumed to be 1 g/1 mL.
Figure 4.9 Weighing the Package in Water

Chapter Page
4 15

To obtain the required data for the equation, the test package is placed
into a transparent cylindrical vessel containing water. The water should
contain a wetting agent to minimise the effect of any air bubbles
clinging to the external surface of the package. The test package is
initially weighted from its position suspended in the water, just below
the water surface (this is weight D).
A vacuum is then applied to the cylindrical vessel containing water and

the package. The package is observed for signs of leakage, such as a
steady stream of escaping bubbles from the leakage location.
To obtain neutral buoyancy, the vacuum in the transparent cylindrical

vessel is increased, gradually allowing the air in the package to expand,
causing the package to rise to the surface (refer to figure 4.10). The
pressure is further adjusted until the package is at the neutral buoyancy
position just below the water line. The pressure reading inside the
vessel is taken at this point by means of a vacuum gauge and is equal to
P2 in the equation.
Note that the values of P1 and P2 are in inches of mercury. A typical

atmospheric reading for P1 may be 30 inches of mercury. In this case, if
the vacuum gauge reading is 0 at atmospheric pressure, then a reading of
10 inches of mercury while under vacuum will be equivalent to 20 inches
of mercury for the value of P2.
Chapter Page
4 16

Figure 4.10 Test Apparatus for Determining Neutral Buoyancy Pressure
It may not be possible to achieve neutral buoyancy for some large size
packages (850 g) which contain a very small amount of air (in the order
of 1 mL or less). This condition should not detract from the value of the
non-destructive test method for the following reasons:
1. if the air content were so low as to be inadequate to cause or

sustain neutral buoyancy, the air volume in relation to the package
size would in such instances meet the required specifications; and
2. it is unlikely that a precise measurement of a very low volume of

air could be obtained for a package, containing actual foodstuffs,
using the conventional destructive test method.
Chapter Page
4 17

4.1.7 Dye Test
The dye test can be used to identify the location of very minute holes.
The container is cut open, contents removed and the inside is cleaned to
remove oil and water. The dye (containing isopropanol and rhodamine B)
is squirted on the inside surface and along the inside seals with a
syringe. After drying for 2 hours, the outside of the container is
observed with UV light to detect dye that has penetrated through any
microleaks 11.
One problem with the dye test is that the solvents used to carry the dye
may attack the plastic, causing false-positive results. The dye test
should be used as a diagnostic test which is used to pin-point the
location of micro-sized holes that have been detected by other tests.
A number of studies have been conducted on the permeability of plain

films and laminated materials to a variety of bacteria. The result of
these studies demonstrates that retortable laminates do not allow
bacterial penetration unless an actual fracture in the laminate exists.
Where actual fractures exist, they can be readily detected by dye stain
techniques that penetrate the defect. Consequently, aluminum foil flex
cracks in the structure represent no immediate microbiological hazard
unless the crack is accompanied by cracks in the plastic components of
the laminate which would allow for dye stain penetration completely
through the laminate14.
4.1.8 Incubation Test
The retorted product is held at temperatures that would encourage the

growth of "spoilage" organisms over a pre-determined period of time
(i.e., 25 oC for 2 weeks). If growth is detected then the hermetic
barrier has been compromised. Bacterial growth may be identified through
standard microbiology tests and/or the presence of gas in the container.
It is difficult to establish a non-destructive microbiological test for

heat-processed pouches unless statistically acceptable sample numbers
have been taken. This sample size is unacceptably high and it is not
feasible to complete microbiological testing on all such samples. The
best compromise is to hold all production for 10-14 days and examine for
swollen or blown spoilage prior to shipping.
Chapter Page
4 18

A small sample should be incubated at relevant temperatures for

microbiological testing to accumulate trend data over a period of time.
Microbiological testing of the sample pouches should be considered an
inspection procedure and should not become a substitute for proper
production line controls.
4.1.9 Gas Leak Detection
Gas leak detection tests have been used successfully in the detection of
micro-leaks. However, the procedure, equipment and time to perform the
test all combine to make this test non-production oriented.
4.2 INSPECTION OF SEALED RETORT POUCHES
Retort pouch processors are encouraged to develop a testing protocol by

working with the sealing machine manufacturer and the pouch material
manufacturer. The evaluation methods for seal quality may differ between
package designs, pouch construction and sealing methods. The frequency of
pouch examinations shall be conducted with sufficient frequency to ensure
adequate seals.
If the processor doesn't have specific testing procedures for the pouch
from the pouch manufacturer, the following table 4.1 will be used for the
minimum frequencies of tests and recommended sample sizes.
Chapter Page
4 19

VISUAL SEAL EXAM - EXTERNAL SEAL APPEARANCE

Inspection Items Frequency Sample Size
Check for: At the sealing machine 1 pouch from each sealer
- wrinkle across the as often as possible. position.
seal
- misaligned seal Minimum time between
- inclusion in the seal inspections is 30
- width of seal minutes. Also after set-
- flex cracks up and sealer
- delamination adjustments.
FILLED POUCH TESTING

Seal strength, and - Once per retort load - 1 pouch from each
(pre-cook), also sealing position
Width of seal - After shutdown
exceeding 30 minutes,
or
- After settings to
sealer are changed
______________________ ______________________
- Once per retort load - a minimum of 4 pouches
(post-cook)
Residual gas test - Once per retort load - 1 pouch
(post-cook)
EMPTY POUCH INSPECTION

- Pouch dimensions Daily. - Random sample of at
- Pouch shape least 20 units.
- Tear notch Also, when changing
- Delamination pouch size or opening a
- Abrasions new box from the
- Day code correct stock manufacturer.
Table 4.1 Retort Pouch Inspection Schedule

Chapter Page
5 1

CHAPTER 5
DEFECT SEVERITY CLASSIFICATION
In addition to defect category and type, retort pouch defects are also
classified according to severity. The following are the definitions used
for severity classification of hermetically sealed and sterilised retort
pouches.
5.1 SERIOUS
A serious condition is one which provides evidence that:
a) there is, or has been, microbial growth in the container contents;

or
b) the hermetic seal of the container has been either lost or seriously
compromised; or
c) the container is unsuitable for distribution and sale as stipulated

in the Food and Drugs Act, section 4, and/or section 27.003 and
27.005 of the Food and Drug Regulations.
5.2 MINOR
A minor condition is one which is clearly an abnormal container

characteristic, but one which does not result in the loss of, or the
potential loss of, container integrity (hermeticity), and consequently
does not represent a potential public health risk.
FOOD AND DRUGS ACT section 4
No person shall sell an article of food that
a) has in or on it any poisonous or harmful substance;

b) is unfit for human consumption;
c) consists in whole or in part of any filthy, putrid, disgusting,
rotten, decomposed or diseased animal or vegetable substance;
d) is adulterated; or
e) was manufactured, prepared, preserved, packaged or stored under
unsanitary conditions.
Chapter Page
5 2

FOOD AND DRUG REGULATIONS 27.003
No person shall sell a low-acid food packaged in a hermetically sealed

container where the container
a) is swollen;
b) is not properly sealed; or
c) has any defect that may adversely affect its hermetic seal.
FOOD AND DRUG REGULATIONS 27.005
No person shall sell a commercially sterile low-acid food packaged in a

hermetically sealed container unless
a) the label or container of the food bears a code or lot number that
identifies, in a legible and permanent manner,
i) the establishment in which the product was rendered

commercially sterile, and
ii) the day, month and year on which the food was rendered
commercially sterile; and
b) the exact meaning of each item in any code or lot number referred to
in paragraph (a) is available to an inspector at the establishment
or, where the food is imported, from the importer.
Chapter Page
6 1

CHAPTER 6
ALPHABETICAL INDEX/GLOSSARY
This section provides an index of defect terminology, including alternate

terminology, specific defect types, and associated defect conditions, and
provides equivalent terms in French.
ABRASION 7.1 ABRASION
BLISTER 7.2 CLOQUE
CHANNEL LEAKER 7.3 CANAL DE FUITE

COMPRESSED SEAL 7.4 JOINT COMPRIMÉ
CONVOLUTION (embossing) 7.4 CIRCONVOLUTIONS (gaufrage)
CONTAMINATED SEAL 7.5 JOINT CONTAMINÉ
COSMETIC SEAL ONLY 7.6 JOINT COSMÉTIQUE SEULEMENT
COSMETIC SEAL 7.7 JOINT COSMÉTIQUE EMPIÉTANT SUR
OVERLAPS PRIMARY SEAL LE JOINT DE FERMETURE
PRINCIPAL
CROOKED SEAL 7.8 JOINT IRRÉGULIER
CUT 7.9 ENTAILLE
DELAMINATION 7.10 SÉPARATION DES COUCHES

DELAMINATION IN 7.10 SÉPARATION DES COUCHES DANS LA
SEAL AREA ZONE DE SCELLAGE
FLEX CRACKS 7.11 CRAQUELURES PAR FLEXION

FRACTURE 7.9 RUPTURE
HOT FOLD 7.12 REPLIURE À CHAUD
INCOMPLETE SEAL 7.13 JOINT INCOMPLET
LEAKER 7.14 FUYARD

LESS THAN 3 mm 7.15 LARGEUR DE JOINT SOUDÉ EN
SEAL WIDTH CONTINU INFÈRIEURE À 3 mm
MISALIGNED SEAL 7.16 JOINT DÉSALIGNÉ
NON BONDING 7.17 ABSENCE DE LIAISON

NOTCH LEAKER 7.18 ENCOCHE FUYANTE
Chapter Page
6 2

PUNCTURE 7.9/7.19 PERFORATION (trou)
SEAL CREEP 7.20 FLUAGE DE JOINT

SEAL FORMED > 25 mm 7.21 JOINT FORMÉ À PLUS DE 25 mm
FROM POUCH EDGE DU BORD DU SACHET
STRINGY SEAL 7.22 JOINT FILAMENTEUX
SWOLLEN PACKAGE 7.23 BOMBAGE
UNEVEN SEAL JUNCTURE 7.24 JOINTURE NON UNIFORME
WAFFLING 7.25 GAUFRAGE

WRINKLE 7.26 RIDE
WAVY SEAL (alternate term) 7.24 JOINT ONDULÉ (synonyme)
Chapter Page
7 Index

CHAPTER 7
DEFECT CATEGORIES
7.1 Abrasion
7.2 Blister
7.3 Channel Leaker
7.4 Compressed Seal (or delamination in the seal area)
7.5 Contaminated Seal
7.6 Cosmetic Seal Only
7.7 Cosmetic Seal Overlaps Primary Seal
7.8 Crooked Seal
7.9 Cut (or Fracture)
7.10 Delamination
7.11 Flex Cracks
7.12 Hot Fold
7.13 Incomplete Seal
7.14 Leaker
7.15 Less than 3 mm of Continuous Bonded Seal Width
7.16 Misaligned Seal
7.17 Non-bonding
7.18 Notch Leaker
7.19 Puncture
7.20 Seal Creep
7.21 Seal Formed Greater Than 25 mm from the Pouch Edge
7.22 Stringy Seal
7.23 Swollen
7.24 Uneven Seal Juncture
7.25 Waffling
7.26 Wrinkle
Chapter Section Page
7 1 1

DEFECT: ABRASION
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CLASSIFICATION:
Abrasion is considered a serious defect if:
1) the abrasion penetrates deeper than the outer layer; or

2) testing shows that there has been a loss of hermetic integrity. Deep
scratches that can be felt as indentations must be tested for hermetic
integrity.
Abrasions are considered to be minor defects if only the outer layer is abraded.
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DESCRIPTION:
An abrasion is a scratch through any of the layers of the package. A serious

abrasion penetrates the foil or the inner polypropylene layers.
A minor abrasion is also called a scuff. It will only affect the outer layer(s) of
the pouch. The foil layer is not affected.
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COMMON SOURCES:
1) The pouches were manually scraped on the retort racks, other equipment or
other pouches.
2) Pouches rotated or shifted over top of one another (for example, if

unrestrained in retorts or in bulk packaging).
3) Plastic was left on the sealing bar from previous sealing.

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7 1 2

DEFECT: ABRASION
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7 2 3

DEFECT: BLISTER
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CLASSIFICATION:
A blister is considered a serious defect if the width of the continuous intact

seal is reduced to less than 3 mm (3/32-inch).
A blister is considered a minor defect if there is 3 mm (3/32-inch) or more of

continuous intact seal.
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DESCRIPTION:
A blister appears as a void within the bonded seal. A blister resembles a bubble
or has a raised appearance in the sealed area of the retort pouch.
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COMMON SOURCES:
1) Food, grease or other contaminants were present in the seal area during seal
formation.
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7 2 4

DEFECT: BLISTER
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7 3 5

DEFECT: CHANNEL LEAKER

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CLASSIFICATION:
A channel leaker is considered a serious defect.

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
DESCRIPTION:
This is an area of "non-bonding" across the width of the seal that will generally
leak. If a retort pouch has a channel leaker, it can usually be detected by
applying pressure towards the seal.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
COMMON SOURCES:
1) The sealing bar settings were not correct (i.e., the temperature, pressure
and/or dwell time).
2) Contaminants were present in the seal area during seal formation.

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 3 6

DEFECT: CHANNEL LEAKER

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
View of Channel Leaker from Inside of Pouch

(arrow indicates channel)
7 4 7

DEFECT: COMPRESSED SEAL

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
CLASSIFICATION:
A compressed seal is considered a serious defect if:
1) there is visual evidence of seal overheating, such as bubbles or exposed

foil; and
2) there is less than 3 mm (3/32-inch) of continuous "good" seal (non-
delaminated area) remaining.
A compressed seal is considered a minor defect if:
1) there is some visual evidence of seal overheating, such as bubbles or

exposed foil; and
2) there is more than 3 mm (3/32-inch) of continuous "good" seal (non-
delaminated area) remaining.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
DESCRIPTION:
A compressed seal is any separation of the laminated plies in the seal area. The
material bond strength is questionable in the area of the defect.
If the delamination continues into the "body" of the pouch, assess the defect
under DELAMINATION.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
COMMON SOURCES:
1) The sealing bars were too hot during seal formation.
2) Material bond strength is inadequate.

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 4 8

DEFECT: COMPRESSED SEAL

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
Delamination and Bubbling of the Polyester Laminate
Polyester Laminate has Melted Due to Overheating of the Seal

7 5 9

DEFECT: CONTAMINATED SEAL

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
CLASSIFICATION:
A contaminated seal is considered a serious defect if the seal width is reduced to

less than 3 mm (3/32-inch).
A contaminated seal is considered a minor defect if the seal width is greater than
3 mm (3/32-inch).
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
DESCRIPTION:
Foreign material is trapped in the seal area. A retort pouch with contamination
will have a noticeable raised area in the seal where the sealing bar has sealed
over the contamination.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
COMMON SOURCES:
1) The seal area was contaminated during the filling stage.

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 5 10

DEFECT: CONTAMINATED SEAL

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 6 11

DEFECT: COSMETIC SEAL ONLY

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
CLASSIFICATION:
A cosmetic seal only is considered a serious defect.
If the processor has documentation indicating that the cosmetic seal is tested
using the same standards and at the same frequency as a primary seal, the cosmetic
seal will be assessed as if it were a primary seal.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
DESCRIPTION:
The primary seal is incomplete or non-existent and the only seal providing the
hermetic condition is the cosmetic seal.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
COMMON SOURCES:
1) A manufacturing step was missed.
2) The primary sealing bar malfunctioned.

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 6 12

DEFECT: COSMETIC SEAL ONLY

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
Pouch with Cosmetic Seal Only
Pouch on Left with Both Primary and Cosmetic Seals;

Pouch on Right with Cosmetic Seal Only
7 7 13

DEFECT: COSMETIC SEAL OVERLAPS PRIMARY SEAL

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
CLASSIFICATION:
Cosmetic seal overlaps primary seal is considered a serious defect when the width
of the primary seal is reduced to less than 3 mm (3/32-inch).
Cosmetic seal overlaps primary seal is considered a minor defect when the width of
the primary seal has more than 3 mm (3/32-inch) of bonded seal.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
DESCRIPTION:
The cosmetic seal, generally applied in a separate operation from the primary
seal, overlaps into the primary seal area. The cosmetic seal must be formed before
the pouch is thermally processed.
Cosmetic seals are not considered essential if the pouches are processed and
handled properly. The inner edge of the primary closing seal is considered a
critical factor to the hermetic seal of the pouch. The inner portion of the
primary seal must be maintained as a continuous seal with a minimum width of
3 mm (3/32-inch).
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
COMMON SOURCES:
1) The pouch was misaligned in the jaws of the cosmetic sealer.

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 7 14

DEFECT: COSMETIC SEAL OVERLAPS PRIMARY SEAL

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 8 15

DEFECT: CROOKED SEAL

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
CLASSIFICATION:
A crooked seal is a serious defect if the seal width is reduced to less than
3 mm (3/32-inch).
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
DESCRIPTION:
A crooked seal is a seal that is not parallel to the cut edge of the pouch.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
COMMON SOURCES:
1) The pouch was misaligned in the sealing jaws.

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 8 16

DEFECT: CROOKED SEAL

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 9 17

DEFECT: CUT (or Fracture)

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
CLASSIFICATION:
A cut is considered a serious defect.

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
DESCRIPTION:
This defect is a breach of all layers of the laminate, where the hermetic
integrity of the package has been compromised. This can be a manufacturer defect
if there is equipment damage or "scrap" between the laminate plies during
formation. Compare to PUNCTURE.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
COMMON SOURCES:
1) The pouch has contacted sharp edges of other pouches.
2) The pouch has contacted burrs or sharp corners on equipment.
3) The pouches were abused during on-line or post-process handling.

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 9 18

DEFECT: CUT
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 10 19

DEFECT: DELAMINATION
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
CLASSIFICATION:
Delamination from the outside edge is considered a serious defect when less than 3
mm (3/32 inch) of seal width is remaining.
Delamination of the inner or outer plies, anywhere in the body of the retort
pouch, in excess of 1 cm2 (or equivalent area) is considered a serious defect.
Delamination outside of the sealed area of the pouch is considered a minor defect
if:
1) it does not extend more than 50% from the outside edge into the seal of the
polyester foil; or
2) the delamination of the inner or outer plies, anywhere in the body of the
retort pouch, is less than 1 cm2 (or equivalent area).
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
DESCRIPTION:
The laminate materials separate, often resulting in subsequent loss of the

hermetic integrity of the pouch. This can occur anywhere on the pouch.
Some locations of the delamination do not affect the hermetic seal, but its
presence can cause potential damage during distribution. Some delamination may be
present at the edge of the pouch before retorting.
Delamination outside of the sealed area of the pouch, which extends from the
outside edge into the seal of the polyester foil, could affect the integrity of
the pouch seal strength.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
COMMON SOURCES:
1) If at the seal, the bars were too hot during the seal formation.
2) If located elsewhere on the pouch, the material bond strength is inadequate.
3) The residual air in the retort pouch was not properly controlled to
eliminate sharp corners on the edge, which would make the pouch expand
during retorting.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 10 20

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
Side view of notch delamination

7 10 21

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 11 22

DEFECT: FLEX CRACKS

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
CLASSIFICATION:
Flex cracks are considered a minor defect.
When there is an indication that the flex crack defect has spread due to the
defect location, or pouch-handling system, then the defect should be evaluated to
determine if it should be classified under DELAMINATION.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
DESCRIPTION:
Flex cracks are small breaks in the foil layer of the laminate; they appear as
small cracks in the pouch surface, where only one layer of laminate is affected.
The defect is similar to a delamination.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
COMMON SOURCES:
1) The package flexed during cooking and/or handling.
2) Too much of a vacuum was drawn during sealing.

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 11 23

DEFECT: FLEX CRACKS

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 12 24

DEFECT: HOT FOLD

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
CLASSIFICATION:
A hot fold is considered a minor defect.

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
DESCRIPTION:
A hot fold is a permanent bend in a seal, formed after sealing and before the area
has cooled. This may appear as a large wrinkle or a fold that has been sealed
over.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
COMMON SOURCES:
1) At the sealing machine, the plastic was folded while the pouch material was
still soft.
2) In the retort, the edges of the pouch were folded during the cook process.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 12 25

DEFECT: HOT FOLD

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 13 26

DEFECT: INCOMPLETE SEAL

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
CLASSIFICATION:
An incomplete seal is considered a serious defect.

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
DESCRIPTION:
The seal area does not extend completely across the width of the pouch.
This defect can be detected visually by the sealing bar impression on the retort
pouch seal. The sealing bar impression provides an indication of uniform sealing
bar settings (i.e., pressure, temperature and/or dwell time).
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
COMMON SOURCES:
1) The pouch was not positioned correctly in the sealer, the result being that
the impression is from the gripper instead of the forming bar.
2) The pouch was positioned away from the heating section of the sealing bar.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 13 27

DEFECT: INCOMPLETE SEAL

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
Normal sealing bar impression Impression of gripper (no cross-over)
Primary seal incomplete No cross-over sealing of the

primary seal with the side seal
7 14 28

DEFECT: LEAKER
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
CLASSIFICATION:
A leaker is considered a serious defect.

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
DESCRIPTION:
A leaker is a retort pouch that is unsealed or in some way has lost container
integrity. Contents generally seep from the pouch. The leak may occur anywhere
on the pouch.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
COMMON SOURCES:
1) The pouch was punctured or cut during processing, handling or distribution.
2) The sealing bar settings were not correct (i.e., the temperature, pressure
and/or dwell time).
3) The seal area was contaminated with product, moisture, grease, or other
contaminants.
4) The corner folded during the sealing operation, resulting in non-fusion at

the corner.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 14 29

DEFECT: LEAKER
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 15 30

DEFECT: LESS THAN 3 mm OF CONTINUOUS BONDED SEAL WIDTH

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
CLASSIFICATION:
Less than 3 mm (3/32-inch) of continuous bonded seal is considered a serious

defect.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
DESCRIPTION:
The container seal area has no margin of safety to accommodate problems such as
seal creep, wrinkles.
This requirement for 3 mm (3/32-inch) of continuous bonded seal is especially

important in pouches where the ink stamp or embossed code is placed on the
secondary or cosmetic seal. The producer should ensure that no part of any coding
or stamping is placed in the primary seal area.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
COMMON SOURCES:
1) Defective sealing bars reduced the seal width to less than 3 mm

(3/32 inch).
2) Defects that cross the seal, seal creep or mechanical separation of the weld
reduce the seal width to less than 3 mm (3/32 inch).
3) The ink stamp or embossed code was not placed properly on the secondary or
cosmetic seal.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 15 31

DEFECT: LESS THAN 3 mm OF CONTINUOUS BONDED SEAL WIDTH

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
Manufacturer's Seal was Hole-punched Resulting in

less than 3 mm of Continuous Bonded Seal Width
7 16 32

DEFECT: MISALIGNED SEAL

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
CLASSIFICATION:
Misaligned seal is a minor defect, if there is at least 3 mm (3/32-inch) of

continuous bonded seal width. If there is less than 3 mm of continuous bonded
seal, the defect should be classified under LESS THAN 3 MM OF CONTINUOUS BONDED
SEAL WIDTH.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
DESCRIPTION:
Misaligned seal is a seal that is not formed in a continuous, straight line.

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
COMMON SOURCES:
1) The seal was positioned improperly.
2) The sealing bars were misaligned.
3) The pouch was not placed properly within the sealing jaws.
4) The vacuum packer drew the top of the retort pouch over the shape of a rigid
product (i.e., salmon side) while the pouch bottom lay flat on the sealing
bar.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 16 33

DEFECT: MISALIGNED SEAL

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 17 34

DEFECT: NON-BONDING
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
CLASSIFICATION:
Non-bonding is considered a serious defect.

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
DESCRIPTION:
The sealing films fail to weld (combine) during the sealing process. This defect
appears as a very faint sealing bar impression on the retort pouch seal.
Application of slight pressure to the seal area will cause seal failure.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
COMMON SOURCES:
1) The seal area was contaminated.
2) The sealing bar settings were not correct (pressure/temperature/dwell time).

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 17 35

DEFECT: NON-BONDING
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 18 36

DEFECT: NOTCH LEAKER

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
CLASSIFICATION:
Notch leaker is considered a serious defect.

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
DESCRIPTION:
A leak occurring at the manufactured notch (which is intended for easy opening of
the retort pouch) has compromised the container integrity.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
COMMON SOURCES:
1) The machine setting at the pouch manufacturer was incorrect, allowing the
notch to be cut too far into the seal.
2) The notch was correctly formed but was torn in transit or during handling.
3) The sealing bar settings (temperature, pressure and/or dwell time) were not
correct during sealing "cold seal" next to the notch.
contaminants.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 18 37

DEFECT: NOTCH LEAKER

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 19 38

DEFECT: PUNCTURE
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
CLASSIFICATION:
A puncture is considered a serious defect.

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
DESCRIPTION:
A puncture appears as a mechanical piercing of the pouch that results in the loss
of hermetic integrity. Compare to CUT.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
COMMON SOURCES:
1) Sharp objects such as staples, knives or other similar tools have punctured
the pouch.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 19 39

DEFECT: PUNCTURE
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 20 40

DEFECT: SEAL CREEP

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
CLASSIFICATION:
Seal creep is considered a serious defect when the seal width is reduced to less
than 3 mm (3/32-inch).
Seal creep is considered a minor defect when the seal width has 3 mm (3/32-inch)
of bonded seal present.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
DESCRIPTION:
Seal creep appears as a partial opening of the inside border of the seal.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
COMMON SOURCES:
1) The sealing bar settings (temperature, pressure and/or dwell time) were not
correct during sealing.
contaminants.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 20 41

DEFECT: SEAL CREEP

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 21 42

DEFECT: SEAL FORMED GREATER THAN 25 mm FROM THE EDGE

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
CLASSIFICATION:
Seal formed greater than 25 mm from the edge is considered a minor defect.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
DESCRIPTION:
This defect appears as an unclosed flap between the primary seal and the top edge
of the pouch.
This situation could result in water being trapped between the pouch material,
making drying difficult and providing a potential location for the growth of
moulds and bacteria. In order to minimise this potential hazard, it is recommended
that processors consider applying a cosmetic seal to each pouch.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
COMMON SOURCES:
1) The seal was positioned improperly.
2) The sealing bars were misaligned.
3) The pouch was misaligned within the sealing jaws.

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 21 43

DEFECT: SEAL FORMED GREATER THAN 25 mm FROM THE EDGE

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 21 44

DEFECT: STRINGY SEAL

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
CLASSIFICATION:
Stringy seal is considered a minor defect if there are excessive plastic threads
showing at the edge of the seal area.
When there is an indication that the stringy seal has resulted in excessive
thinning of the seal area, then the defect should be evaluated to determine if it
should be classified under COMPRESSED SEAL.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))--))))))))))))))))
DESCRIPTION:
Stringy seal appears as the presence of plastic threads emerging at the edges of
the cutoff seal.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))--))))))
COMMON SOURCES:
1) The heat and pressure at sealing were excessive.

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 21 45

DEFECT: STRINGY SEAL

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 23 46

DEFECT: SWOLLEN
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
CLASSIFICATION:
This must be treated as a serious defect, unless testing proves otherwise.

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
DESCRIPTION:
The pouch bulges due to gas formation from bacterial contamination, or excess
internal residual air.
The pouch must be checked for weight, microbial growth, or a chemical reaction
such as hydrogen gas production.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
COMMON SOURCES:
1) The pouch was overfilled or a proper vacuum was not drawn, which resulted in
an improper thermal process.
2) The pouch leaked after processing.
3) The pouch was under-processed.
4) There was insufficient chlorine in the cooling water.
5) The post-process handling was too rough.

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 23 47

DEFECT: SWOLLEN
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 24 48

DEFECT: UNEVEN SEAL JUNCTURE

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
CLASSIFICATION:
An uneven seal juncture is considered a minor defect.

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
DESCRIPTION:
The bonded polymer at the inner seal juncture appears wavy or rough (may also be
called wavy seal). This will appear as small wrinkles, but not the fold over type.
The inner seal juncture may also have a wavy appearance.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
COMMON SOURCES:
1) The pouch was misaligned.
2) The pouch laminates were heated unevenly.

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 24 49

DEFECT: UNEVEN SEAL JUNCTURE

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 25 50

DEFECT: WAFFLING
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
CLASSIFICATION:
Waffling is considered a minor defect.

))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
DESCRIPTION:
Waffling appears as heavy embossing of the retort tray rack pattern on the surface
of the pouch body, from contact with the racks during thermal processing.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
COMMON SOURCES:
1) The pouch expanded against the racks during thermal processing and a heavy
impression was left on the surface of the pouch material.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 25 51

DEFECT: WAFFLING
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
Impressions of retort rack pattern on pouch body
Close-up of impression on surface of pouch body - Waffling

7 26 52

DEFECT: WRINKLE
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
CLASSIFICATION:
A wrinkle is considered a serious defect if:
1) the fold in the seal area leaves less than 3 mm (3/32-inch) continuous
acceptable seal; or
2) the fold-over wrinkle extends through all plies across the seal area.
A wrinkle is considered a minor defect if it extends from the inner seal width,
but does not form a channel across the entire seal area.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
DESCRIPTION:
A wrinkle is a material fold on one seal surface, caused when one seal surface is
longer than the other, at least in a localized area at the moment of seal fusion.
A wrinkle can also be a severe fold over both seal surfaces at the time of
sealing. Until experience shows that these wrinkles are not hazards, they should
be avoided, and seals containing such wrinkles should be rejected.
Minor wrinkles or convolutions evident on both sides of the pouch, indented on one
side and raised on the other, may be caused by minor irregularities in sealing bar
or anvil surfaces. These are not channels or leaks and do not constitute a hazard.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
COMMON SOURCES:
1) The sealing surfaces were not flat and parallel or were not tensioned
properly.
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
7 26 53

DEFECT: WRINKLE
))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))
Wrinkle leaves less than

3 mm of acceptable seal
Foldover wrinkle extends through

all plies across the seal area
Chapter Page
8 1

CHAPTER 8
BIBLIOGRAPHY
1. United States Food and Drug Administration (USFDA). 1998.

Bacteriological Analytical Manual, 8th Edition.
2. American Society for Testing and Materials (ASTM) Designation F1140-88,

May 1988, Standard Test Methods for Failure Resistance of Unrestrained
and Nonrigid Packages for Medical Applications.
3. ASTM Designation F88-85, Jan. 1988, Standard Test Method for Seal
Strength of Flexible Barrier Materials.
4. ASTM Designation F1168-88, Oct. 1988, Standard for Use in the

Establishment of Thermal Processes for Foods Packaged in Flexible
Containers.
5. Barnes, Frank L., Paper in FDA "Course Manual - Low-acid Canned Foods",
Retort Pouches, pages 197-21.
6. Canadian General Standards Board, CGSB/ASTM Standard, October 1986,

Standard Practice for the Establishment of Thermal Processes for Foods
Packaged in Flexible Containers.
7. Canadian General Standards Board, CAN/CGSB-32.302-M87, November 1987, Use

of Flexible Laminated Pouches for Thermally Processed Foods.
8. Evans, K.W., R.H. Thorpe, and D. Atherton, Guidelines on Good

Manufacturing Practice for Sterilisable Flexible Packaging Operations for
Low-acid Foods, Technical Manual #4, 1978, Campden and Chorleywood Food
Research Association Group.
9. Gavin, Austin, Lisa M. Weddig, 1995, CANNED FOODS - Principles of Thermal

Process Control, Acidification and Container Closure Evaluation, The Food
Processors Institute, 6th edition.
10. Health and Welfare Canada, 1990, Recommended Canadian Code of Hygienic
Practice for Low-acid and Acidified Low-acid Foods in Hermetically Sealed
Containers (Canned Foods), Minister of Supply and Services Canada.
Chapter Page
8 2

11. Health Protection Branch, Feb. 1989, Tentative Lab Procedure TMFLP-41.
12. Hendrickson, March 1992, Flexible Packaging used in the Thermal

Processing and Aseptic Filling of Low-acid Foods, National Food
Processor's Association (NFPA).
13. Lampi, R.A., G.L. Schultz, T. Ciavarini, and P.T. Burke, 1976,
Performance and Integrity of Retort Pouch Seals, Food Technology 30, 38-
40, 42, 44-45, 47-48.
14. Lopez, Anthony (1987). "Retortable Flexible Containers", in A Complete

Course in Canning and Related Processes, Book II - Packaging, Aseptic
Processing Ingredients, 12th edition. The Canning Trade Inc., Baltimore,
MD.
15. McEldowney, S., M. Fletcher, The Effect of Physical and Microbiological

Factors on Food Container Leakage, Journal of Applied Bacteriology, 1990,
69, 190-205.
16. Mermelstein, June 1978, Retort Pouch Earns 1978 IFT Food Technology
Industrial Achievement Award, Food Technology 32, 22-23, 26, 30, 32-33.
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Contamination of Retort Pouches, Journal of Applied Bacteriology, 1979,
47, 105-111.
18. McEldowney, S., M. Fletcher, 1990, A Model System for the Study of Food
Container Leakage, Journal of Applied Bacteriology, 1990, 69, 206-210.
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Processes for Low-acid Foods in Metal Containers, 1996, National Food
Processors Association, 13th edition, Washington, DC.
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Canned Food Containers, National Food Processors Association, Washington,
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in Flexible Containers, P-FLX, National Food Processors Association,
Washington, DC.
Chapter Page
8 3

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Leatherhead Food RA, Layman's Guide No.20.

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FLEXIBLE RETORT POUCH DEFECTS

Identification and Classification Manual

Flexible Retort Pouch Defects Status Date

An important element in the production of any safe, wholesome and good

1. clarify current regulatory requirements for classification of

2. provide information to assist in the communication of issues

3. provide a standard terminology and description for industry and

This manual provides for standardised classification criteria as well as

Flexible Retort Pouch Defects

2.2 Pouch Material Characteristics and Specifications

2.3 Pouch Laminates

2.4 Types of Pouches

2.5 Container Terminology

3.1 Pouch Filling

3.2 Exhausting the Filled Pouch

3.3 Seal Formation

3.4 Handling of Closed Pouches

3.5 Post-process Pouch Handling

Flexible Retort Pouch Defects

4. EXAMINATION AND EVALUATION PROCEDURES

4.1 Container Examination and Tests

4.2 Inspection of Sealed Retort Pouches

5. DEFECT SEVERITY CLASSIFICATION

5.1 Serious Defect

5.2 Minor Defect

Flexible Retort Pouch Defects Status Date

This is a compliance manual for flexible pouch defect identification and

The material in this manual will:

1. provide a basis for assessment of container integrity, by using

2. assist in communicating specific defect conditions, by using

3. provide a severity classification of the various defect types, by

These defect classification standards are applicable to both domestic and

This manual also provides some general information on flexible pouch

Flexible Retort Pouch Defects Status Date

Flexible Retort Pouch Defects Status Date

trailer holds 200,000 8 oz cans or 2.3 million retort pouches.

The retort pouch system has disadvantages in processing.

1. The first obstacle is that processors often require a large capital

Figure 2.1 Examples of Retort Pouches

Flexible Retort Pouch Defects Status Date

2.2 POUCH MATERIAL CHARACTERISTICS AND SPECIFICATIONS

The choice of materials for the manufacture of retort pouches is very

Characteristics essential to a satisfactory retort pouch are:

Low gas permeability (oxygen)

A processor may purchase pouches in a number of different forms. The

Flexible Retort Pouch Defects Status Date

laminate tensile strength

2.2.1 Basis Weight of the Laminate

The basis weight of the laminate is determined by the use of a laboratory

Note: 1 ream equals 516 sheets of paper.

2.2.2 Laminate Tensile Strength

The laminate tensile strength is measured using an Instron or similar

Processors generally choose the pre-formed pouches. These have three

Processors inspect empty flexible pouches prior to use for: pouch

2.3 POUCH LAMINATES

Flexible Retort Pouch Defects Status Date

Each component performs a specific function that is critical to product

In some cases a clear layer, to permit viewing of the product, replaces

Figure 2.2 Pouch Laminations