Retort pouches for wet food: securely packaged and long-lasting

Wet food for dogs and cats places special demands on packaging. If the filled product is subsequently pasteurized or sterilized, the pouch must reliably withstand the thermal treatment while also protecting the wet food throughout its intended shelf life. As a manufacturer, tbs-pack GmbH develops and produces custom Castelli® retort pouches for wet food. We specifically tailor the material composition, barrier properties, pouch format, and sealing characteristics to the product, the fill volume, and the respective processing method.

What requirements must a retort pouch for wet food meet?

For wet food, the packaging must fulfill several functions at once. Depending on the product and formulation, a suitable barrier against oxygen, moisture, and light is required. It helps protect the flavor and product quality and supports the intended shelf life of the wet food.

Thermal treatment poses a particular challenge. During pasteurization or sterilization, elevated temperatures and other process stresses affect the material and seal lines. The packaging structure must therefore be designed for the specific conditions and ensure that the seal line remains reliably sealed during the process as well as during transport and storage.

There is no one-size-fits-all answer to what material structure and barrier properties are required. Key factors include the recipe, desired shelf life, thermal process, and fill volume. That is why we develop our Castelli® retort pouches individually for each wet food application and can verify the selected design through product, seal, and processing tests.

Retort pouches offer a flexible alternative to traditional packaging such as cans, trays, or jars. From smaller portion pouches for cat food to larger fill volumes for dog food, the format and dimensions can be tailored to the specific application. Custom printing also enables an eye-catching brand and product presentation.

Recyclable Retort Pouches: What Are the Options for Wet Food?

The recyclability of packaging is also becoming increasingly important for wet food. However, particularly for retort applications, it is essential to carefully evaluate which material solutions can actually meet the high technical requirements.

When evaluating recycling-oriented monomaterial solutions, product protection, food safety, necessary barrier properties, sealability, and durability during thermal processing must continue to be ensured. A change in materials must not compromise the safety or shelf life of the wet food.

For this reason, we do not simply classify a retort pouch as “PPWR-compliant” across the board. Instead, we examine the specific application and assess which packaging structure is technically necessary and which recycling-oriented alternatives are suitable for the respective wet food product.

Retort pouches and packaging technology tailored to the application

A reliable packaging process does not depend solely on the retort pouch. The material, pouch format, fill quantity, sealing properties, and machinery must all be coordinated so that the wet food can be reliably portioned, filled, and the pouch securely sealed.

Under the umbrella of Home of Packaging, tbs-pack GmbH and alpha-pack GmbH combine their expertise. tbs-pack GmbH develops and manufactures custom Castelli® retort pouches for wet food, while alpha-pack GmbH complements this by supplying the appropriate filling and packaging technology, such as our automatic Doypack packaging machines. This allows the pouches, material, sealing properties, and machinery to be specifically tailored to the respective application.

Upon request, we also provide support after production. Through Home of Packaging’s fulfillment service, we can handle, among other things, needs-based storage, inventory management, and order processing, as well as domestic and international shipping.