1、Designation: F 1278 96 (Reapproved 2003)Standard Guide forUse and Handling of Flexible Retort Food Pouches in theProcessing Environment1This standard is issued under the fixed designation F 1278; the number immediately following the designation indicates the year oforiginal adoption or, in the case
2、of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. Asuperscript epsilon (e) indicates an editorial change since the last revision or reapproval.1. Scope1.1 This guide is recommended for use by all producers offood in retort pouches. Adherence to th
3、is guide will helpprevent damage to the pouches by preventing and avoidingknown causes of damage that occur in the processing environ-ment.1.2 This guide for flexible retort food pouches is based onthe recommendations of a task force created by the Departmentof the Army in 1986.2The purpose of the t
4、ask force was todetermine the possible causes of holes in pouches of foodproduct produced for operational rations for the Department ofDefense at that time. Members of the task force visited severalfood processors to observe and evaluate manufacturing meth-ods commonly being used for processing reto
5、rt pouches. Therecommendations in this guide should be useful as the basis forgood manufacturing practices and employee training programsused by food pouch processors.31.3 This standard may involve hazardous materials, opera-tions, and equipment. This standard does not purport toaddress all of the s
6、afety concerns associated with its use. It isthe responsibility of the user of this standard to establishappropriate safety and health practices and determine theapplicability of regulatory limitations prior to use.2. Terminology2.1 Definitions:2.1.1 defectany damage to a flexible pouch that wouldal
7、low the entrance of foreign substances or the escape of thepouch contents.2.1.2 flexible retort food poucha flat container formedfrom flexible materials, sometimes laminated with a layer ofmetallic or other barrier material. It is designed to be hermeti-cally sealed, compatible with the thermal ster
8、ilization process,and to protect the contained food from recontamination.Because of the generally flat profile when filled, the productmay be easily reheated.2.1.3 retort rackscompartmented shelf-like racks in-tended to be stacked in layers in retort carts during use. Racksshould be designed to hold
9、, separate, and often restrainindividual pouches during the retorting cycle. To prevent pouchdamage, the rack design must provide for support of the pouchduring retorting, while still allowing heat transfer from theheating and cooling medium.3. Significance and Use3.1 Use of this guide, supplemental
10、 to the use of properlydesigned and maintained equipment and effective managementof the production unit process, is expected to minimize costsand product loss. Training of operational personnel is essential.Each of the topics stated in this guide should be addressed inthe producers program of traini
11、ng for operators and supervisorsto ensure that each individual is aware of them and consciouslyemploys them wherever the need or opportunity exists.4. Personnel Considerations4.1 Employee Training:4.1.1 Careful handling Employees should be trained tohandle pouches very carefully to avoid causing def
12、ects.NOTE 1A keen awareness of factors affecting pouch integrity must bepromoted through on-going employee training and education. Employeesshould demonstrate an attitude of care and concern for pouch integrity.While pouches are moving through the production process, being filled,sealed, heated, and
13、 handled by inspectors and other operators, they aremost susceptible to damage. They are relatively safe from being damagedonce they have been put into protective cartons or shipping containers.Until then, extreme care must be taken to avoid possible damage to thepouches which can lead to food spoil
14、age later.4.1.2 Recognizing defectsManagement should providetraining manuals and selected examples of defects to employ-ees for training, and as reminders of conditions to be avoided.4.2 Safety conditionsEmployees and inspectors should beprohibited from wearing jewelry, wrist watches, neckties, orot
15、her items which could cause either pouch damage or personalinjury.1This guide is under the jurisdiction of ASTM Committee F02 on FlexibleBarrier Materials and is the direct responsibility of Subcommittee F02.50 onPackage Design and Development.Current edition approved Oct. 10, 1996. Published Decemb
16、er 1996. Originallypublished as F 1278 90. Last previous edition F 1278 90.2For additional information, see Report by Meal, Ready-to-Eat (MRE) TaskForce, July 1986, sponsored by the Office of the Deputy Chief of Staff for LogisticsHeadquarters, Dept. of the Army, Pentagon, Washington, DC 20310.3For
17、additional information, see Flexible Package Integrity Bulletin (Bulletin41-L), available from National Food Processors Assoc., 1401 New York Avenue,NW, Washington, DC 20005 and Classification of Visible (Exterior) FlexiblePackage Defects, published by Assoc. of Official Analytical Chemists, 2200 Wi
18、lsonBlvd, Suite 400, Arlington, VA 22201.1Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.4.3 Hand protection Suitable gloves should be providedon the production line for handling hot products. Gloves alsoprotect pouches from rips cau
19、sed by fingernails.4.4 Adequate staffngAdequate numbers of trained per-sonnel must be assigned to perform all operations with therequired proficiency.4.4.1 Avoidance of conveyor jamsAssign enough opera-tors to enable them to prevent jamming and bunching ofpouches on conveyors and other work surfaces
20、.4.4.2 Avoidance of damage at retortsAssign enoughpeople for loading or unloading retort racks to enable them toprevent rough handling, or dropping of individual pouches, orof racks filled with pouches.4.4.3 Production rate changesWhen production rates areincreased and longer shifts are used, care m
21、ust be taken toensure that equipment and people are prepared to cope withthese increases without allowing damage to pouches.NOTE 2To prevent boredom and a decrease in quality that can occurfrom extended assignment at one position, personnel trained in severalwork functions should be alternated or re
22、assigned, allowing them toperform a variety of different tasks.5. Work Environment5.1 ConditionsWork station conditions should be madeconducive to high morale and productivity, according to goodmanufacturing practices.5.2 Work areaAdequate space should be provided so thateach individual can perform
23、the assigned work carefully.5.3 Sanitizing facilitiesHand washing and sanitizing fa-cilities for food and pouch handlers should be provided in thesame room, adjacent to the work stations, especially betweenthe retort operation and the cartoning operation where warmwet pouches are susceptible to cont
24、amination.5.4 LightingHigh illumination non-glare lighting shouldbe used throughout the production area, with emphasis given towork surfaces.6. Pouch Handling Procedures6.1 GeneralThe best type of quality assurance is theprevention of pouch defects through careful analysis andmonitoring of the entir
25、e process to eliminate the causes ofpouch defects. Elimination of the causes of defects is prefer-able to detecting defects by inspection.6.2 Pouch Filling:6.2.1 Pouch Fill TemperatureIf not otherwise provided,appropriate filling temperature ranges should be established foreach product. Improper fil
26、l temperatures may result in prob-lems such as pouch deformation, excessive head space, or poorseal integrity.6.2.2 Air Removal Use an appropriate evacuation system(steam or vacuum) for the type of product being filled: vacuumfor placeable foods (such as frankfurters or ham) and steam forpumpable fo
27、ods (such as chicken a la king or beef stew).6.3 Pouch Sealing:6.3.1 Pouch Seal Time Synchronize line speed of poucheswith required sealing time to assure adequate time to formgood seals on each pouch.6.3.2 Pouch Seal TemperatureSeal bar temperatureshould be set and monitored for optimum seal charac
28、teristics.6.3.3 Pouch Seal PressureSeal bar pressure should be setand monitored for optimum seal characteristics.6.4 Pouch-to-Pouch ContactPouches should not be al-lowed to fall on or contact other pouches: the firm sharp edgesof one pouch can damage the sides of other pouches.NOTE 3Using pouches wi
29、th rounded corners helps to decrease thepotential for pouches to be punctured or scratched if pouch-to-pouchcontact does occur.6.5 Excessive HandlingAvoid excessive handling andmanipulation of pouches, especially during sampling andinspection. Pouches should be handled individually, one at atime, ra
30、ther than in bunches. Gently pick one up, turn it over,examine it, and gently lay it down when finished.NOTE 4To avoid excessive handling and manipulation of pouchesduring sampling and inspection, it is recommended that machine visionapplications be considered. While currently available machine visi
31、ondevices are not foolproof, there are opportunities for replacing presentmaterial handling and inspection positions with machine vision, or sensorstations, or both. These devices can automatically and repetitivelydetermine the quality of heat seals, presence of alphanumeric or bar codes,cleanliness
32、 of completed packages and other conditions.6.6 FoldingAvoid folding or creasing pouches. Neverfold or crease filled pouches prior to the retorting operation.6.7 DroppingAvoid dropping pouches, and prohibit toss-ing pouches onto other pouches or anywhere. Dropped pouchesshould be set aside for furth
33、er examination and disposition.6.8 Bulk Packing Whenever possible, avoid temporarybulk packing of filled or retorted pouches, since this bringspouches in contact with other pouches and risks damage.6.9 SlidingAvoid sliding pouches across conveyor belts,retort racks, or other pouch handling surfaces.
34、6.10 Loading Retort RacksCarefully place pouches insingle layers to prevent pouches overlapping compartments orprotruding above or out of the retort rack compartments. Avoiddropping pouches into retort racks. Carefully place each pouchindividually into the rack.6.11 Handling Empty Retort RacksCarefu
35、lly stack emptyracks to avoid damaging one rack with another rack.6.12 Handling Full Retort RacksCarefully load full racksinto carts so upper racks do not damage pouches in lowerracks.6.13 Unloading Retort RacksCarefully unload racks bylifting individual pouches to avoid snagging or draggingpouches
36、on rack surfaces.6.14 Pouch Drying Air-dry pouches as soon after retort-ing as possible. The use of mechanical air drying devices ratherthan hand wiping is preferred to avoid excessive handling andpossible contamination.NOTE 5Some significant reasons for drying pouches soon afterretorting include: (
37、1) drying can be accomplished with air easier when thepouches are still warm from the retort, and (2) the dry pouch will not pickup contamination as easily as will a wet pouch.6.15 Visual InspectionVisually inspect pouches betweenremoval from retort racks and just prior to placing into pouchcartons
38、or shipping containers to avoid temporary bulk storage.Check for the presence of holes, tears, abrasions, inadequateseals, product leakage or any combination thereof.F 1278 96 (2003)26.16 PlacementWhen placing pouches into pouch cartonsor shipping containers avoid damaging the pouch by contactwith t
39、he sharp edges of any pouch contact surface or the sharpedges of the carton or shipping container.7. Design, Inspection and Maintenance of Equipment7.1 GeneralEquipment used in the manufacture and han-dling of food pouches must be free of features that could allowthe integrity of the pouch to be com
40、promised. Such featuresinclude burrs, sharp corners, exposed nuts and bolts, and placesfor pouches to drop or bunch up on each other. Equipmentshould be constructed so that all areas that may come in contactwith pouches may be easily and routinely accessed. All suchequipment should be maintained and
41、 routinely inspected toensure that the potential for pouch damage by the equipment isminimized.7.2 Equipment MonitoringWhen pouch inspection re-veals the presence of defects, the cause should be determinedimmediately by checking equipment and conditions on theproduction line preceding that inspectio
42、n station. Correctiveaction should be promptly taken.7.3 Maintenance and InspectionPouch-to-machine con-tact points (at filling and sealing, along conveyors, at retorts,and at inspection and packaging positions) should be checkedfor sharp burrs and snags on a routine basis. Contact pointsshould be c
43、hecked especially following maintenance work,because tools such as wrenches, etc., can leave burrs in themetal. Burrs can be easily detected by wiping the equipmentwith hosiery materials. A burr will snag the material.7.4 Filling Equipment:7.4.1 AlignmentAlign filling equipment so that nozzles donot
44、 distort or otherwise adversely affect the pouch duringfilling.7.4.2 Clean nozzles Maintain and clean filler nozzles asneeded to prevent seal area contamination by dripping product.7.5 Conveying Equipment:7.5.1 Material selectionWhile seamless belts are pre-ferred, belts with metal parts and joints
45、may be used, providedthey are kept smooth to avoid damaging pouches.7.5.2 Synchronization All equipment should be arrangedto ensure an even, continuous flow of product through theoperation, without allowing damage to pouches by droppingthem onto conveyors or onto other equipment. Conveyor linespeeds
46、 should be synchronized with production machinery toprevent piling or bunching of pouches.7.6 Retort Racks:7.6.1 DesignCompartments for pouches must be largeenough to avoid the need to force pouches into them and toavoid folding or overlapping, and small enough to preventlateral movement during reto
47、rting. Retort racks should bedesigned for horizontal placement of pouches, except in thecase of special items such as cakes. Racks should be coated ormade of smooth non-metallic material to avoid metal-to-pouchcontact. However, if metal racks are used, extra care should bepracticed by the employees
48、placing pouches into the cavities.7.6.2 Maintenance Retort racks selected for processingpouches should be handled, inspected, and maintained in amanner that does not lead to the occurrence of defects that maycause damage to the pouches.7.7 Retorts:7.7.1 Water treatment If needed, a descaling solutio
49、n, orsurfactant agreeable to the authorities having jurisdiction, maybe added to the retort water to prevent scaling and to facilitatedrying.7.7.2 InspectionThe appearance of film and loose scaleon pouches being removed from retorts indicates that condi-tions within the retort need to be checked. Interior surfaces ofretorts must be inspected for loose scale as often as necessary,and scale must be removed before it collects on pouches andcauses damage.ASTM International takes no position respecting the validity of any patent rights as
