1、Designation: F1278 96 (Reapproved 2015)Standard Guide forUse and Handling of Flexible Retort Food Pouches in theProcessing Environment1This standard is issued under the fixed designation F1278; the number immediately following the designation indicates the year oforiginal adoption or, in the case of
2、 revision, the year of last revision. A number in parentheses indicates the year of last reapproval. Asuperscript epsilon () 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 this
3、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 task
4、 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 retort
5、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,operations, and equipment. This standard does not purport toaddress all of the safety
6、 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 wouldallow t
7、he 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 steriliza
8、tion 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 intendedto be stacked in layers in retort carts during use. Racks shouldbe designed to hold, separ
9、ate, and often restrain individualpouches during the retorting cycle. To prevent pouch damage,the rack design must provide for support of the pouch duringretorting, while still allowing heat transfer from the heating andcooling medium.3. Significance and Use3.1 Use of this guide, supplemental to the
10、 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 training for
11、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 defects.NO
12、TE 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 handle
13、d 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 spoilage lat
14、er.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.1This guide is under the jurisdiction of ASTM Committee F02 on FlexibleBarrier Packaging and is the direct responsibility of
15、 Subcommittee F02.50 onPackage Design and Development.Current edition approved Oct. 1, 2015. Published October 2015. Originallyapproved in 1990. Last previous edition approved in 2008 as F1278 96 (2008).DOI: 10.1520/F1278-96R15.2For additional information, see Report by Meal, Ready-to-Eat (MRE) Task
16、Force, July 1986, sponsored by the Office of the Deputy Chief of Staff for LogisticsHeadquarters, Dept. of the Army, Pentagon, Washington, DC 20310.3For additional information, see Flexible Package Integrity Bulletin (Bulletin41-L), available from National Food Processors Assoc., 1401 New York Avenu
17、e,NW, Washington, DC 20005 and Classification of Visible (Exterior) FlexiblePackage Defects, published by Assoc. of Official Analytical Chemists, 2200 WilsonBlvd, Suite 400, Arlington, VA 22201.Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United
18、 States14.2 Safety conditionsEmployees and inspectors should beprohibited from wearing jewelry, wrist watches, neckties, orother items which could cause either pouch damage or personalinjury.4.3 Hand protection Suitable gloves should be providedon the production line for handling hot products. Glove
19、s alsoprotect pouches from rips caused 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 jams Assign enough opera-tors to enable them to prevent jamming and bunching ofpouches
20、on conveyors and other work surfaces.4.4.2 Avoidance of damage at retorts Assign 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 areincreas
21、ed and longer shifts are used, care must 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
22、 functions should be alternated or reassigned, 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 provide
23、d so thateach individual can perform 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 wa
24、rmwet pouches are susceptible to contamination.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 carefu
25、l analysis andmonitoring of the entire 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 esta
26、blished foreach product. Improper fill 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 frankfur
27、ters or ham) and steam forpumpable foods (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 temperature shouldbe set
28、and monitored for optimum seal characteristics.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
29、 other pouches.NOTE 3Using pouches with 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 and ma-nipulation of pouches, especially during sampling and inspec-tion. Pouches should
30、be handled individually, one at a time,rather 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 considere
31、d. While currently available machine visiondevices 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
32、 of alphanumeric or bar codes,cleanliness of completed packages and other conditions.6.6 FoldingAvoid folding or creasing pouches. Never foldor crease filled pouches prior to the retorting operation.6.7 DroppingAvoid dropping pouches, and prohibit toss-ing pouches onto other pouches or anywhere. Dro
33、pped pouchesshould be set aside for further 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
34、 racks, or other pouch handling surfaces.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 ra
35、ck.6.11 Handling Empty Retort Racks Carefully stack emptyracks to avoid damaging one rack with another rack.6.12 Handling Full Retort Racks Carefully load full racksinto carts so upper racks do not damage pouches in lowerracks.6.13 Unloading Retort RacksCarefully unload racks bylifting individual po
36、uches to avoid snagging or draggingpouches 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 dr
37、ying pouches soon afterF1278 96 (2015)2retorting include: (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 fro
38、m retort racks and just prior to placing into pouchcartons or shipping containers to avoid temporary bulk storage.Check for the presence of holes, tears, abrasions, inadequateseals, product leakage or any combination thereof.6.16 PlacementWhen placing pouches into pouch cartonsor shipping containers
39、 avoid damaging the pouch by contactwith the 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
40、 allowthe integrity of the pouch to be compromised. 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.
41、All suchequipment should be maintained and routinely inspected toensure that the potential for pouch damage by the equipment isminimized.7.2 Equipment MonitoringWhen pouch inspection revealsthe presence of defects, the cause should be determinedimmediately by checking equipment and conditions on the
42、production line preceding that inspection station. Correctiveaction should be promptly taken.7.3 Maintenance and Inspection Pouch-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
43、 routine basis. Contact pointsshould be checked 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 AlignmentAlig
44、n filling equipment so that nozzles donot 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 areprefer
45、red, belts with metal parts and joints may be used,provided they 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 on
46、to other equipment. Conveyor linespeeds 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
47、 to preventlateral movement during retorting. 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 ca
48、re should bepracticed by the employees 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 t
49、reatment If needed, a descaling solution, 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 scale onpouches being removed from retorts indicates that conditionswithin the retort need to be checked. Interior surfaces of retortsmust be inspected for loose scale as often as necessary, andscale must be removed before it collects on pouches and causesdamage.ASTM International takes no position respecting
