Packtastic is a professional manufacturer of high-performance retort pouches, purpose-engineered for the demanding requirements of seafood and tuna packaging. Retort pouches are flexible, heat-sterilizable laminated packages that serve as a modern, high-performance alternative to traditional metal cans, delivering the same commercial sterility with superior convenience and product quality.
Our retort pouches are constructed from multi-layer laminates designed to withstand high-temperature sterilization processes (121°C–135°C), delivering shelf-stable seafood products that retain their natural flavour, texture, colour, and nutritional integrity. Unlike canned tuna, which often contains excess liquid and can suffer from overcooking, our pouches preserve the product with superior heat penetration—resulting in firmer, fresher-tasting tuna with virtually no draining required.
We serve seafood processors, ready-meal manufacturers, pet food producers, and foodservice suppliers with custom-designed retort packaging solutions that combine exceptional barrier protection, heat resilience, and brand-enhancing print quality. All materials are food-grade, non-toxic, and compliant with FDA, EU, and GB food-contact standards.
Retort pouches are flexible laminated packages capable of withstanding the high heat and pressure of commercial sterilization. They are processed in retort vessels (pressure cookers) where filled and sealed pouches are heated to sterilize the contents, creating shelf-stable products that require no refrigeration.
For seafood and tuna specifically, retort pouches offer:
| Advantage | Benefit |
|---|---|
| Extended shelf life | Ambient storage for 12–24+ months |
| Superior product quality | Faster heat penetration than cans—reduces overcooking, preserves texture |
| Consumer convenience | Easy-open, boil-in-bag, and microwaveable options |
| Space & weight efficiency | Lightweight and compact—reduces storage and transport costs |
| Premium presentation | High-definition printing for strong brand shelf presence |
Our retort pouches are constructed from multi-layer laminates, each layer serving a specific function:
| Layer | Material | Function |
|---|---|---|
| Outer | PET (Polyester) | Printability, mechanical strength, scuff resistance; thickness ~12μm |
| Barrier | Aluminium Foil (7–9μm) | Complete oxygen, moisture, and light barrier—prevents photo-oxidation |
| Reinforcement | NY/Nylon (BOPA) | Puncture resistance—protects against bone fragments and sharp edges |
| Sealant | Retortable CPP | Heat-sealable layer; withstands 121–135°C without deformation |
Our standard structures include:
PET/AL/NY/RCPP – Four-layer aluminium foil structure with nylon reinforcement; provides maximum durability, complete light/oxygen barrier, and puncture resistance. Recommended for 130–135°C sterilization and products requiring long shelf life with total light protection.
PET/AL/CPP – Three-layer aluminium foil structure for general retort applications.
NY/PE – Transparent, puncture-resistant construction without aluminium layer; suitable for products where product visibility is desired.
Our retort pouches are engineered to withstand rigorous sterilization conditions:
| Parameter | Specification |
|---|---|
| Sterilization temperature | 121°C (standard) up to 135°C (high-temperature retort) |
| Sterilization time | 15–30 minutes depending on product, pouch size, and retort system |
| Bacterial kill rate | 99.9%—ensures commercial sterility |
| Shelf life | 12–24 months at room temperature without refrigeration |
| Process compatibility | Steam, water immersion, and rotary retort systems |
| Material integrity | No deformation, sealing failure, or harmful leaching after sterilization |
| Style | Description | Best For |
|---|---|---|
| 3-Side Seal | Standard flat pouch | Single-serve tuna (150–300g), retail packs |
| Stand-Up Pouch | Self-standing with gusseted bottom | Retail ready-meals, premium seafood presentations |
| Flat-Bottom Pouch | Wide base for stable shelf display | Premium tuna and salmon products |
| Spouted Pouch | With re-sealable spout | Liquid seafood products, sauces, soups |
| Zipper Pouch | Re-sealable closure | Multi-use products, bulk consumer packs |
| Large-Format | 2kg+ foodservice packs | Institutional and catering use |
Complete light barrier – Aluminium foil layer prevents photo-oxidation, preserving natural colour, flavour, and nutritional value
Superior oxygen & moisture barrier – Prevents dehydration, rancidity, and flavour degradation
Puncture resistance – Nylon layer protects against bone fragments, shells, and sharp edges
High-temperature resilience – Withstands retort sterilization without delamination or seal failure
Easy-open tear notch – Convenient consumer opening without tools
Custom printing – High-definition gravure printing up to 10 colours with brand-specific designs
| Option | Details |
|---|---|
| Bag style | 3-side seal, stand-up, spouted, zipper, flat-bottom, large-format |
| Size | Custom dimensions from single-serve (150g) to bulk foodservice (5kg+) |
| Material | Aluminium foil (opaque), transparent high-barrier, or custom laminates |
| Thickness | Adjustable based on product, processing, and protection requirements |
| Printing | 8–10 colour gravure printing, CMYK + spot colours, matte/gloss finishes |
| Features | Tear notches, hang holes, zippers, spouts, easy-peel seals, microwaveable options |
Food-grade materials – All layers are non-toxic, phthalate-free, and migration-free
FDA compliance – Suitable for direct food contact in the US market
EU standards – Meeting European food packaging regulations
BRC / ISO 9001 – Certified manufacturing facilities
Batch traceability – Full supply chain tracking and documentation
HACCP support – Packaging designed to integrate with seafood HACCP plans
Tuna – Chunk light, solid white, flavoured varieties, ready-to-eat meals in oil, brine, or sauce
Salmon – Fillets, portions, flavoured salmon products
Shellfish – Shrimp, prawns, crab meat
Ready meals – Seafood curries, stews, pasta sauces, soups
Pet food – Premium wet pet food in retortable pouches
| Item | Details |
|---|---|
| MOQ | 1,000 pieces (standard); negotiable for trial orders |
| Sample lead time | 5–7 working days (physical samples) |
| Mass production | 10–18 working days (depending on quantity and complexity) |
| Plate-making | 5–7 working days for new gravure cylinders |
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