Packtastic is a professional manufacturer of high-performance retort pouches, specifically engineered for the demanding requirements of seafood and tuna packaging. Retort pouches are flexible, heat-sterilizable packages that serve as a modern alternative to traditional metal cans, offering the same commercial sterility with superior convenience.
Our retort pouches are designed to withstand high-temperature sterilization processes (121°C–135°C), delivering shelf-stable seafood products that retain their natural flavour, texture, and nutritional value. Unlike canned tuna, which often contains excess liquid, our pouches preserve the product with virtually no draining required—delivering firmer, fresher-tasting tuna.
We serve seafood processors, ready-meal manufacturers, and foodservice suppliers with custom-designed retort packaging solutions that combine exceptional barrier protection, heat resistance, and brand-enhancing print quality. All materials are food-grade 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 the 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:
Extended shelf life – ambient storage for 12–24+ months
Superior product quality – faster heat penetration than cans, reducing overcooking
Convenience – easy-open, boil-in-bag, and microwaveable options
Space efficiency – lightweight and compact for storage and transport
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 |
| Barrier | Aluminium Foil (7–9μm) | Complete light, oxygen, and moisture barrier |
| Reinforcement | PA/Nylon (OPA) | Puncture resistance, heat penetration |
| Sealant | Retortable CPP | Heat-sealable layer, withstands 121–135°C |
Standard structures include:
PET/AL/NY/RCPP – Four-layer aluminium foil structure with nylon reinforcement for maximum durability and barrier
PET/AL/CPP – Three-layer structure for general retort applications
PET/NY/AL/RCPP – Opaque, puncture-resistant construction ideal for large-capacity seafood packs
Transparent High-Barrier – Without aluminium layer, offering product visibility with good barrier properties
Our retort pouches are engineered to withstand:
Sterilization temperature: 121°C (standard) up to 135°C (high-temperature retort)
Sterilization time: 12–30 minutes depending on product and pouch size
Oxygen permeability: 0 cc/m²/24hr/atm – complete barrier
Process compatibility: Steam, water immersion, and rotary retort systems
| Style | Description | Best For |
|---|---|---|
| 3-Side Seal | Standard flat pouch | Single-serve tuna (150–300g) |
| Stand-Up Pouch | Self-standing with gusseted bottom | Retail ready-meals, premium seafood |
| Spouted Pouch | With re-sealable spout | Liquid seafood products, sauces |
| Zipper Pouch | Re-sealable closure | Multi-use products, bulk packs |
| Large-Format | 2kg+ foodservice packs | Institutional and catering use |
Complete light barrier – Aluminium foil layer prevents photo-oxidation, preserving colour and flavour
Moisture and oxygen barrier – Prevents dehydration and rancidity
Puncture resistance – Nylon layer protects against bone fragments and sharp edges
Easy-open tear notch – Convenient consumer opening
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 |
| Size | Custom dimensions from single-serve to bulk foodservice |
| Material | Aluminium foil, transparent high-barrier, or custom laminates |
| Thickness | Adjustable based on product and processing requirements |
| Printing | Gravure printing, CMYK + spot colours, matte/gloss finishes |
| Features | Tear notches, hang holes, zippers, spouts, easy-peel seals |
Food-grade materials – All layers are non-toxic and migration-free
FDA compliance – Suitable for direct food contact
EU standards – Meeting European food packaging regulations
BRC / ISO 9001 – Certified manufacturing facilities
Traceability – Batch coding for full supply chain tracking
HACCP support – Packaging designed for seafood HACCP plans
Tuna – Chunk light, solid white, flavoured varieties, ready-to-eat meals
Salmon – Fillets, portions, flavoured salmon products
Shellfish – Shrimp, prawns, crab meat
Ready meals – Seafood curries, stews, pasta sauces
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 |
A Chinese manufacturer and global supplier with over 26 years of flexible packaging expertise. Based in the heart of China's flexible packaging production region, we integrate packaging industry resources to deliver reliable solutions worldwide. Trusted by Fortune 500 companies, we focus not only on business, but also on supporting and caring for our customers.
