ASTM F1278-96
(Guide)Standard Guide for Use and Handling of Flexible Retort Food Pouches in the Processing Environment
Standard Guide for Use and Handling of Flexible Retort Food Pouches in the Processing Environment
SCOPE
1.1 This guide is recommended for use by all producers of food in retort pouches. Adherence to this guide will help prevent damage to the pouches by preventing and avoiding known causes of damage that occur in the manufacturing environment.
1.2 This guide for flexible retort food pouches is based on the recommendations of a task force created by the Department of the Army in 1986. The purpose of the task force was to determine the possible causes of holes in pouches of food product being used in operational rations for the Department of Defense at that time. Members of the task force visited several food processors to observe and evaluate manufacturing methods commonly being used for processing retort pouches. The recommendations in this guide should be useful as the basis for good manufacturing practices and employee training programs used by food pouch processors.
1.3 This standard may involve hazardous materials, operations, and equipment. This standard does not purport to address all of the safety concerns associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use.
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NOTICE: This standard has either been superceded and replaced by a new version or discontinued.
Contact ASTM International (www.astm.org) for the latest information.
Designation: F 1278 – 96
Standard Guide for
Use and Handling of Flexible Retort Food Pouches in the
Processing Environment
This standard is issued under the fixed designation F 1278; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (e) indicates an editorial change since the last revision or reapproval.
1. Scope metallic or other barrier material. It is designed to be hermeti-
cally sealed, compatible with the thermal sterilization process,
1.1 This guide is recommended for use by all producers of
and to protect the contained food from recontamination.
food in retort pouches. Adherence to this guide will help
Because of the generally flat profile when filled, the product
prevent damage to the pouches by preventing and avoiding
may be easily reheated.
known causes of damage that occur in the processing environ-
2.1.3 retort racks—compartmented shelf-like racks in-
ment.
tended to be stacked in layers in retort carts during use. Racks
1.2 This guide for flexible retort food pouches is based on
should be designed to hold, separate, and often restrain
the recommendations of a task force created by the Department
2 individual pouches during the retorting cycle. To prevent pouch
of the Army in 1986. The purpose of the task force was to
damage, the rack design must provide for support of the pouch
determine the possible causes of holes in pouches of food
during retorting, while still allowing heat transfer from the
product produced for operational rations for the Department of
heating and cooling medium.
Defense at that time. Members of the task force visited several
food processors to observe and evaluate manufacturing meth-
3. Significance and Use
ods commonly being used for processing retort pouches. The
3.1 Use of this guide, supplemental to the use of properly
recommendations in this guide should be useful as the basis for
designed and maintained equipment and effective management
good manufacturing practices and employee training programs
3 of the production unit process, is expected to minimize costs
used by food pouch processors.
and product loss. Training of operational personnel is essential.
1.3 This standard may involve hazardous materials, opera-
Each of the topics stated in this guide should be addressed in
tions, and equipment. This standard does not purport to
the producers program of training for operators and supervisors
address all of the safety concerns associated with its use. It is
to ensure that each individual is aware of them and consciously
the responsibility of the user of this standard to establish
employs them wherever the need or opportunity exists.
appropriate safety and health practices and determine the
applicability of regulatory limitations prior to use.
4. Personnel Considerations
4.1 Employee Training:
2. Terminology
4.1.1 Careful handling— Employees should be trained to
2.1 Definitions:
handle pouches very carefully to avoid causing defects.
2.1.1 defect—any damage to a flexible pouch that would
allow the entrance of foreign substances or the escape of the
NOTE 1—A keen awareness of factors affecting pouch integrity must be
pouch contents. promoted through on-going employee training and education. Employees
should demonstrate an attitude of care and concern for pouch integrity.
2.1.2 flexible retort food pouch—a flat container formed
While pouches are moving through the production process, being filled,
from flexible materials, sometimes laminated with a layer of
sealed, heated, and handled by inspectors and other operators, they are
most susceptible to damage. They are relatively safe from being damaged
once they have been put into protective cartons or shipping containers.
This guide is under the jurisdiction of ASTM Committee F-2 on Flexible Until then, extreme care must be taken to avoid possible damage to the
Barrier Materials and is the direct responsibility of Subcommittee F02.30 on Test
pouches which can lead to food spoilage later.
Methods.
4.1.2 Recognizing defects—Management should provide
Current edition approved Oct. 10, 1996. Published December 1996. Originally
published as F 1278 – 90. Last previous edition F 1278 – 90.
training manuals and selected examples of defects to employ-
For additional information, see Report by Meal, Ready-to-Eat (MRE) Task
ees for training, and as reminders of conditions to be avoided.
Force, July 1986, sponsored by the Office of the Deputy Chief of Staff for Logistics
4.2 Safety conditions—Employees and inspectors should be
Headquarters, Dept. of the Army, Pentagon, Washington, DC 20310.
prohibited from wearing jewelry, wrist watches, neckties, or
For additional information, see Flexible Package Integrity Bulletin (Bulletin
41-L), available from National Food Processors Assoc., 1401 New York Avenue,
other items which could cause either pouch damage or personal
NW, Washington, DC 20005 and Classification of Visible (Exterior) Flexible
injury.
Package Defects, published by Assoc. of Official Analytical Chemists, 2200 Wilson
4.3 Hand protection— Suitable gloves should be provided
Blvd, Suite 400, Arlington, VA 22201.
Copyright © ASTM, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959, United States.
NOTICE: This standard has either been superceded and replaced by a new version or discontinued.
Contact ASTM International (www.astm.org) for the latest information.
F 1278
on the production line for handling hot products. Gloves also and monitored for optimum seal characteristics.
protect pouches from rips caused by fingernails. 6.4 Pouch-to-Pouch Contact—Pouches should not be al-
4.4 Adequate staffıng—Adequate numbers of trained per- lowed to fall on or contact other pouches: the firm sharp edges
sonnel must be assigned to perform all operations with the of one pouch can damage the sides of other pouches.
required proficiency.
NOTE 3—Using pouches with rounded corners helps to decrease the
4.4.1 Avoidance of conveyor jams—Assign enough opera-
potential for pouches to be punctured or scratched if pouch-to-pouch
tors to enable them to prevent jamming and bunching of
contact does occur.
pouches on conveyors and other work surfaces.
6.5 Excessive Handling—Avoid excessive handling and
4.4.2 Avoidance of damage at retorts—Assign enough
manipulation of pouches, especially during sampling and
people for loading or unloading retort racks to enable them to
inspection. Pouches should be handled individually, one at a
prevent rough handling, or dropping of individual pouches, or
time, rather than in bunches. Gently pick one up, turn it over,
of racks filled with pouches.
examine it, and gently lay it down when finished.
4.4.3 Production rate changes—When production rates are
increased and longer shifts are used, care must be taken to NOTE 4—To avoid excessive handling and manipulation of pouches
during sampling and inspection, it is recommended that machine vision
ensure that equipment and people are prepared to cope with
applications be considered. While currently available machine vision
these increases without allowing damage to pouches.
devices are not foolproof, there are opportunities for replacing present
NOTE 2—To prevent boredom and a decrease in quality that can occur material handling and inspection positions with machine vision, or sensor
from extended assignment at one position, personnel trained in several stations, or both. These devices can automatically and repetitively
work functions should be alternated or reassigned, allowing them to determine the quality of heat seals, presence of alphanumeric or bar codes,
perform a variety of different tasks.
cleanliness of completed packages and other conditions.
6.6 Folding—Avoid folding or creasing pouches. Never
5. Work Environment
fold or crease filled pouches prior to the retorting operation.
5.1 Conditions—Work station conditions should be made
6.7 Dropping—Avoid dropping pouches, and prohibit toss-
conducive to high morale and productivity, according to good
ing pouches onto other pouches or anywhere. Dropped pouches
manufacturing practices.
should be set aside for further examination and disposition.
5.2 Work area—Adequate space should be provided so that
6.8 Bulk Packing— W
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