Why More Brands Are Replacing Cans with Retort Pouches

More and more brands are switching from metal cans to retort pouches — especially for pet food, frutos do mar, and ready-to-eat meals.

Today, sobre50% of new ready-meal and pet food products have replaced cans with pouches.

The global retort pouch market is growing steadily as brands look for packaging that’s lighter, easier to use, and more cost-efficient.

What Are Retort Pouches?

Retort pouches are heat-resistant food bags made of multiple layers of plastic film.

They can withstand high-temperature sterilization (121°C-135°C), just like metal cans, and keep food shelf-stable foraté 2 years.

Commonly used for:

• Tuna, salmon, and seafood
• Wet pet food
• Luncheon meat and stews
• Refeições prontas para comer

Why Switch from Cans to Pouches?

Lower Shipping & Storage Costs

• A 400g metal can weighs ~50g, while a retort pouch of the same volume is just ~8g
• Lighter packaging = lower air/sea freight
• Flat pouches take 80% less space than cans in warehouses & containers
• Ideal for e-commerce brands, where shipping cost is key

• g. One pet food client saved 15% on total logistics costs after switching to pouches.

Flexible and Easy to Customize

Unlike cans, retort pouches can be made in a wide range of shapes and sizes — from tiny 2g single-serve packs to large 20kg industrial bags.

This flexibility makes them ideal for pet food, frutos do mar, molhos, and processed meats, covering both retail and bulk packaging needs.

For example:

• Many pet food brands use small pouches (like 50g–85g) as trial packs to attract new customers. Others create portable snack-style packs, such as cat sticks, which are easy to carry and feed while traveling.
• Traditional luncheon meat cans are often heavy, hard to open, and take up a lot of space. Some even pose a safety risk due to sharp edges. By switching to retort pouches, brands can offer one-slice-per-pack formats that are:
• Easy to open (no tools needed)
• Lightweight and space-saving
• Safer and more convenient for outdoor, travel, or daily use.

Whether you’re testing a new product, offering variety packs, or improving user experience, retort pouches offer the flexibility to meet your needs.

How Retort Packaging Keeps Food Safe and Shelf-Stable?

• Heat Sterilization: After food is sealed in retort packaging, it goes through a high-heat process (typically 121°C or 250°F) to eliminate harmful microorganisms. This process is similar to pressure cooking, ensuring that the food is safe to eat and free from bacteria like Clostridium botulinum.

• Long Shelf Life: Retort packaging can keep food shelf-stable for up to two years. This reduces food waste and helps with storage and shipping, especially in areas without refrigeration.

• Strong Barrier Protection: The multilayer structure of retort pouches blocks out oxygen, luz, and moisture—all of which can spoil food. This protection ensures the product remains flavorful, nutritious, and safe. And here’s another benefit — retort pouches can also be vacuum-sealed, which removes excess air and further preserves the food’s freshness and shape.

• High-Grade Inks and Adhesives: Retort pouches use special retort-grade inks and adhesives that won’t fade or break under high temperatures. Even after sterilization(like (121°C-135°C ), the bags maintain excellent print quality and structural integrity.

Why Choose Wellfa for Retort Pouches?

Wellfa was founded in 1992, with over 32 years of experience in flexible packaging manufacturing.

Retort pouches are not just one of our products — they’re one of our core specialties. Our team of experienced engineers and technicians works closely with clients to offer:

Material structure suggestions based on food type, temperature, and shelf-life needs.

• Reliable materials with certifications: FDA, EU food contact, SGS, Halal
• Strong technical support for heat resistance, seal strength, and food safety
• Custom shapes, tamanhos, and printing
• Assist with free design

Ready to Upgrade Your Packaging?

Whether you’re launching a new product or improving an existing one, retort pouches can help you save costs, meet modern consumer needs, and protect your food better.

Contact Wellfa today

let’s create packaging that’s smart, seguro, and ready for the future.