Study on the Impact of Reducing Aluminium Foil Thickness on the Barrier Properties of Retort Pouches During Shelf Life: Simulated Physical Stress Considering Distribution Environment

ABSTRACT Retort pouches, valued for their lightness, efficient heat transfer and user convenience, are globally popular. Addressing environmental concerns associated with retort packaging involves efforts to reduce materials and greenhouse gases. We aimed to cut the aluminium foil layer's thickness in retort pouches from 9 to 7 μm. Despite concerns about quality degradation, tests, including crumpling and oxygen permeability measurements, revealed minimal differences between 9‐ and 7‐μm aluminium foil pouches during sterilization and storage. The observed behaviour may be linked to the foil's flexibility. Efforts to decrease foil thickness align with a broader plan to mitigate environmental impact. The study indicates that a reduction from 9 to 7 μm in aluminium foil thickness maintains performance integrity underscoring the feasibility of more eco‐friendly packaging strategies in the context of retort pouches.