Retort Pouch Market Size, Share & Trends Analysis Report By Material (PP, PE, PA), By Packaging Type (Stand-up, Flat), By Closure Type (Tear Notch, Zipper, Spout), By Application, By Region, And Segment Forecasts, 2023 - 2030

Retort Pouch Market Size & Trends

The global retort pouch market size was valued at USD 4.85 billion in 2022 and is anticipated to grow at a compound annual growth rate (CAGR) of 6.2% from 2023 to 2030.Factors such as changing consumer lifestyle and preferences, growing middle class population, and rising number of working people, are expected to drive the demand for packaged foods in the coming years, thereby acting as key drivers for the growth of the retort pouch industry. The growing demand for packaging solutions to extend the shelf-life of food products, such as meat, seafood, baby food, and pet food, is likely to augment the demand for retort packaging over the forecast period. Furthermore, growing demand for pouches owing to their light weight, convenience, and portability as compared to rigid packaging products, is further expected to have a positive impact on market growth.

Retorting is a process in which the prepared food, which can either be semi-cooked or raw, is sealed in a retort pouch. This retort pouch is then heated to a temperature usually ranging between 116-121 °C under high pressure for several minutes inside an autoclave or retort machine. This kills any microorganisms present, thus avoiding food spoilage and extending its shelf life. These pouches have a high surface-to-volume ratio, due to which it takes less time to cook food, compared to metal cans. Also, the heat exposure to food is reduced in retort pouches, which aids in retaining its nutritional value and taste. Retort pouches have a large package space, on which attractive graphics can be easily printed.

Material Insights

Based on material, the market for retort pouches has been segmented into polypropylene, polyethylene, polyamide, polyethylene terephthalate (PET), aluminum foil, and others. Retort packaging is generally manufactured from either three or four plastic laminates, with the inner layer generally made from polypropylene, followed by an optional polyamide layer, a barrier layer of aluminum foil, and an outer layer of PET.

The polypropylene segment accounted for the largest revenue share of 37.4% in 2022 in the retort pouch market. Polypropylene acts as a sealing layer and provides flexibility and strength to the pouch. Polypropylene is a tough and robust plastic material that assists in retaining the freshness of various food items, owing to which it is widely used in manufacturing retort pouches.

The aluminum foil segment is expected to expand at the fastest CAGR of 7.4% during the forecast period. One of the key drivers of the aluminum retort pouch demand is the growing need for convenient and lightweight packaging solutions. Aluminum retort pouches are lightweight and easy to carry, making them ideal for on-the-go consumption. They are also flexible, which allows for easy storage and transportation. The convenience factor associated with these pouches has led to their increased adoption in various industries, including food and beverage, healthcare, and personal care.

The polyamide segment is expected to advance at a significant CAGR through 2030. Polyamide offers properties such as puncture resistance, abrasion resistance, heat stabilization, dimensional stability, and high stiffness, thereby increasing the overall strength of the retort pouch. Aluminum foil, on the other hand, acts as a barrier layer and protects the pouch from odors, light, moisture, and gases.

PET is generally used as an outer layer in retort pouches. It provides strength and also acts as an excellent printable surface, owing to which it is widely utilized in making retort pouches. Moreover, beneficial properties including high strength, lightweight, non-reactivity, flexibility, and recyclability, among others, make PET a suitable choice as a packaging material in retort pouches.

Packaging Type Insights

The global market has been segmented into stand-up pouches and flat pouches, based on packaging type. The stand-up pouches segment accounted for the largest revenue share of 54.9% in 2022 and is further expected to expand at the fastest CAGR of 6.5% during the forecast period, owing to their various advantages such as aesthetics, performance, and cost. The overall construction and aesthetics of stand-up pouches act as an excellent product marketing tool, which is further expected to augment its demand in the coming years

Stand-up pouches assist in product differentiation as they have large surfaces on which high-quality graphics can be printed, thereby attracting customers, especially in supermarkets and convenience stores where people make quick purchasing decisions. In addition, these stand-up pouches also come with several value-added features such as different types of closure, including spouts, tear notches, and zippers, which offer convenience and functionality.

The flat pouches segment is anticipated to advance at a notable CAGR during the forecast period. Various types of flat retort pouches such as pillow pouch, four-side-seal pouches, and three-side-seal pouches are used across several food and pet food applications. Flat retort pouches are used for packaging various food items such as meat, seafood, and poultry, among others, as well as pet food, including cat food and dog food. The growing trend towards the use of single-serve and portion packs is likely to drive the demand for this segment over the coming years.

Closure Type Insights

Based on the closure type, the global market has been segmented into tear notch, zipper, and spout. The zippersegment accounted for the largest revenue share of 40.2% in 2022. Zippers offer several benefits to the packaging, including convenient recloseability, as well as protection against spills and contamination. Furthermore, zipper pouches also help in lessening food wastage as people can use the contents in the pouch at a later stage.

The tear notchsegment is expected to expand at a CAGR of 6.3% during the forecast period. Tear notch closure assists the consumer in easy opening of the pouch in order to access the pouch’s contents. The rapidly rising demand for single-serve packages, ready-to-eat meals, and smaller portion packages is likely to augment the growth of this segment over the forecast period. The spout closure segment is likely to grow at the fastest rate through 2030, as it offers advantages such as functionality and convenience in dispensing pouch contents. This is particularly applicable to liquid and semi-liquid products.

Application Insights

In terms of application, the market has been segmented into food, beverages, pet food, and others. The food segment accounted for the largest revenue share of 54.9% in 2022. Retort pouches are widely used for packaging several food products, including soups, sauces, baby food, dry-ready meals, frozen ready meals, chilled ready meals, meal replacement products, and dairy products.

The pet food segment is expected to expand at the fastest CAGR of 7.4% during the forecast period. The growing trend of pet humanization has led to an increased number of people owning pets and feeding them high-quality food. In addition, the rising trend towards pet adoption, especially among families characterized by working parents and a single child, is further likely to augment the demand for pet food globally, which is very likely to favor the market growth.

The beverages segment is also expected to grow at a lucrative rate during the forecast period. Retort pouches are widely used for packaging several types of beverages, including ready-to-drink products, energy & sports drinks, soft drinks, and juices. The rapidly rising demand for a wide variety of beverages, particularly organic and healthy beverages, is expected to have a positive impact on market growth over the coming years.

Regional Insights

Asia Pacific dominated the market and accounted for a revenue share of 33.6% in 2022. Moreover, the region is expected to expand at the fastest CAGR of 7.1% during the forecast period. Asia Pacific comprises several emerging economies, including China and India. Factors such as changing consumer lifestyles, rising disposable incomes, and growing demand for packaged foods such as ready-to-eat meals are expected to augment the demand for retort pouches in the region over the forecast period.

The North American region is anticipated to expand at a substantial CAGR during the forecast period. Increasing use of pouches in place of rigid packaging solutions, owing to the former’s superior properties such as lightweight, portability, and reduced material usage, is anticipated to have a significant impact on the overall market growth in the region.

The Middle East & Africa region is likely to witness the highest growth rate over the forecast period. Factors including infrastructure development, high birth rates, and urban expansion have increased the demand for food and beverage items across the Middle East & Africa in recent years. In addition, the rising consumption of seafood, meat, and poultry is expected to have a positive impact on the overall regional market growth during the projection period.

Key Companies & Market Share Insights

Major companies are engaged in manufacturing retort pouches, offering products that are available in different formats as well as sizes.Companies operating in the market further offer customization in terms of size, type of packaging, materials, and closure type.

Recent Developments

• In April 2023, Huhtamaki announced that it would be launching innovative sustainable flexible packaging. The company has employed scientific techniques to create revolutionary mono-material technology. This flexible packaging is ecological and inventive and claims to address the needs of both its clients and their end-users. The solutions have been made available in paper, PE, and PP retort forms

• In April 2022, ProAmpac introduced its distinctive ProActive PCR Retort pouch. These pouches have been designed for food packaging for humans and pets.  The packaging uses less virgin resins, instead offering 30% weight or higher PCR content. These inventive pouches also adhere to UK Plastics Packaging Tax (PPT) regulations

• In October 2021, Mondi launched the RetortPouch Recyclable, a high-barrier pouch designed for wet pet food and food items. This 100% recyclable mono-material retort packaging solution aims to replace multi-layer, non-recyclable packaging, ensuring product preservation and reducing food waste

Retort Pouch Market Report Scope

Global Retort Pouch Market Report Segmentation

This report forecasts revenue growth at the global, regional, and country levels and provides an analysis of the latest industry trends in each of the sub-segments from 2018 to 2030. For the purpose of this study, Grand View Research has segmented the global retort pouch market report on the basis of material, packaging type, closure type, application, and region:

• Material Outlook (Revenue, USD Million, 2018 - 2030)

  • Polypropylene (PP)

  • Polyethylene (PE)

  • Polyamide (PA)

  • Polyethylene Terephthalate (PET)

  • Aluminium Foil

  • Others

• Packaging Type Outlook (Revenue, USD Million, 2018 - 2030)

  • Stand-up Pouches

  • Flat Pouches

• Closure Type Outlook (Revenue, USD Million, 2018 - 2030)

  • Tear Notch

  • Zipper

  • Spout

• Application Outlook (Revenue, USD Million, 2018 - 2030)

  • Food

  • Beverages

  • Pet Food

  • Others

• Regional Outlook (Revenue, USD Million, 2018 - 2030)

  • North America

    • U.S.

    • Canada

    • Mexico

  • Europe

    • Germany

    • UK

    • France

    • Italy

    • Spain

  • Asia Pacific

    • China

    • India

    • Japan

    • South Korea

    • Thailand

    • Indonesia

    • Malaysia

    • Australia

  • Central & South America

    • Brazil

    • Argentina

  • Middle East & Africa

    • Saudi Arabia

    • South Africa