McCormick launches sauce line in microwaveable, retortable standup pouches from Ampac Flexibles

The introduction is thought to be the first time sauces are being marketed in a retort pouch in the United States.

Cincinnati, OH—McCormick & Co., Inc. has launched a new line of sauces in microwaveable, retortable standup pouches from Ampac Flexibles—Converted Products, a unit of Ampac Packaging, LLC. The introduction is thought to be the first time sauces are being marketed in a retort pouch in the United States.

Called Finishing Sauce, the line offers consumers five different, 5-ounce, microwaveable choices to make weeknight meals special. (Honey Mustard, Red Burgundy Wine for Beef, Roasted Chicken Gravy with Herbs, Creamy Mushroom and Roasted Beef.)

"There are no other wet gravies in flexible pouches [in the United States]. Typically those types of products are in glass jars," explains Stefanie Woodhouse, product manager, Finishing Sauce product line, McCormick.

In order for the standup pouches to be both retortable and microwaveable, Ampac Flexibles had to develop a structure without a foil layer that could also withstand the temperature of the retort (250 degrees Fahrenheit). The end result is an adhesive lamination which is (outer to inner layer) reverse printed, high-barrier polyester/oriented nylon/polypropylene.

"Ampac’s technical expertise and manufacturing capability allows it to produce a structure that most converters cannot. Converting and printing of these sophisticated, high-barrier structures can be prone to flex cracking [which degrades barrier properties] without the level of technical "know how" that Ampac possesses," says Craig Rutman, director of sales, Ampac Flexibles—Converted Products.

"We wanted to offer consumers a package that is easy-to-use and does not require refrigeration before it is opened," Woodhouse says. "We also wanted the package to have a shelf life of at least 12 months."

To facilitate the easy-to-use aspect, Ampac Flexibles developed "cool grip" heat seals on either side of the pouch. The grips are located on opposite edges of the upper half of the package and create a way for consumers to handle the package after microwaving. In the shape of a vertical half oval, the heat seals prevent the hot microwaved sauce from coming in contact with that part of the structure—making it cool to the touch.

"Being able to properly execute the cool grips was another area in which Ampac had to rely on its considerable expertise. In order for the structure to function properly, the heat seals needed to be created within a very tight operating window. Too much pressure can create a weak structural area, so executing the heat seals within very tight parameters was critical," Rutman notes.

Additionally, Ampac needed to make sure that the heat seals were wide enough to provide an adequate grip surface but not too wide as to interfere with the opening needed to efficiently fill/seal the pouches.

"The pouch is also gusseted and has a clear bottom so the consumer can see the contents," Woodhouse says.

Although the front and back panels are printed with product, usage and ingredient information, the bottom gusset is intentionally unprinted so that consumers can actually view the sauce.

"Clear structures can often be challenging to print," Rutman explains. "For this structure we used special inks that could withstand retort temperatures. We were also going after opaque coverage on both the front and back panels to execute the best possible graphics for McCormick."

Ampac Flexibles has long been considered a leader in rotogravure pouch printing. The company’s investment in an eight-color Toshiba Sectional Drive press enables cost-effective, high-definition printing.

"The artwork and pouch portray an upscale image. The product offers consumers who are cooking smaller meals, or perhaps heating leftovers, a way to take preparation to a higher level," Woodhouse says.

The 5-ounce pouch makes two to three servings and can be either microwaved (approximately 45 seconds) or can be poured into a saucepan and heated. Prior to microwaving, the pouch is cut diagonally across a score line printed on the back panel. This enables for venting during heating and also facilitates pouring. Leftover sauce can be refrigerated and used for a subsequent meal.

The pouches are shipped six to a corrugated case that doubles as a point-of-purchase display tray once the top panel is removed. McCormick’s Finishing Sauce line is now available nationally at $1.99 per pouch.