Which is better? For most food manufacturers, retort pouches offer superior TCO, better product quality, and stronger market positioning—despite higher per-unit material costs. Metal cans remain advantageous for extremely high-volume commodity products or applications requiring maximum abuse resistance.
Key Decision Factors:
• Pouches: 25-35% lower TCO through weight, energy, and logistics savings
• Pouches: 70% weight reduction, 80% less storage space
• Cans: Established recyclability, lower capital for existing lines
Table of Contents
1. Why This Comparison Matters Now
The Packaging Transition Accelerating
The food packaging industry is experiencing a fundamental shift. According to Grand View Research, the global retort pouch market is growing at 7.0% CAGR (2024-2033), significantly outpacing the overall food packaging market growth of 4.1%. This reflects deliberate decisions by food manufacturers reassessing their packaging strategies.
What's Driving the Shift?
Driver
Impact
E-commerce growth
Pouches ship more efficiently than cans (70% lighter)
Sustainability pressure
Lower carbon footprint per unit despite recycling challenges
Consumer preferences
"Modern" perception vs. "old-fashioned" can image
Production economics
Faster processing times, lower energy consumption
Quality demands
Premium products require superior quality retention
By 2033, the retort pouch market will exceed $10.21 billion. Manufacturers choosing between packaging formats today are making decisions that will affect their competitiveness for the next decade.
2. Cost Economics: The Complete TCO Analysis
Beyond Unit Price: Understanding Total Cost of Ownership
The single biggest mistake in packaging procurement is comparing unit prices. A can may cost $0.15 and a pouch $0.18—but the pouch might actually be 25-35% cheaper when you account for total costs.
Direct Cost Comparison
Cost Category
Retort Pouch
Metal Can
Difference
Package weight
~15g
~50g
70% lighter
Material cost per unit
Higher
Lower
Can wins on unit cost
Empty package storage
Flat (minimal space)
Pre-formed (bulky)
80% less space for pouches
Inbound freight (empties)
Lower (compact)
Higher (bulky, heavy)
40-60% savings
Processing Cost Comparison
Processing Factor
Retort Pouch
Metal Can
Impact
Thermal processing time
3-30 minutes
30-90 minutes
50-90% faster
Energy per unit
Baseline
+30-40%
Significant energy savings
Line speed potential
Higher (faster cycles)
Lower
Higher throughput
Changeover time
Fast (FFS flexibility)
Slower (size changes)
Better flexibility
Real-World TCO: 10 Million Units/Year
Cost Element
Retort Pouch
Metal Can
Annual Difference
Package material
$1,800,000
$1,500,000
+$300,000 (pouch)
Energy (processing)
$120,000
$168,000
-$48,000 (pouch)
Inbound freight
$80,000
$140,000
-$60,000 (pouch)
Warehouse
$40,000
$100,000
-$60,000 (pouch)
Outbound freight
$350,000
$455,000
-$105,000 (pouch)
Damage/returns
$25,000
$45,000
-$20,000 (pouch)
TOTAL
$2,415,000
$2,408,000
≈ Break-even
Key insight: At this volume, costs are roughly equivalent—but the pouch delivers superior product quality, better shelf presence, and stronger market positioning at the same total cost.
3. Product Quality: What the Science Says
The Physics of Quality Retention
The fundamental quality difference comes from thermal processing physics. Pouches have thin, flat profiles enabling rapid heat transfer. Cans have thick, cylindrical profiles with slower heat penetration. Result: Pouches reach sterilization temperature faster and can be removed sooner, reducing total thermal exposure by 40-60%.
Measurable Quality Differences
Quality Factor
Retort Pouch
Metal Can
Scientific Basis
Nutrient retention
Higher (15-25% better)
Lower
Less thermal degradation
Vitamin C retention
40-60% retained
20-35% retained
Heat-sensitive vitamin
Color preservation
Excellent
Often faded
Reduced Maillard browning
Texture integrity
Natural
Often "mushy"
Less protein denaturation
Flavor profile
Fresh, natural
"Canned" taste
Less oxidation, no metal contact
Consumer Preference (Blind Taste Tests)
Product Category
Prefer Pouch
Prefer Can
No Preference
Ready meals (general)
68%
22%
10%
Pet food (owner perception)
74%
16%
10%
Seafood (tuna, salmon)
71%
19%
10%
Soups and broths
62%
28%
10%
4. Operational Efficiency
Production Line Efficiency
Operational Factor
Retort Pouch
Metal Can
Advantage
Processing cycle time
3-30 minutes
30-90 minutes
Pouch (50-90% faster)
Line changeover
15-30 minutes (FFS)
1-2 hours
Pouch
SKU flexibility
High (same equipment)
Limited
Pouch
Minimum run size
Smaller viable
Larger required
Pouch
Equipment footprint
Moderate
Larger
Pouch
Warehouse Operations
Metric
Retort Pouch
Metal Can
Difference
Storage density (empty)
~100,000 units/m³
~20,000 units/m³
5x higher density
Handling (empty)
Light, easy
Heavy, awkward
Easier handling
JIT feasibility
High
Lower
Better inventory management
Damage during storage
Minimal
Denting possible
Lower waste
Distribution and Logistics
Distribution Factor
Retort Pouch
Metal Can
Advantage
Units per pallet
+25-35% more
Baseline
Pouch
Transportation weight
Baseline
+70% package weight
Pouch
E-commerce shipping
Excellent
Good
Pouch (lightweight, damage-resistant)
International freight
Lower cost/unit
Higher cost/unit
Pouch
5. Market Positioning and Consumer Perception
Shelf Presence Comparison
Shelf Factor
Retort Pouch
Metal Can
Winner
Visual impact
360° visibility (stand-up)
Front label only
Pouch
Print surface area
5 surfaces printable
Label + lid
Pouch
Premium perception
"Modern, premium"
"Traditional, commodity"
Pouch
Brand differentiation
Custom shapes possible
Standard cylindrical
Pouch
Impulse purchase appeal
Higher
Lower
Pouch
Consumer Perception Research
Perception Factor
Pouch Rating
Can Rating
"Modern"
78% agree
22% agree
"Premium quality"
65% agree
35% agree
"Fresh ingredients"
71% agree
29% agree
"Convenient"
82% agree
48% agree
"Good value"
58% agree
72% agree
"Environmentally friendly"
45% agree
55% agree
Convenience Features Comparison
Convenience Feature
Retort Pouch
Metal Can
Easy opening
Tear notch, peel corner
Requires can opener (or pull-tab)
Reclosability
Zipper option available
Not possible
Microwave heating
Direct heating possible
Transfer required
Portion control
Single-serve formats easy
Limited options
Portable/on-the-go
Lightweight, flexible
Heavy, rigid
6. Sustainability: Environmental Impact Compared
Life Cycle Assessment Summary
Environmental Factor
Retort Pouch
Metal Can
Better Option
Material weight
~15g
~50g
Pouch (70% less)
Production energy
Lower
Higher
Pouch
Transportation CO2
Lower (lighter)
Higher
Pouch
Total carbon footprint
40-60% lower
Baseline
Pouch
Current recyclability
Challenging (<5%)
Established (>70%)
Can
Future recyclability
Improving (mono-material)
Mature
Evolving
The Recyclability Reality
Current State: Metal cans: >70% recycling rate in developed markets. Retort pouches: <5% recycling rate (most multi-layer laminates not recyclable).
Emerging Solutions: Mono-material PP pouches (commercializing now), chemical recycling (2-3 years to mainstream), 30%+ PCR content available, advanced sorting technology (3-5 years).
Key insight: Pouches have lower total environmental impact, but cans have a better recyclability story today. This gap is closing as mono-material and chemical recycling solutions mature.
7. Decision Framework: Which Is Right for You?
Choose Retort Pouch When:
• Product quality is a key differentiator
• Targeting premium or natural/organic positioning
• E-commerce is a significant or growing channel
• Logistics costs are a major concern
• Production flexibility and SKU variety are important
• Starting a new line (no existing infrastructure lock-in)
Choose Metal Can When:
• Extreme durability is absolutely required
• Existing can lines are already amortized
• "Recyclable" claim is essential for market positioning
• Very high volume commodity production
• Products with extended shelf life requirements (5+ years)
8. Case Studies: Real Manufacturer Experiences
Case Study 1: Premium Ready Meal Producer
Company Profile: Mid-sized European ready meal manufacturer. Transition: 100% can → 100% pouch over 3 years.
Metric
Before (Can)
After (Pouch)
Change
Retail price point
€3.49
€4.29
+23%
Unit margin
18%
26%
+8 points
Market share
8%
14%
+75%
Production cost/unit
€1.85
€1.72
-7%
Consumer quality rating
3.2/5
4.4/5
+38%
Key learning: "The pouch allowed us to reposition as premium. Consumers perceive our product as restaurant-quality now."
Case Study 2: Pet Food Manufacturer
Company Profile: North American wet pet food producer. Transition: Mixed (50% can / 50% pouch by SKU).
Metric
Can SKUs
Pouch SKUs
Insight
Growth rate
+2%/year
+18%/year
Pouches driving growth
Price premium
Baseline
+35%
Premiumization works
Consumer retention
65%
78%
Higher loyalty
E-commerce share
15%
42%
Pouch dominates online
Key learning: "We're not phasing out cans—but all new premium SKUs launch in pouches first."
Conclusion: Making the Right Choice
The retort pouch vs. can decision isn't about finding a universally "better" option—it's about matching packaging to your specific product, market, and operational requirements.
The data is clear:
• Pouches win on quality, efficiency, logistics, and market positioning
• Cans win on extreme durability and current recyclability
• Total cost is often comparable, with pouches increasingly advantageous at scale
For most food manufacturers entering or expanding in the shelf-stable market, retort pouches represent the future-forward choice. The market is moving in this direction (7.0% CAGR vs. 2-3% for traditional canning), consumer preferences favor pouches, and the sustainability gap is closing.
Next Steps:
1. Calculate your specific TCO using the framework in this guide
2. Request pouch samples for your products
3. Conduct quality comparisons with your current format
4. Evaluate market positioning opportunities
5. Contact us to discuss your specific application
Data Sources
This comparison was prepared using data from Grand View Research, Fortune Business Insights, peer-reviewed food science literature, and manufacturer case studies. Market data reflects 2024-2025 figures.
Select your packaging needs by filtering through our comprehensive categories. If you don't find what you're looking for, feel free to contact us for custom solutions.
