Mastering retort room automation: Key insights for integration

As the food and beverage industry advances toward greater efficiency and traceability, the automation of retort rooms has become a central focus. Yet integrating thermal processing systems like retorts with automated material handling remains a complex challenge in food production environments.

At Surdry, we specialize in manufacturing high-performance retorts and closely works with automation experts in big projects for fully automated retort rooms. Automating this environment not only improves productivity but also ensures food safety, compliance with regulatory standards, and long-term operational reliability.

Key shuttle technologies for retort room automation

One of the most critical components in a fully automated retort room is the shuttle car system, the mechanism responsible for transporting loaded baskets or trays between infeed stations, retorts, and discharge points. The right choice of shuttle system has a direct impact on throughput, reliability, and maintenance requirements.

Several technologies are used across the industry. The most common shuttle types include:

• Chain conveyor shuttle cars

The chain conveyor moves the load of trays or baskets. The movement is guided and mechanically driven to ensure alignment with retorts rails. However this solution can lead to higher wear and maintenance.

• Push-pull shuttle systems

Push-pull systems operate using a guided shuttle that physically pushes a full basket into the retort and pulls it out once the cycle is complete. No moving mechanisms are required inside the retort, only static roller tracks (that allow baskets to glide smoothly in and out. This is the most commonly used shuttle solution in batch retort automation.

• Tongue-type shuttle systems

The tongue-type shuttle uses an extendable fork or platform (“tongue”) that slides under a carrier or basket to move it into or out of the retort. Unlike push-pull systems, the tongue mechanism does not require rollers inside the retort.

This means that the retort interior can be entirely free of rails, chains, or moving parts. Tongue-type shuttles generally involve a higher upfront investment.

Integration challenges and strategic considerations

Successful automation depends heavily on mechanical compatibility between equipment. Differences in basket dimensions, retort openings, or shuttle reach can lead to basket misalignments and several unplanned downtimes. The objective is not just to move baskets through sterilization, but to synchronize multiple control layers so that the entire room operates with minimal human intervention, efficiently, safely, and in compliance with hygiene and food safety requirements

One of the most unique challenges in retort room automation is the mismatch in process duration between sterilization and other stages of the production line. While upstream filling and downstream packaging lines may operate continuously and at high speed, retort cycles typically last between 60 and 90 minutes.

Without intelligent buffering and dynamic scheduling, this can create bottlenecks, idle equipment, or underutilized retorts.

Automated systems involve the movement of heavy, high-temperature baskets, often in enclosed and pressurized environments. Ensuring a safe and maintainable layout is critical. The control systems that govern retorts, handling machinery, and overall production must communicate seamlessly to ensure traceability, cycle validation, and safe operations. Defining clear communication protocols between control is key to ensure compatibility between retort control software and the handling system logic.

Building a sustainable automation strategy

Retort room automation is a strategic investment in safety, performance, and quality. It demands more than just new equipment, it requires coordination, foresight, and a systems approach. 

Automating your retort room doesn't have to be complicated. Surdry offers the expertise to make the process efficient, safe, and future-proof. Contact us to learn more.