Furan and its derivates are present in a wide range of thermally processed foods and are of significant concern in jarred baby and toddler foods. Furan formation is attributed to chemical reactions between a variety of precursors and a high processing temperature. Also, some kinetic models to represent its formation in different food materials have been studied and could predict the furan formation under simulated operating conditions. Therefore, this review aims to analyze and visualize how thermally processed foods might be improved based on optimal control of processing temperature and package design (e.g., retort pouches) to diminish furan formation and maximize quality retention. Many strategies have been studied and applied to reduce furan levels. However, an interesting approach that has not been explored is the thermal process design based on optimum variable retort temperature profiles (VRTPs) and the use of retortable pouches considering the microstructural changes of food along the process. The target of process optimization would be developed by minimizing the microstructural damage of the food product. It could be possible to reduce the furan level and simultaneously preserve the nutritional value through process optimization.