Lines by Product Type
Filling Line for Sauces, Jams, and Viscous Products
A viscous product does not flow freely and often contains particulates. The line is built around a piston doser, product heating, and the ability to transfer particulates without damaging them.
What Determines the Design
Viscosity is measured at the filling temperature, not at room temperature. Many sauces are filled while heated: this can reduce viscosity by half and allow the use of a smaller doser.
Particulates—pieces of vegetables, berries, and herbs—determine the minimum valve flow passage. If the passage is too small, the product is crushed and loses its specified texture.
The third factor is air. Viscous products entrain bubbles, creating voids beneath the lid. This is addressed by applying vacuum to the blending tank and using the correct nozzle geometry.
Line Configuration
- 1
Cooking Kettle
Preparation with an agitator and heating jacket, with precise temperature control.
- 2
Buffer Tank
Maintains product temperature and uniformity before filling.
- 3
Piston Filler
Volumetric dosing with accuracy within one percent and a wide flow passage.
- 4
Capping
Twist-off cap for glass jars, screw cap, or induction seal for PET.
- 5
Pasteurization or Cooling
Tunnel treatment or jar inversion to sterilize the lid with the hot product.
- 6
Labeling and Packaging
Pressure-sensitive labeling, case packing, and palletizing.
Doser Selection by Product
| Product | Viscosity | Doser |
|---|---|---|
| Ketchup, chili sauce | Medium | 250-1000 mL piston doser |
| Mayonnaise | High | Piston doser with heated piping |
| Jam with fruit pieces | High, with particulates | Piston doser with an enlarged valve passage |
| Honey | Very high | Piston doser with a heating jacket |
| Thin sauce | Low | Volumetric or level filling |
FAQ
What dosing accuracy can be achieved?
A piston doser consistently maintains plus or minus one percent volumetric accuracy. If accuracy by mass is required, a checkweigher with feedback control is added.
Can liquid products be filled on this line?
Yes, a piston doser also works with low-viscosity products, but it is slower than a level filler when filling water.
Which should be selected: glass or PET?
Glass is more familiar for jams and premium sauces and handles hot filling without restrictions. PET is less expensive and lighter, but requires heat-resistant containers.
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