Chili Oil Sauce Bottling Line Case Study - Scalable Solution from Single to Dual Head
By:Salinovate Team
I. Customer Background
The customer is a mid-sized condiment manufacturer engaged in chili oil sauce business. The hot selling sauce is packaged in 400g plastic bottle. To reduce labor cost and enhance the production efficiency, the customer planned to introduce a fully automatic bottling line from the filling to the labeling and marking. The requirements are as followed:
● Handle chunky chili sauce
● Achieve 10-15BPM for the whole filling line speed
● Be scalable for future growth
● Integrate all steps from bottle feeding to final coding
II. The Solution
We designed and delivered a complete bottling line based on the chili oil sauce characteristics, bottle type, filling volume and the required functions. You can watch the video to see the specific bottle filling line running and read the following information to know the solution design.
2.1 Scheme Planning
Working Station | Equipment | Function |
Bottle feeding | Automatic bottle unscrambler | Sort and feed bottles smoothly. |
Filling | Single-head pneumatic piston filler | 400g per bottle, gentle on chili particles. |
Capping | Automatic screw capping machine with cap feeder | Ensure secure sealing. |
Sealing | Aluminum foil sealing machine | Aluminum foil sealing for freshness. |
Labeling | Automatic round bottle labeling machine | Precise front/back labeling . |
Coding | Laser marking machine | Permanent batch number on cap top. |
2.2 Key Design Features
1)Pneumatic Piston Filler:
Chosen for its gentle handling of chunky sauces. Unlike rotor pumps, the piston action has less damage to the granules.
2)Modular Filling Section:
The single-head filler is mounted on a frame that can accommodate a second head in the future.
3)Oversized Downstream Equipment:
The screw capping machine, sealing machine, labeling machine and marking machine are all rated for 30+bpm, so they won't become bottlenecks after upgrade.
2.3 The Results
After installation and commissioning, the line achieved:
Metric | Result |
Current speed | 12-15bpm |
Filling accuracy | ±2-3g |
Particle integrity | Chili flakes intact (visual inspection) |
Seal quality | 100% pass rate |
Coding clarity | Permanent |
2.4 Future Scalability
The most valuable aspect of this solution is its built-in scalability:
Upgrade | Current | Future | Result |
Filler heads | Single head | Double head | The cost rise by purchasing the double head piston filling machine to replace the old single head one. |
Line speed | 12-15bpm | 20-30bpm | 60-100% capacity rise |
Equipment replacement | no | The filling part only | Cost rise of the filling part |
Remark: The customer can upgrade at any time by simply replacing the filling part machine– no need to replace other machines in the bottling line.
III. Lessons for Similar Producers
This case demonstrates that smart design beats over-sizing. By choosing a modular, scalable approach, the customer got:
A line that meets today's needs perfectly.
Room to grow without replacing equipment.
If you're planning a bottling line for the chili oi sauces, we can help you design the customized production line. For any need, welcome to contact us.
