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Ketchup bottling Equipment

Bottling equipment draws a measured quantity of your drink, food, or formulation from a holding tank and fills it into bottles. These bottles usually need to be checked, capped, labeled, and sealed for distribution. Bottling solutions differ in product metering system, sterilization level, and bottle type and sealing system depending on your production scale and product format and regulations. Bottling systems are utilized in a variety of industries. For example, in the food and beverage industry as well as in cosmetics and pharma.

Bottling

Ketchup processing begins with tons of tomato paste that is mixed and heated together with sugar, vinegar, and spices in a cooking kettle. After cooking, any remaining fibers and particles are filtered out. Once it reaches the right viscosity, your tomato ketchup production process is finished and ready for packaging and transport.

Ketchup

As your businesses grow and you’re looking to reduce costs, a highly flexible, end of line system that can adapt to your sector’s specific needs is what you need. With the right system in place you can boost productivity and keep costs down by reducing space, staff, energy, materials and time.


<h2>Integrated system to design, build and manage your whole end of line</h2>
The OCME Blox system let you design, build and manage the whole end of line, such end of line system for bottling plants combines the entire dry part of your production line into a single, integrated and synchronized monoblock that takes up only 35x14 meters of space.

Efficiently managing all the line as a single machine, Blox is controlled by a single operator, and helps ensure shorter distances, simplification of the label change, an automatic label splicer, external and integrated reel holder (that is ergonomic and easy to reach), an integrated handle applicator placed outside the machine, one operator panel, and an automatic film slicer.

End of line system for bottling plants

Accurate bottle sorting system that differentiates between the bottles on the basis of their colour, shapes and sizes.


<h2>Sort on bottle colour, shapes and sizes</h2>
The Multicon 3 from Miho is an accurate bottle sorting system with a detection facility for all optical features of the bottle. Any differences in bottle-shape, colour and size can be detected and the system is able to make a fine distinction, so that only bottles of the required bottle-type enter to the filling process.

It can also sort the remaining bottles in accordance with the criteria set by the user and divert these bottles onto different conveyors. One of the strong points of the Miho Multicon 3 is the compensation of different classic disruptive factors which, until now, have led to incorrect sorting.

Empty bottle shape, colour and size sorting system

Quality bottle sorting machine and inspection system which can be put to use not only after your labeling process, but also for sorting empty bottles either before or after your bottle washing machine.


<h2>Bottle sorting machine for versatile sorting and inspection tasks</h2>
The Allround, Versatile bottle sorting system, from Miho can be used in the filling process with two different functions.

Firstly: As an extensive final inspection, installed after the labelling process, it inspects all the components of filled bottles and all optically visible features. For instance, the quality of the labelling, the printed expiry date, and if visible, also the fill level.

Secondly, the Miho Allround can also be used as an empty bottle sorting system that is installed before or after the washing machine. With this function, the bottles are sorted by size, shape and color. And, if necessary, the components can also be checked with a specific printed label (ACL).

Versatile bottle sorting system

During a shrink-wrapping process, a change of reel can slow down the production cycle as manual intervention is required. A system that automatically changes the reel after it has been used to the end, makes it possible to continue working without interruptions, even without an operator present.


<h2>Shrink wrap PET bottles while eliminating any waste of film</h2>
The Shrink wrapper from Baumer is a highly versatile and configurable shrink-wrapping system fit for most production requirements. Products can be shrink wrapped with film only or a combination of pad and film or tray and film. The system also features a green tech tunnel that helps save energy. Other features include automatic reel changeover for less interruption in production and touch screen panel controls for product packing configuration. Apart from smoother operation, automatic reel change lets you reduce film waste, which is usually generated when the photocells detect the end of the reel. Speeds can also be adjusted and go as much as 200 cycles per minute.

Shrink wrapping machine for PET bottles

Large-volume producers of single-serve packs, such as sugar sticks, instant coffee, and instant soup, continuously pack different product sizes into cartons. Intelligent and flexible infeed systems are needed to ensure your products integrate smoothly into the carton line at higher speeds.


<h2>Pack stick packs or flow packs into cartons continuously</h2>
The VENTO Cartoner from Mpac is a carton packaging system with a smart infeed system suitable for single-serve products such as condiments or coffee and milk powders. The unit is made of hygienic stainless steel materials. It has an open design for easy visibility of product flow and quick access to the components in case of maintenance and cleaning.

The entire system is servo-driven and coupled directly to its components for minimum maintenance and long operating life. It is designed to operate 24/7, allowing maximum production yield, and is equipped with an advanced intelligent machine interface that provides information on machine status, maintenance, and changeover controls based on product application. The processes include carton erecting, loading, transportation, and closing. Changeover for different carton sizes and types can be done quickly and automatically.

High-speed Cartoner For Single-Serve Products

Basically, to make milk powder, you need to remove the water content from the liquid milk and turn it into powder. How to do it? After pasteurizing and homogenizing the milk, milk’s water content is removed through filtration, evaporation, and drying. You have then to cool and sieve it before filling the containers. Here's how you get milk powder.

Milk powder

Sugar is the fuel that drives photosynthesis in plants. The leafy organisms constantly convert water and carbon dioxide into glucose. But it takes manufacturers specialized sugar processing technology to extract the sweet crystals from them. Today, most sugar products are derived either from sugarcane or sugar beet.

Sugar

Mayonnaise is created by blending oil with eggs, and then flavoring with vinegar, mustard, herbs, and spices. The eggs are a natural emulsifier that creates a uniform mixture. Ingredients are pumped into mayonnaise manufacturing equipment. First, a dynamic mixer maintains the desired level of emulsification of the mixture, which then moves on to packaging and bottling once reaching a satisfactory consistency.

Mayonnaise 

White, black and brown seeds from the mustard plant are the key constituents of this colorful and classic condiment. The various mustard production technology includes a mixer that mixes the mustard seeds with a handful of other ingredients and a mill that finely grinds the seeds to impart their characteristic flavor.

Mustard

Mpac Group is an industry leader in packaging automation, cartoning, and case-packing technologies.

Its complexity begins with the term itself, which has no clear and precise definition in the industry. As Jan Verweijen and Frank Jeurissen from the Mpac Group explain, the big question is always: is it a sachet or a stick pack?

“What is what” is defined by the way it is sealed, not by its width or length. A stick pack is a product with three seals, one of which is in the middle, lengthwise. Instead, a sachet is a four-sided sealed product with no seal in the middle.

First introduced in Japan in the 70s to pack sugar, these single-use sticks are now used to pack everything you can think of. But what impact does your product have on the cartoning process?


<h2>The first step is to find the right balance.</h2>
Stick packs are first filled vertically; this means that all the product is on the bottom.

Before entering the stick packs into the cartons, you need to evenly divide the product over the left and the right side of the stick packs. This step is called equalization and it is done by horizontally shaking the product to redistribute the contents inside the sticks.

“<em>If the weight is not evenly distributed, all the stick packs will slide off toward one corner of the box leading to an unstable formation that can damage the sticks</em>.” Frank points out.

For mere mortals, powder is powder, but for the experts, coffee powder, for instance, has a different structure than cocoa powder.

“<em>Liquids do not need equalization as the fluids divide automatically.” </em>Jan explains.

In addition, the sticks must have a minimum size, usually around 80 or 90 millimeters, to be cartoned horizontally and the shorter the sticks, the more difficult to keep them stable.
<h2>On edge vs. random orientation - Which side do you stand on?</h2>
Premium single-use products, such as coffee or pharmaceuticals, are often packed with the brand name and description always facing the consumer.

“<em>When this is the case, we use a paddle conveyor that brings each stick pack on a single edge so that when pulled out of the box, the branded face is the first thing the consumer sees,</em>” says Jan.

Frank adds: “<em>In 90 percent of cases, manufacturers choose speed over where the stick pack is facing. With random orientation, you can easily speed up to 900 sticks per minute</em>”.

“<em>Our bomb bay system counts each stick individually and puts them together in the quantity the producer requires; then it drops the sticks into the bucket conveyor</em>.” continues Jan.

To prevent damage, the bomb bay system consists of multiple drop levels, and the sticks need to be always dropped at a limited height - no higher than 250 mm.

As every stick has two ends, cartoning single-serve packs may seem easy, but as Jan and Frank explained, the journey from equalization to orientation and bomb bay dropping is not exactly a piece of cake.

Unpacking the world of stick pack cartoning

Cosmetic

Food

Pharmaceutical

With over one-third of the population consuming it daily in different forms, coffee is one of the most popular processed beverages worldwide. Not only serving as drinks, but coffee is also often regarded as a culture. Coffee manufacturing is a knowledge-intensive industry. Coffee beans from different regions will reveal different tastes, while the level of caffeine could also be different. When it comes to coffee bean processing, the range of roasts varies from light golden brown all the way to dark. The method of tasting coffee differs between countries, habits, and tools.

Coffee

According to a legend, Cleopatra soaked her sails in her perfume so that Mark Antony could smell her ships before they arrived. This is to say that, from soaps and shampoos to perfumes, conditioners and pomades, cosmetics have always been highly valued and used for their properties of aesthetic enhancement. Cosmetics are a broad class of topical agents applied for various purposes such as cleansing, protecting, beautifying, or otherwise altering your appearance. As a result, a wide array of processing equipment is used in the cosmetics industry.

Cosmetics

Eating is more than just nutrition, but we have found ways to increase the nourishing power of our foods. Nutraceuticals manufacturing, from vitamin C powder and probiotics to omega 3 oil, is a concentration of natural ingredients and health supplements that complement our diets. While dietary supplements are not quite haute cuisine, the process of extraction and purification is no less a blend of science and art.

Nutraceuticals

The building blocks of matter have driven the imagination of philosophers, scientists, and artists for millennia. But, for manufacturers, these elements have a more concrete existence as powders. Powder processing technology conditions these primary materials to create a vast range of products, from chemicals and foods to pharmaceuticals and ceramics.

Powder

Sauces bring personality to a dish. From a spicy, dense Zhoug to a tangy, runny Suero, sauces add an extra dimension of flavor, texture, and mouthfeel. But developing recipes into industrial products with long shelf lives and consistent tastes is a complex process. Specialized sauce making equipment prepares and combines the ingredients into delicious, high-quality foods. The result is a sauce ready to elevate meals.

Sauce

<span style="font-weight: 400">Spice manufacturing is one of the world's oldest trading products. The word spice refers to any dried part of a plant other than the leaves and is used for seasoning and food coloring. Spices are made from dried barks, roots, berries, and twigs, while green leafy parts of plants are considered herbs. Well-known examples include cinnamon, chilies, star anise, ginger, garlic salt, turmeric, cumin, or pepper, as well as pre-mixed blends such as Masala, Five-Spice Powder, or Old Bay.</span>

Spices

Frigojollinox is an Italian company specialized in the manufacturing of equipment for the canning, dairy, fishing, confectionary, and cosmetic industries.

There was a period when ketchup bottles looked more like poster colors than condiments. The fad filled retail shelves with edgy ketchup palettes of purple, blue, green, pink. But the introduction coincided with a growing appetite for unprocessed food ingredients, and producers quickly reverted to red ketchup.

Most consumers will not be aware of lycopene, the compound that gives tomatoes their pigment. However, they know that the natural color of ripe berries is a rich red. The era of multicolor ketchup was, alas, short-lived.

But ketchup is more than tomato sauce. The classic recipe combines vinegar, sugar, and seasoning into the base sauce. Cooking combines the aromas and reduces the sauce into a denser liquid. But while it enriches the taste and texture, the rise in temperatures turns the glowing red of the tomatoes into a fading brown.


<h3>Natural pigments on red alert</h3>
“Conventional industrial cookers subject the ketchup mixture to temperatures up to 100°C,” explains Maurizo Pettini from Frigojolinox. The elevated heat diffuses the natural pigmentation and makes the orange and yellow undertones of lycopene more pronounced.

The discoloration can be corrected with food-grade additives, often Allura Red AC (E129 / FD&amp;C Red 40). However, preserving the original red pigment of the tomato sauce minimizes the degree of color adjustment required.

The trick is to balance temperatures with atmospheric pressure. Cooking the ketchup mixture under a vacuum reduces the thermal stresses considerably, circumventing the 'burn’ effect caused by traditional high-heat cookers.

“Vacuum cooking is conducted at around 50°C and removes a significant measure of the thermal burden from tomatoes,” Maurizio tells us. The decreased pressure lowers the boiling point of the moisture content in the sauce and the water in the vacuum cooker.
<h3>Take the pressure off color, texture, and taste</h3>
Lycopene perishes under intense heat, but the vacuum technique treats them gently. While the ingredients combine and thicken into ketchup, the tomatoes retain vivid redness.

But that is not the whole story, Maurizio points out. Besides the color, vacuum cooking develops other organoleptic qualities. It controls the extraction of water which regulates the viscosity levels. Meanwhile, the low temperatures prevent the caramelization of sugars that often produce off-tastes.

The vacuum technique protects the natural color of tomatoes and produces more authentic ketchup hues. However, that is no guarantee that the polychromatic craze will not make a comeback.

Ketchup shows its true colors with vacuum cooking

Our food chain starts in the soil, growing crops and livestock. But between the fields and the stores, there is a line of industrial food processing equipment. Processes may be as minimalistic as cleaning fruit and as complex as homogenizing milk alternatives made from pressed legumes. In each case, processing technology is an important link in the food production chain.

If you want to pack into unique bag styles like Quad-seal and Doypack, but you don’t require acceleration &amp; deceleration, you can save costs by choosing a bagger with a mechanical drive.


<h2>Steady speed vertical form fill sealing</h2>
The VikingMašek Intermittent Bagmaker series (M250, M400, M500 ) are high-performance vertical form fill and seal machines. Its rugged construction and enclosed jaw drive enables hassle-free packaging in dusty or wet environments.

It can accommodate multiple bag designs and dimensions with high speed and accuracy. It can produce maximum up to 70-100 bags per minute and handles bag sizes from 50 x 60 mm (M250) up to 500 x 600 mm (M500).

This vertical bagger is perfect for packaging quad seal, flat bottom, doy style, brick fold down/tape down, and pillow bags, snacks, candy, coffee, fresh and frozen fruit and more.

Bagger with mechanical driven jaw actuation

If you are looking for a compact packing machine that packs multiple smaller packs in one master bag; this automated product is exactly what you need.


<h2>Compact bag-in-bag machine for packing applications</h2>
The VikingMašek Intermittent Bag maker (M250 BiB) is a machine for all types of bag-in-bag applications, from airline/hotel single serves coffee packs to multiple smaller packs in one master bag. This Bag-in-Bag machine has enclosed, direct jaw drive, that provides you with years of smooth maintenance and free operation.

This vertical Bag-in-Bag machine is perfect for packaging from small to large bags of snacks, coffee, pet food, hardware products and more.

Bag-in-Bag machine

If you are looking for a compact packing machine that fits into tight space and tight budgets, proven basic bagging technologies may be your solution.


<h2>Compact and economic vertical form fill sealing</h2>
The VikingMašek Intermittent Bag maker series (E250, E400) is the most compact and economical bag maker for the packaging of small to large bags. It can produce maximum up to 50-60 bags per minute depending on the series of machine. Bag size can vary from 50 x 60 mm (E250) up to 400 x 600 mm (E400).

The robust, stainless steel, open-design frame is easy to access for maintenance. This vertical bagger is perfect for packaging small to large bags of snacks, coffee, pet food, hardware products and more.

Bagger with rotary jaw drive actuation

If you want to pack into gusseted and pillow style bags and packing speed is important for your packaging process, a continuous bagger with twin sealing jaws could be a good investment.


<h2>The world’s fastest vertical form fill sealing machine</h2>
The VikingMašek Continuous motion bag maker velocity is capable of high speed production up to 300 bpm. The unique center mounted filling tube and natural counterbalanced sealing profiles are designed to provide vibration free, extremely smooth operation at all speeds.

The Velocity is also extremely versatile, handling package sizes up to 300 mm wide and multiple package styles. Patented, independently phased, twin sealing jaws separate the velocity from all other high speed machines and virtually eliminate lost cycle time. This is the world´s fastest bagging machine on the market that has no competition.

Continuous bagger with twin sealing jaws

If you want to pack into eye-catching 4-side sealed sachets between 40x50 mm and 250x200 mm in size, investing in a reliable sachet machine will be a good investment.


<h2>Fast and flexible solution for your sachet needs</h2>
The Sachet Machine series SA 300 &amp; SA 600 by VikingMašek are continuous motion multi-lane sachet machines. They make eye-catching 4-side seal packets using just one roll of packaging film that can seal your product with high speed and efficiency.

The versatile multi-lane sachet machines can accommodate from 1 to 6 lanes (SA600) or from 1 to 10 lanes (SA600) to form sachet pouches, running as fast as 80 cycles per minute.

Designed to pack powders, dense, fine, loose and particulate materials as well as liquids and semi-liquids into 4-side sealed sachets and to accommodate different bag shapes including tear notches and easy-open system. They can be fitted with servo auger fillers &amp; volumetric fillers for powder applications, and two different liquid fillers for sauces or creams.

Sachet Machine

If you are looking to pack your product into stick packs from 17 x 40 mm to 100 x 200 mm in size, you may benefit from the experience from the largest manufacturer of stick pack machines in Europe.


<h2>Benefit from the experience from Europe’s leading producer</h2>
This multilane Stickpack Machine series (ST200, ST400, ST560, ST800, ST1200 ) by VikingMašek can accommodate a large variety of different shapes of stickpack pouches with high efficiency and flexibility.

The versatile multi-lane stick pack machines can accommodate from 1 to 20 lanes, running as fast as 80 cycles per minute.

They are designed to pack powders, dense, fine, loose and particulate materials as well as liquids into StickPack bags and to accommodate different bag shapes including pour spouts, tear notches and easy-open system.

Semi- or fully automated cartoning solutions are also available for individual or bulk cartoning.

Stickpack Machine

VikingMašek is a global leading manufacturer of vertical baggers &amp; multilane packaging solutions.

Due to the fact that meal-kit subscription delivery companies deliver the box of ingredients that they assemble in the kitchen, their business models seem more sensible compared to the food delivery business which depends largely on the affiliated partners. Some restaurants, which only offer dine-in options before, have started to take similar measures to deliver half-processed meals to the end consumers. From kitchen to the consumers' table at home, there are a lot of considerations and challenges regarding the packaging of the food.


<h2>The driving forces of meal kit subscription services and restaurants joining food delivery</h2>
Since cooking at home can generate the sense of being in control during this out-of-control time, <a href="https://www.adweek.com/brand-marketing/meal-kits-had-their-chance-covid-19-has-given-them-another-one/">meal kit subscription businesses have taken initiatives to capture this quarantine-driven momentum.</a>  Meanwhile, the COVID-19 pandemic has also shown us that restaurants which do little takeaway or delivery business have adjusted to expand these capacities to maintain same level business due to the stay-at-home order.

Consumer behaviour is currently changing short term. However, when the consumers become more comfortable with order-in and meal kit preparation, chances are that their behaviours could be impacted long-term.
<h2>Packaging challenges and solutions for food delivery service</h2>
Either to deliver fresh food meal kit or to send fresh-cooked food, the process involves complex logistic and packaging challenges to bring the products across the city to the end consumer. The manufactures need to consider how to keep the ingredients fresh, how to prevent the liquid such as soup or sauce from leaking, and how to save employees' time if the food is packed manually.

While packing all the ingredients in the meal could not be perfectly automated in the standardized serving size, here are some most-requested food delivery packaging automation solutions:

<strong>- Meat, fresh-cut fruits and vegetables</strong>: Putting the ingredients in the sealed bag protects the food go wrong quickly. <a href="https://vikingmasek.com/packaging-machines/vertical-form-fill-seal">Vertical form fill seal (VFFS) machines</a> ensure high packaging speed and accuracy.

<strong>- Spices and sauces</strong>:  <a href="https://making.com/equipment/sachet-machine">Sachet</a> and <a href="https://making.com/equipment/stickpack-machine">stickpack machines</a> automatically form, fill, and seal small packets of ingredients like spices and sauces.

<strong>- Cold packs</strong>: Another emerging application is the packaging of cold packs for shipment of the ingredients to consumers' homes.

https://www.youtube.com/watch?v=JoIHv73s2zY

Packaging solutions for meal kit and food delivery

Find production technology for Ketchup bottling, and connect directly with leading machine manufacturers worldwide

Ketchup bottling Equipment

Which ketchup bottling equipment do you need?

End of line system for bottling plants

Empty bottle shape, colour and size sorting system

Versatile bottle sorting system

Shrink wrapping machine for PET bottles

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