Packaging Line Project
Low-Cost Semi-Automatic Sauce Filling Machine
Designed for startups and small sauce producers, this compact machine supports small-batch filling of smooth, particle-free sauces with a low initial investment.
The operator positions each bottle and starts the fill cycle with a foot pedal. For foaming products, the nozzle can stay close to the liquid surface as the bottle is lowered to reduce splashing and foam.
- Product
- Japanese soy sauce and Japanese-style barbecue sauce
- Customer Target Output
- About 360 bottles/hour at 500 mL
- Designed Line Capacity
- Published filler reference: about 360 bottles/hour at 500 mL
This video shows related LEKA equipment or a relevant process stage. It is not presented as testing evidence from a completed customer project.
Semi-Automatic Liquid Filling Machine Control Setup
Project Overview
Key project data for equipment selection and line planning.
- Application / Industry
- Startups and small sauce producers
- Product
- Japanese soy sauce and Japanese-style barbecue sauce
- Customer Target Output
- About 360 bottles/hour at 500 mL
- Designed Line Capacity
- Published filler reference: about 360 bottles/hour at 500 mL
- Reference Fill Volume
- 500 mL
- Product Boundary
- Smooth, particle-free, water-based sauces
- Bottle Handling
- Manual loading and removal
- Closure and Label
- Manual or separately configured stations
- Changeover Basis
- Sauce-specific cleaning and filling-setting reset
The reference output is for LEKA-FLsemi-CLB02. Actual output depends on sauce viscosity, foam behavior, fill volume, operator speed, manual handling, and cleaning frequency.
Customer Requirements
What the customer needed the line to handle and achieve.
The customer needed a practical filling setup for 500 mL batches of smooth, particle-free sauces, with stable output and simple changeover between recipes.
Customer Challenge and Project Goal
The production constraints that shaped the proposed solution.
Production Challenge
Typical challenges included a limited startup budget, small order sizes, inconsistent hand filling, sauce foaming, dripping, and frequent recipe changeovers.
Required Improvement
The proposed machine replaces hand pouring for short runs and improves repeatability through controlled filling settings and sauce-specific cleaning.
Why This Configuration Was Selected
How the product, package and output target influenced equipment selection.
This configuration balances startup budget, small batch size, sauce flow behavior, and simple operation. The selected 5–5,000 mL filling range includes the 500 mL bottle used in this project.
It reduces hand-pouring errors while keeping cleaning and recipe changeover manageable. Final settings are confirmed with actual sauce and package samples.
Complete Line Configuration
The machines and functions included in the proposed packaging process.
| Machine Configuration | Model | Production Use | Project-Specific Requirement |
|---|---|---|---|
| Bottle Staging Table | Project-configured | Holds clean bottles for manual loading. | Confirm bottle size, stability, neck opening, and batch identification. |
| Double-Head Sauce Filler | LEKA-FLsemi-CLB02 | Fills the two sauces in the planned 500 mL batch format. | Test each sauce to confirm viscosity, foam behavior, temperature, particle-free condition, nozzle cut-off, seal compatibility, and cleaning. |
| Manual Cap Application | Project-configured | Bottle caps are placed and tightened by the operator. | Confirm cap type, bottle-neck fit, and any hand or torque tool. |
| Manual Labeling and Coding | Project-configured | Labels and batch codes are applied separately. | Confirm label position, coding area, and recipe changeover checks. |
| Finished-Bottle Inspection | Project-configured | Checks fill appearance and closure before packing. | Define fill, foam, leakage, cap, label, and traceability checks. |
Quality Control and Project Results
Verified factory-test and acceptance information for this packaging line.
Quality Inspection
Recommended batch checks cover recipe and filling settings, fill weight, foam, dripping, leakage, cap condition, label accuracy, batch code, cleaning records, and changeover release. Food-safety and allergen controls remain within the producer’s validated plan.
Project Result Summary
The proposed machine delivers repeatable semi-automatic filling for the two sauces in this project while keeping bottle, cap, and label handling manual.
Final output, settings, and cleaning procedures must be confirmed with actual product and package samples.
How the Packaging Line Works
The connected production sequence from container infeed to finished product.
Batch and Machine Check
Confirm the selected sauce recipe, clean status, filling settings, bottles, caps, labels and batch code before production.
Sauce Bottle Staging
Place clean empty 500 mL bottles at the operator station.
Semi-Automatic Sauce Filling
Position each bottle under the nozzle and press the foot pedal; for foaming sauce, gradually lower the bottle during filling to reduce impact and foam.
Manual Cap Application
Place and tighten the specified sauce-bottle cap.
Manual Labeling and Coding
Apply the correct sauce label and batch identification.
Finished-Bottle Inspection
Check fill volume, foam level, leakage, cap condition, label and traceability.
Batch End and Sauce Recovery
Drain or recover the remaining sauce according to the approved batch procedure.
Cleaning and Next-Recipe Release
Clean and inspect the product-contact path before switching between soy sauce and barbecue sauce.
Key Engineering Features
Project-specific functions that improve stability, accuracy, safety and ease of operation.
Two-Head Sauce Filling
Supports small-batch filling for the two sauce types in this project.
Foot-Pedal Operation
Lets the operator start each fill cycle while positioning the bottle.
5–5,000 mL Filling Range
The published range covers the 500 mL bottle used in this project.
Manual Foam Control
Allows the operator to lower the bottle during filling to reduce splashing and foam.
Sauce Sample Testing
Confirms viscosity, foam behavior, temperature, particle-free condition, nozzle cut-off, material compatibility, and cleaning settings.
Manual Sauce Changeover
Uses sauce-specific cleaning, inspection, and setting resets between recipes.
Packaging Specifications
Container, closure and labeling details considered during line configuration.
Container Type
- Bottle
Container Shape
- Round Bottle
- Square Bottle
- Sample Required
Cap Type
- Screw Cap
- Custom Cap
Labeling Method
- Single Side Labeling
- Custom Labeling
Delivered Equipment and Line Scope
The supplied equipment and integration boundary for this project.
Proposed compact setup: bottle staging, LEKA-FLsemi-CLB02 filling, manual cap application, separate labeling and coding, finished-bottle inspection, and changeover cleaning tools.
Operation, Changeover and Site Requirements
Information used to plan cleaning, package changeover, utilities and installation.
Materials, Cleaning and Safety
Product-contact materials must be suitable for food use and compatible with both sauces and the selected cleaning chemicals. This setup is for smooth, particle-free products. Sauces with seeds, herbs, garlic pieces, or other solids—and very thick or hot-filled products—require separate sample testing and may need a different pump or nozzle system.
Changeover and Optional Equipment
Recipe changeover can include flushing or disassembly, hose and nozzle inspection, filling-setting reset, and cap and label checks. Dedicated product-contact parts may be required when the approved cleaning method cannot control flavor or allergen carryover.
- Electrical Supply
- Published reference: 0.8 kW and 220 V 50 Hz; confirm destination supply.
- Compressed Air
- Published reference: 0.4–0.6 MPa where pneumatic parts are used; confirm final configuration.
- Sauce Feed
- Confirm a clean feed vessel, suitable hose length and stable suction conditions for each approved sauce.
- Cleaning Utilities
- Confirm water, detergent, sanitizer, drainage and drying or inspection methods for sauce residue removal.
- Operator Area
- Provide safe bottle staging, foot-pedal operation, cap handling, label control and finished-bottle inspection space.
Delivery and Technical Support
Support available for installation, commissioning, training and continued operation.
Available support can include sauce-sample review, bottle and cap review, sample filling trials, filling-setting guidance, cleaning-planning support, operating documents, remote commissioning guidance and remote training.
Need a Packaging Line Configured for Your Product?
Send your product, container, cap, label, filling volume and target output. LEKA Pack Line will review the details before recommending a practical machine configuration.
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