German Jam Producer Tin Can Packaging Solution: 250g Airtight Vacuum Sealing & Automated Filling Line
📌 What You'll Learn
A complete solution guide for automating jam, sauce, honey, and paste packaging — covering the key production challenges, how the ZONESUN ZS-FAL180V9 integrated line solves them, process stage breakdowns, application categories, and how to configure the right solution for your factory output requirements.
📖 Table of Contents
With the increasing global demand for packaged food products, jam, sauce, honey, and paste manufacturers face growing pressure to scale production while maintaining consistent quality, hygiene standards, and cost efficiency. Traditional manual filling and packaging methods are no longer sufficient for medium to large-scale operations.
ZONESUN's ZS-FAL180V9 Automatic Jam Paste Production Line integrates servo piston filling, steam vacuum capping, and high-speed labeling into one continuous system — delivering up to 5,000 bottles per hour with ±1% filling accuracy and full food-grade compliance.
Challenges in Traditional Jam Production
Food manufacturers relying on manual or semi-automatic packaging face three core operational problems that limit growth and product consistency:
- Low throughput & high labor cost — Manual filling, capping, and labeling require multiple operators and cannot sustain high-volume continuous output
- Inconsistent filling accuracy — Viscous products like jam and paste behave differently from liquids; manual filling produces uneven volumes, product waste, and inconsistent package weight
- Hygiene & sealing reliability — Extended human contact increases contamination risk; manual capping produces variable seal quality that affects shelf life and food safety compliance
“For food manufacturers targeting retail distribution, consistent fill weight, airtight vacuum sealing, and professional label placement are not optional — they are baseline requirements for shelf acceptance and regulatory compliance.”
— ZONESUN Engineering Team
The ZS-FAL180V9 Integrated Production Line
The ZONESUN ZS-FAL180V9 is a fully automatic servo tracking filling and vacuum capping production line designed specifically for high-speed packaging of jams, sauces, and viscous products into glass jars. It combines three core systems into one continuous inline solution:
Complete Production Flow
Bottle Feeding → Servo Piston Filling (6-Head) → Steam Vacuum Capping → High-Speed Labeling → Date Coding → Finished Product Collection
Key Process Stages
🔵 Stage 1 — 6-Head Servo Piston Filling System
Precision Filling for High-Viscosity Products
The filling system uses servo-driven piston pumps with synchronized 6-head tracking — meaning the filling heads move with the bottles on the conveyor for continuous operation without stopping the line. This is critical for maintaining high throughput with viscous products that require controlled dispensing speed.
- Filling accuracy: ±1% — servo-controlled piston displacement ensures consistent fill volume
- Filling range: 100–1,000ml — adjustable via HMI touchscreen, no tools required
- Contact parts: SUS316 stainless steel — food-grade, corrosion-resistant, CIP-compatible
- Speed: 2,000–5,000 BPH — depending on fill volume and product viscosity
🟢 Stage 2 — Steam Vacuum Capping System
Airtight Sealing for Extended Shelf Life
Before the cap is applied, steam is injected into the jar headspace to displace oxygen. As the steam condenses after sealing, it creates a vacuum inside the jar — producing an airtight seal that significantly extends shelf life and prevents oxidative spoilage without chemical preservatives.
- Steam vacuum displacement — removes headspace oxygen before sealing
- Dual-belt cap tightening — consistent torque for reliable twist-off cap sealing
- Electric cap sorter — low-noise, smooth cap alignment and feeding
- Suitable for: Glass jars with twist-off caps (standard jam/sauce jar format)
🟡 Stage 3 — High-Speed Inline Labeling System
Professional Label Placement at Production Speed
After capping, bottles are transferred directly to the integrated labeling station. A star wheel separation system spaces bottles precisely for accurate label application — supporting single-side, double-side, and wrap-around labeling configurations.
- Star wheel bottle separation for precise label positioning
- Supports single-side, double-side, and wrap-around label formats
- Compatible with self-adhesive labels in standard roll format
- Adjustable for different bottle diameters and heights
Applications & Suitable Products
The ZS-FAL180V9 is optimized for viscous and semi-viscous products packaged in glass jars with twist-off caps. It is widely used across food, condiment, and personal care manufacturing:
| Product Category | Typical Products |
|---|---|
| Jams & Preserves | Strawberry jam, blueberry jam, apricot jam, fruit preserves |
| Sauces & Pastes | Tomato sauce, chili paste, peanut butter, BBQ sauce |
| Honey & Syrups | Natural honey, maple syrup, glucose syrup, chocolate sauce |
| Condiments | Mustard, mayonnaise, salad dressing, horseradish |
| Cosmetic & Personal Care | Body cream, hair mask, face gel in glass jars |
Technical Specifications
| Parameter | Specification |
|---|---|
| Model | ZS-FAL180V9 (Filling Unit: ZS-VTPF6) |
| Filling Speed | 2,000–5,000 BPH |
| Filling Range | 100–1,000ml (customizable) |
| Filling Accuracy | ±1% |
| Filling Pump | Servo piston pump |
| Contact Parts | SUS316 stainless steel |
| Cap Type | Twist-off cap |
| Power | 6 kW |
| Voltage | 220V / 380V, 50–60Hz |
| Air Supply | 0.6–0.7 MPa, 0.6–0.7 m³/min |
| Dimensions (L×W×H) | 8,000 × 1,500 × 2,100 mm |
| Weight | 1,200 kg |
Customization & Configuration
Every production project has different requirements. ZONESUN engineers configure the ZS-FAL180V9 based on your specific product, container, and output specifications:
- Product viscosity & particle size — determines piston size, nozzle diameter, and filling speed
- Filling temperature — hot-fill configuration available for high-temperature products
- Bottle size & shape — conveyor width, star wheel, and cap sorter adjusted accordingly
- Cap type — twist-off standard; other cap types available on request
- Labeling format — single-side, double-side, or wrap-around
- Production capacity — filling head count and line speed optimized for your BPH target
- Factory layout — straight or L-shaped line configuration adapted to floor space
FAQ
What products can the ZS-FAL180V9 fill?
The line handles jam, sauce, honey, syrup, cream, paste, and other viscous or semi-viscous products. It is optimized for glass jar packaging with twist-off caps.
Can it handle different bottle sizes?
Yes. Bottle size, filling volume (100–1,000ml standard), conveyor width, and cap sorting system are all adjustable. Custom configurations for larger volumes are available on request.
What information is needed to get a quote?
Please provide:
- Product name and viscosity
- Bottle size and shape
- Cap type
- Required production capacity (BPH)
- Filling temperature (ambient or hot-fill)
Is the line suitable for a new factory setup?
Yes. ZONESUN provides complete production line design, machine configuration, installation guidance, and technical support — suitable for both new factory setups and existing line upgrades.
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📩 Get a Customized Jam Production Line Solution
Contact ZONESUN today with your product details and production requirements. Our engineering team will design the right ZS-FAL180V9 configuration for your factory — including filling volume, line speed, bottle format, and labeling setup.