Customized Automatic Jam Filling Line for a European Customer

ZONESUN recently completed a customized automatic jam filling and packaging line for a customer in Europe. The system was designed for filling high-viscosity jam containing fine fruit particles into glass jars with capacities ranging from 150 to 350 ml.

The customer needed one production line to accommodate several regular-shaped glass jar formats while maintaining a target output of approximately 2,000–3,000 jars per hour. The complete solution integrates bottle rinsing, servo piston filling, automatic cap feeding, steam vacuum capping, double-sided labeling and finished-product collection.

Before shipment, the complete line was assembled and tested using the customer’s actual jam, jars and caps. The customer also attended the factory acceptance test and confirmed the operation of the system on site.

Project Requirements

The customer’s main production requirements included:

• Product: High-viscosity jam containing fine particles

• Container: Glass jars

• Filling range: 150–350 ml

• Target output: Approximately 2,000–3,000 jars per hour

• Closure: Standard twist-off jar caps

• Labeling method: Double-sided labeling

• Container formats: Multiple jar sizes on one production line

• Production direction: Left-to-right

• Electrical components: Mitsubishi and Siemens components as specified

• Testing material: The customer’s actual jam and packaging samples

Handling several jar formats on the same line was one of the main engineering considerations. The equipment had to provide reliable jar transfer while allowing the operators to complete format adjustments efficiently.

Complete Production Process

The main packaging process is configured as follows:

Bottle Rinsing → Servo Piston Filling → Cap Feeding → Steam Vacuum Capping → Double-Sided Labeling → Finished-Product Collection

The principal machines include:

• ZS-WB02A automatic bottle rinsing system

• ZS-VTPF6 servo tracking piston filling machine

• ZS-XG01 automatic steam vacuum capping machine

• ZS-TB700 automatic labeling machine

These machines are connected by a continuous conveyor system and arranged in a left-to-right production direction.

Customized Bottle Rinsing for Multiple Jar Sizes

Before filling, the glass jars pass through the ZS-WB02A automatic bottle rinsing machine. The system grips and inverts each jar so that its interior can be cleaned with water and air before it enters the filling section.

Because the customer needed to process multiple jar sizes, the bottle-gripping and inverting mechanism was customized. During testing, the engineering team evaluated the compatibility of the gripping structure with each supplied jar.

The final design uses a roller-driven adjustment structure, allowing the gripping width to be changed more conveniently when switching between different jar formats. This adjustment helps the rinsing machine accommodate the customer’s containers without requiring an entirely separate system for each jar size.

Servo Tracking Piston Filling for Viscous Jam

After rinsing, the jars enter the ZS-VTPF6 filling section of the ZS-FAL180V9 automatic jam production line.

A servo-controlled piston filling system was selected because the customer’s jam has high viscosity and contains fine particles. The piston pump supports the controlled transfer and dosing of viscous food products, while the servo tracking system allows the filling nozzles to follow the moving jars during filling.

This tracking method reduces the need to stop each container directly beneath a fixed filling nozzle and supports continuous production. The filling section is also equipped with anti-drip and diving nozzle functions to help control product discharge and reduce contamination around the jar opening and conveyor.

The filling configuration was tested using the customer’s actual jam rather than a substitute material. This allowed the engineering team to evaluate how the system handled the product’s real viscosity and fine particle content.

Steam Vacuum Capping

After filling, the jars proceed to automatic cap feeding and steam vacuum capping.

Before the caps are tightened, steam is introduced around the jar opening to displace air from the headspace. The cap is then applied and tightened as part of the continuous capping process. As the jar cools, a vacuum is formed inside the sealed container.

This capping method is suitable for glass jars containing jam, sauces and other preserved food products. It helps create a secure closure and supports the product preservation process.

The cap feeding system was configured for the customer’s standard jar caps. During testing, the engineering team checked cap sorting, cap transfer, jar positioning and tightening performance.

Automatic Double-Sided Labeling

The capped jars then enter the ZS-TB700 automatic labeling machine.

For this project, the labeling system was configured to apply labels to both sides of the jars. The machine separates and positions the containers before label application, helping maintain a consistent labeling process during continuous production.

The labeling section was tested with the customer’s actual jars to verify container transfer and label placement across the required jar formats.

Electrical and Control Configuration

The customer requested Mitsubishi and Siemens electrical components for the production line. The control system allows operators to manage the main operating parameters and coordinate the individual machines through the integrated conveyor line.

During the factory test, the engineering team checked:

• Compatibility with different jar sizes

• Jar gripping and inversion during rinsing

• Filling performance with actual jam

• Filling nozzle tracking

• Anti-drip and diving nozzle operation

• Cap sorting and feeding

• Steam vacuum capping

• Double-sided label application

• Sensor response

• Conveyor connection between machines

• Coordination of the complete production line

Factory Acceptance Testing with Customer Samples

The complete line was assembled and tested at the ZONESUN manufacturing facility before shipment. The customer provided actual jam, glass jars and caps for the factory acceptance test.

Testing multiple jar formats revealed that the bottle-gripping structure of the rinsing section required easier adjustment. In response, the engineering team refined the mechanism so that the gripping width could be adjusted through a roller-driven structure.

After the adjustment, the supplied jar formats were tested again to verify compatibility throughout the complete process. The customer attended the test and confirmed the system on site.

Following final inspection and confirmation, the production line was prepared and shipped to Europe.

Optional Upstream and Inspection Equipment

Depending on the customer’s complete production process, additional equipment can be integrated before or after the main filling line.

ZS-FC100L Electric Cooking Pot

The ZS-FC100L electric cooking pot can be used as an upstream food-processing unit for cooking or heating jam before it is transferred to the filling system.

ZS-MB300L3 Material Preparation System

The ZS-MB300L3 mixing system can be considered when the production process requires additional material preparation, mixing or intermediate product storage.

ZS-WB16 Bottle Washing and Drying Tunnel

For projects requiring an additional external cleaning and drying process, the ZS-WB16 bottle washing and drying machine can be configured according to the container and required production process.

ZS-MD60 Foreign-Object Inspection System

A ZS-MD60 industrial inspection system can be added as an optional inspection step when required by the customer’s quality-control process.

The final equipment selection depends on the food-processing method, container format, inspection requirements, target output and available factory layout.

Project Result

This project demonstrates how a jam packaging line can be configured around the actual characteristics of the product and containers rather than relying on a fixed standard layout.

The completed system provides:

• Automatic rinsing of glass jars

• Adjustable handling for multiple jar sizes

• Servo piston filling for high-viscosity jam

• Handling of products containing fine particles

• Anti-drip and diving nozzle functions

• Automatic cap sorting and feeding

• Steam vacuum capping

• Double-sided labeling

• Integrated left-to-right conveying

• Factory testing with actual customer samples

By testing the complete line with the customer’s jam, jars and caps, the engineering team was able to identify and adjust the bottle-handling structure before shipment.

Watch the Production Line in Operation

Watch the project video to see the jam filling, capping and labeling process:

Watch the ZONESUN Automatic Jam Filling Line Video

Planning a Jam or Sauce Packaging Line?

Jam and sauce packaging projects can differ considerably in product viscosity, particle size, filling temperature, jar dimensions, cap design, labeling method and required output.

When planning a customized line, customers can provide:

• Product samples

• Jars and caps

• Filling-volume range

• Product viscosity and particle information

• Required production capacity

• Label samples

• Factory layout

• Electrical-component requirements

ZONESUN can evaluate these details and configure the rinsing, filling, capping, labeling, conveying and optional inspection equipment around the actual production requirements.

ZONESUN is a packaging machinery brand of Guangdong Shanghang Technology Limited, a packaging machinery manufacturer based in Foshan, Guangdong, China. ZONESUN develops filling, capping, labeling and integrated packaging line solutions for food, beverage, cosmetics, pharmaceutical and daily chemical applications.

Explore ZONESUN Food and Sauce Packaging Solutions or contact ZONESUN to discuss your packaging project.