Shanghai Guangzhi’s turnkey ketchup line fills/seals 500-3000ml bottles at 120 bpm with ±0.5% accuracy. Features anti-settling filling, steam sterilization & leak-proof capping.
Shanghai Guangzhi Automation delivers a fully synchronized line for bottling, filling, sealing, labeling, and palletizing ketchup sauces (10-50% pulp content). Engineered for PET/glass bottles (500-3000ml), this GMP-compliant system combines 85°C hot-fill sterilization, anti-pulp settling technology, and robotic handling to achieve 120 bottles/min with zero cross-contamination.
1. Precision Hot-Fill Station
Pulp Management System: Agitating hopper with helical ribbon mixer prevents tomato pulp sedimentation (±1% density variance)
±0.5% Volumetric Accuracy: Corrosion-resistant ceramic pistons handle 15,000 cP viscosity at 85±2°C
Nitrogen Overpressure: Maintains 0.3-0.5 bar during filling to prevent bubble formation
2. Hermetic Sealing System
| Process | Technology | Performance |
|---|---|---|
| Steam Sterilization | Saturated steam tunnel | 6-log pathogen reduction |
| Vacuum Capping | Rotary chuck torque control | 5-18 in-lb seal integrity |
| Cooling Tunnel | Progressive temperature zones | Prevents bottle distortion |
3. In-Line Quality Control
AI Vision Inspection: Checks fill level (±2mm), cap alignment, label position
Pressure Decay Tester: Detects microleaks ≥0.05cc/min
Weight Rejector: ±1g accuracy with automated diverter
4. Palletizing Robotics
Delta robot stacks 25kg cases at 18 cycles/min
Integrated stretch wrapping for humidity protection
Throughput: 120 bottles/minute (1L PET bottle)
Bottle Compatibility: Round/square PET/glass (?50-120mm × H150-320mm)
Cap Types: 38-53mm continuous thread, press-on lug
Filling Temp: 82-88°C (adjustable)
Cooling Rate: 85°C→45°C in 8 min (water spray + forced air)
Power: 380V/50Hz, 28kW
Line Footprint: 16m × 3.2m × 3.5m (L×W×H)
OEE: ≥93% (validated @ 24/7 operation)
Pulp Handling Breakthroughs
Anti-Jam Nozzles: 8mm ID ceramic-coated tips resist pulp clogging
Particle Size Tolerance: Up to 8mm tomato solids
Acid Resistance: Hastelloy C276 components withstand pH 3.3-3.9
HACCP-Critical Design
CIP/SIP Integration: 4-channel spray balls (flow ≥1.5m/s)
Drainable Frame: 3° slope with no fluid entrapment zones
Material Traceability: Laser-etched batch codes on all product-contact parts
Heinz-Style Plant Retrofit (Vietnam)
Challenge: 8% underfill in 700ml bottles due to pulp settling
Solution: Helical mixer + viscosity-compensated pistons
Results:
99.4% fill accuracy
40% energy saving via heat recovery cooling
ROI in 14 months
Global Certifications
FDA 21 CFR 114 (Low-Acid Canned Foods)
EU Regulation No 1935/2004
ISO 22000 & HACCP
3-A Symbol-08 (Option)
Critical Options
| Upgrade | Function |
|---|---|
| Aseptic Cold Fill Module | For sensitive ingredients |
| X-Ray Detection | Foreign object scan (≥2mm glass/metal) |
| Blockchain Traceability | End-to-end batch tracking via IBM Food Trust |
| Solar Thermal System | Cuts steam generation cost 65% |
Support Commitment
24/7 remote diagnostics with predictive maintenance alerts
Sanitary spare kit (gaskets/pistons) global delivery ≤72h
APPLICABLE BARREL TYPE
COMPANY PROFILE
Shanghai Guangzhi Automation Equipment Co., Ltd. is a production and trading company specializing in the weighing industry. We are located in Shanghai, China's economic city, with convenient transportation and export ports all over the world. We cooperate with state-owned factories and international companies, and the quality is guaranteed.
We mainly focus on providing customers with weighing solutions, from commercial scales to industrial weighing machines. Such as pneumatic valve bag packaging machine, dry mix mortar bag packaging machine, cement packaging machine, natural stone powder packaging machine, flour powder packaging machine, wheat packaging machine, potato starch packaging machine, air packaging machine, granule bag packaging machine, grain packaging machine, fertilizer bag packaging machine, lubricant filling machine, 200 kg drum filling machine, 216L drum filling machine, 208L drum filling machine, ton barrel filling machine, IBC barrel filling machine, jumbo bag packaging machine, ton bag packaging machine, 30L pail filling machine, 50L pail asphalt filling machine, ATEX barrel filling machine, explosion-proof filling machine, etc.
Company Certificate
Our office and workshop
Consulting-Design-Procurement-Processing-Production-Installation-Debugging-Training-Maintenance
This is a partial 
service for us
in China.
Over 30 years of experience, every time we produce in
Shanghai, our friends can visit our factory at any time.
Brand components
We will ensure that our company's equipment has safety, stability, high efficiency and intelli-gent technology, so as to meet your needs, we can also cooperate with you in selecting in-ternational product brand production and business.
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Complete solution provided
Telephone exchange joint business design plan, you can also visit our company ; we have a good environmental office vehicle,you can visit from time to time.
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Our music team has a strong heart, and the customer's suspicions are also the purpose 24 hours of phone cell service and listing to the conversation at any time.
Technology group
We have a wealth of technical personnel and our technical team has been developing technical skills for over ten years.
Successful collaboration
Our factory in Shanghai. China provides free training for our technical staff.Better guarantee good product safety , our company provides safety, convenience, high efficlency packaging servic.
packge and delivery
Multiple Transportation way :Express(Fedex/DHL/TNT/EMS/UPS etc),air and shipping for your choose
FAQs
Our in-house designers and engineers have produced countless great designs for customers from different industries
CONTACT US
Skype: fayfaywang1027
QQ: 429682794
Whatsapp: 008618016442021
E-mail: [email protected]
https://glzon.en.alibaba.com/
cel: +0086 18016442021
