ZONESUN ZS-FAL180V18 Automatic Kaya Jam Packaging Line: Glass Jar Rinsing, Drying, Filling, Capping & Labeling Machine

Description

The ZONESUN ZS-FAL180V18 is a complete automatic kaya jam filling and packaging line for kaya jam and other viscous food products packaged in glass jars. It integrates bottle rinsing, high-temperature drying, 6-head servo piston filling, steam vacuum twist-off capping, and automatic labeling into one continuous production process — covering every stage from empty jar to finished labeled product.

The 6-head servo piston filling system provides a 100–1000 ml filling range. Product-contact parts are SUS316 stainless steel for hygienic food processing. Before filling, containers are cleaned through water and air rinsing and passed through a high-temperature drying tunnel to remove residual moisture. After filling, the steam vacuum capping system and differential belt sealing provide reliable twist-off jar closure. The labeling section uses star-wheel positioning for consistent jar spacing and accurate label application. Line capacity is approximately 2,000–5,000 bottles/hour depending on filling volume and product characteristics.

Applications
1. Popular Food & Condiment Applications
• Kaya Jam & Sweet Spreads: Specially optimized for coconut kaya jam, chocolate spreads, hazelnut paste, and traditional fruit preserves.
• Fruit Jams & Marmalades: Smooth or particulate jams including strawberry jam, blueberry preserve, mango puree, and citrus marmalade. • Viscous Sauces & Chili Pastes: Chili sauce, garlic paste, tomato/pasta sauce, curry paste, oyster sauce, and BBQ sauces.
• Nut Butters & Heavy Oils: Peanut butter, almond butter, sesame paste (tahini), and thick condiment mixtures.
• Food Purees & Specialty Ingredients: Ginger paste, onion puree, honey, syrup, and baby food purees.
2. Container & Closure Compatibility
• Supported Containers: Rigid glass jars, glass bottles, and high-temperature resistant containers.
• Standard Volume Range: 100 ml to 1,000 ml (e.g., standard 250g, 380g, 500g, and 1kg glass jars; customizable for larger capacities).
• Cap Types: Metal lug caps, twist-off vacuum caps, and standard threaded metal closures.
3. Production Scale & Industry Fit
• Production Capacity: High-efficiency output ranging from 2,000 to 5,000 bottles/hour (varies by product viscosity and bottle volume).
• Target Buyers: Medium to large-scale food manufacturing plants, OEM/ODM co-packers, regional sauce brands, and commercial kitchen setups looking to automate from manual filling to a full turnkey packaging line.

Water & Air Rinsing Nozzle

Nozzles insert directly inside bottles, combining water and air cleaning to maximize internal cleaning efficiency and hygiene.

Gripping & Inverting

Holds bottles securely and inverts them for complete internal rinsing, with easy adjustment to fit different bottle sizes.

Drying Tunnel

Utilizes high-temperature hot air circulation to remove residual moisture from rinsed containers before filling.

6-Head Servo Piston Filling

Filling nozzle quantity is customizable. Filling is controlled by a precise servo piston pump for consistent viscous food product dispensing.

Cap Sealing

The differential belt system pre-tightens and securely seals each cap, ensuring consistent positioning and reliable sealing performance.

Labeling Structure

Equipped with a star wheel for precise bottle spacing and positioning, ensuring stable conveying and accurate, consistent labeling.

Key Features

✅ Complete Turnkey Line — Empty Jar to Finished Product: Integrates Bottle Rinsing → High-Temperature Drying → 6-Head Servo Piston Filling → Steam Vacuum Twist-Off Capping → Star-Wheel Labeling into one continuous automated packaging process.

✅ Water & Air Bottle Rinsing — Cleaner Jars Before Filling: Rinsing nozzles insert directly inside each glass jar, combining water and air to thoroughly clean jar interiors before drying and filling.

✅ High-Temperature Drying Tunnel — Residual Moisture Removal: After rinsing, jars pass through a far-infrared heating and hot-air circulation drying tunnel to remove residual moisture before product contact.

✅ 6-Head Servo Piston Filling — ±1% Accuracy for Viscous Foods: Six servo-controlled piston filling heads dispense kaya jam, fruit jam, sauces, and pastes with ±1% accuracy across a 100–1000 ml filling range (larger range customizable).

✅ 2,000–5,000 BPH — Medium to Large-Scale Production: Filling section capacity of approximately 2,000–5,000 bottles/hour supports medium- to large-scale food glass jar packaging production.

✅ SUS316 Product Contact Parts — Hygienic Food Processing: Filling machine product-contact components are SUS316 stainless steel, supporting hygienic handling of compatible food products.

✅ Steam Vacuum Capping — Reliable Twist-Off Jar Closure: Steam + vacuum processing combined with controlled cap tightening provides reliable and consistent closure for compatible glass jars with twist-off caps.

✅ Differential Belt Sealing — Stable Cap Tightening: Differential belt system pre-tightens and securely seals each cap for consistent cap positioning and sealing performance across every jar.

✅ Star-Wheel Labeling — Precise Jar Positioning: Star-wheel structure spaces and positions jars accurately before label application, improving conveying stability and finished-label placement consistency.

✅ Customizable Configuration: Bottle size, filling range, nozzle count, cap specifications, and overall equipment layout can be adapted to actual product viscosity, jar dimensions, and required production capacity.

Applications

• Kaya Jam Glass Jar Packaging: Primary application — complete automatic line for rinsing, drying, filling, twist-off capping, and labeling of kaya jam into compatible glass jars, with 250 g glass jar packaging as a representative production format.
• Fruit Jam & Preserve Filling: Servo piston filling of strawberry jam, blueberry jam, marmalade, and other fruit jam products into glass jars with steam vacuum twist-off cap sealing.
• Sauce & Condiment Glass Jar Packaging: Filling chili sauce, tomato sauce, pasta sauce, oyster sauce, and other compatible viscous condiment products into glass jars requiring controlled piston filling and secure twist-off closure.
• Nut Butter & Spread Filling: Piston filling of peanut butter, almond butter, tahini, and other viscous spread products into glass jars for food brand and private label packaging lines.
• Paste & Puree Glass Jar Filling: Filling compatible food pastes, vegetable purees, and other viscous products into glass jars requiring hygienic SUS316 contact-part filling equipment and reliable twist-off cap closure.
• 250 g – 1,000 ml Glass Jar Products: Standard filling range covers 100–1000 ml, directly accommodating common glass jar formats for jam, sauce, and condiment products; larger volumes available through customization.
• Medium & Large-Scale Food Production Lines: At 2,000–5,000 BPH, the ZS-FAL180V18 is designed for food manufacturers scaling from manual or semi-automatic operations to fully continuous automated glass jar packaging.