A tomato ketchup packaging machine is an automated packaging device designed for fluid, semi-fluid, or viscous materials (e.g., ketchup, jam, shampoo) and is widely used in food, daily chemical, and pharmaceutical industries. Its core functions include metering, bag forming, filling, sealing, coding, and cutting, enabling fully automated operations. It supports multiple packaging formats (e.g., quad-seal, three-side seal, back-seal bags, Doypack pouches) and allows customization of fill volumes, bag dimensions, and packaging speeds.
Working Principle and Process
The machine operates through a PLC intelligent control system and precision mechanical components. Key steps include:
- Material Feeding: Ketchup is transferred via vacuum or gravity to a storage hopper, with optional stirring to prevent settling.
- Metering and Filling: High-precision pumps (liquid piston, peristaltic, or ceramic) ensure accuracy within ±1%, adaptable to varying viscosities.
- Bag Forming and Filling: Servo motors shape packaging film into bags, aligned by photoelectric sensors; material is injected via pumps.
- Sealing and Cutting: Multi-stage heat sealing (with independent temperature control for horizontal/vertical seals) ensures airtightness; cutting styles (straight, zigzag, or continuous) vary by application.
- Coding and Output: Integrated coders print dates/batch numbers; finished products are conveyed out, optionally with checkweighers or metal detectors.
Technical Specifications and Performance
Key parameters vary by model, with typical configurations as follows:
| Parameter | Specifications |
|---|---|
| Model | LTC-480Y/720Y/960Y, LTC8-260, LTC-Y4/Y6/Y8 |
| Speed | Single-channel: 30-60 bags/min; Multi-channel (4-12 lanes): up to 300 bags/min |
| Bag Dimensions | Length: 20-160mm; Width: 25-260mm (supports stand-up, spout pouches, etc.) |
| Fill Volume | 10ml-2500ml, customizable (e.g., 30-125ml, 500-2500ml) |
| Power & Energy | Voltage: 220V/380V; Power: 1.1-3.6KW; Air pressure: 0.6-0.8MPa |
| Control System | PLC + touchscreen HMI, bilingual interface, parameter storage, fault diagnostics |
| Material & Hygiene | 304/316 stainless steel contact parts, compliant with GMP and food-grade standards |
Key Features:
- High Precision: Servo motors and PID temperature control ensure consistent filling and sealing.
- Flexibility: Adjustable bag lengths, multi-lane configurations, and material compatibility (PE laminate, aluminum foil).
- Smart Functions: Photoelectric alignment, auto-alarm systems (temperature/pressure anomalies) minimize downtime.
Pricing and Cost Factors
Prices vary significantly based on features:
- Basic Models: Semi-automatic single-channel machines: RMB 20,000-50,000.
- Full Automation: Multi-channel (4-8 lanes) models: RMB 70,000-168,000.
- High-End Customization: Aseptic/brick-type machines: RMB 200,000+.Key Cost Drivers: Number of lanes, automation level, materials, and add-ons (e.g., metal detection).
Model Comparison and Selection Guide
| Model | Pros | Cons | Applications |
|---|---|---|---|
| Single-Channel Back-Seal | Cost-effective, supports irregular shapes; stainless steel build | Lower speed (30-60 bags/min) | Small batches, diverse pouch types (gift packs) |
| Multi-Channel Auto | High efficiency (up to 300 bags/min), multi-lane parallel processing | High upfront cost, large footprint | Mass production (fast-food supply chains) |
| Vertical Packager | Space-saving, gravity-assisted filling; ideal for small pouches | Limited for high-viscosity materials | Retail single-use packs (10ml sachets) |
| Doypack Machine | Spout design for usability; low material costs, customizable shapes | Mold customization required | Premium sauces, cosmetic samples |
| Can/Bottle Filler | Extends shelf life; integrates capping/labeling | Slower speed, complex maintenance | Family-sized ketchup, premium products |
| Aseptic Brick Packer | Preservative-free, ultra-long shelf life; liquid ketchup optimized | High cost, technical complexity | Export goods, extended shelf-life needs |
Selection Tips:
- Fast-Food Sector: Prioritize multi-channel machines for speed and standardization.
- Premium/Consumer Markets: Opt for canning or Doypack machines for aesthetics and convenience.
- Small-Scale Flexibility: Choose single-channel or vertical models for lower investment.
Industry Trends and Innovations
- Miniaturization: 5-20ml single-use pouches for fast food/travel, reducing waste.
- Material Advancements: Biodegradable films and aluminum laminates enhance freshness and sustainability.
- Smart Technology: AI vision inspection, IoT remote monitoring for predictive maintenance.
- Integrated Lines: Seamless connectivity with filling, labeling, and palletizing systems.
By balancing production needs, packaging formats, costs, and industry-specific requirements, businesses can optimize tomato ketchup packaging solutions, while ongoing innovations drive efficiency, intelligence, and eco-friendliness.
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