Sauces have gained a lot of popularity due to the delicious and appealing flavor they add to food. As a result, the production of various sauces with new and unique flavors has turned into a highly profitable investment. However, the process of offering this product has always come with challenges. To stay ahead of competitors in this industry, alongside product quality, you also need attractive and unique packaging. Don’t miss the continuation of this article for success in this delicious and thriving business.
History of Sauce
There are many types of sauces around the world, but interestingly, all of them are made from four main types of sauces: Bechamel (white), Tomato (Ketchup), Hollandaise, and Spanish. The origin of all these mother sauces traces back to France.
Types of Sauces
Due to the growth of the food industry, the popularity of sauces has also increased significantly, becoming a part of people’s meals. As a result, today we see the production of various sauces. Below are some of the most famous ones.
Mayonnaise Sauce
When shopping in the store, mayonnaise is always a definite choice. You might think that mayonnaise is unhealthy, but interestingly, consuming this delicious and popular sauce has its benefits. This is why mayonnaise is one of the most commonly used condiments alongside food.
Production Method of Mayonnaise Sauce
The first stage of processing this product is the production of the sauce. In this stage, we add water, starch, sugar, vinegar, lemon juice, and salt to a vacuum homogenizer mixer.
If we don’t use a vacuum mixer, the air present will cause the mixture to spoil. Not using an efficient mixer will result in contamination of the product in the first stage of the process.
Next, we slowly add oil to the mixture until the device creates a completely smooth, uniform, and homogeneous blend.
Then, we add egg yolk. Due to the lecithin in the egg yolk, which is both water and fat-loving, it keeps the water and oil together, preventing the mixture from separating into two phases.
Afterward, we use the vacuum homogenizer mixer to homogenize the sauce. This device, due to its lack of contact with air molecules, extends the shelf life of the product and increases its uniformity in appearance, achieving complete homogenization—something that cannot be achieved with regular mixers.
For more information about different types of sauce mixers, click here.
Ketchup Sauce
Ketchup sauce adds vibrant colors to our tables. For pizza, pasta, burgers, French fries, various sandwiches, and lasagna lovers, a world without ketchup is unimaginable. Due to its unique flavor and numerous benefits, this sauce has a dedicated fanbase.
Method of Producing Ketchup Sauce
First, tomatoes are heated to 90°C in cooking tanks under atmospheric conditions.
Small changes can alter the final taste and color, so using high-quality, rust-resistant tanks is of great importance.
Next, water, sugar, starch, vinegar, and various spices are added, and the three-layer atmospheric mixer blends them into a stable mixture.
To homogenize the ketchup sauce, our recommendation is the vacuum homogenizer mixer from Radan Machine. This device prevents rapid spoilage and helps create a smooth texture without lumps. Then, stainless steel and rust-resistant pumps are used for transferring the sauce.
Salad Sauce
Consuming salad is part of a healthy diet. Adding salad dressing to this mix makes its flavor extraordinary. In the past, mayonnaise was used as a salad dressing, but with the advancement of technology, different types of salad dressings have been developed to cater to various tastes, and now they are served with all kinds of salads.
Method of Producing Salad Sauce
Eggs, water, sugar, salt, vegetables, lemon juice, and vinegar are added to a vacuum or atmospheric mixer.
The continuous mixing of this device prevents the separation of the final product’s ingredients.
Next, olive oil, starch, and mayonnaise are gradually added to reach the final mix.
After mixing the product, using a vacuum homogenizer mixer is essential as it increases the stability and shelf life of the product and prevents phase separation.
Types of Salad Sauce Packaging
After producing the sauce, we move to the second stage—packaging. One of the challenges in offering various edible sauces is packaging.
An attractive package not only preserves the quality of the product but also plays an important role in high sales and the growth of your business.
There are different methods for packaging sauces, and the following is a detailed explanation of them.
Single-Serve Sachets
One common method of packaging is the single-serve sachet, which most of us have used multiple times.
Single-serve packaging has less permeability, a longer shelf life, and a more affordable cost compared to other packaging types. Additionally, it is very useful for branding.
The materials used for creating these sachets include PP for ease of sealing, polyester for high printability, metallized films for reducing sunlight penetration, and aluminum foil for minimizing permeability.
This type of packaging is used for various sauces, including French, mayonnaise, mustard, thousand island, ketchup, salad, spices, animal fat, and even honey.
In this packaging, three or four sides are sealed, and the sachet is shaped in a rectangular form with your desired design. This type of packaging is done using a single-nozzle or four-nozzle sachet filler machine in various capacities.
These machines, with their capabilities, can easily fill single-serve sauce sachets, making the final product ready for use.
To print production and expiration dates on the sachets, a roll-to-roll device combined with a jet printer can be used.
Lid-Sealed Cartons
Lid-sealed cartons have gained popularity due to their attractive appearance, high durability, and ease of transportation. In this method, similar to the appearance of sandwich packets, three sides of the packet are sealed, and the sauce is filled into the container using the semi-automatic RPF20 sauce filler machine. Then, the lid is sealed with a special machine.
To prevent the sauce from spilling out of the container, a lid is installed on top and sealed. It is certainly very labor-intensive and difficult to close these lids manually, so using an efficient lid-sealing machine greatly speeds up the process. Next, the production and expiration dates are printed on the packets using a date printer.
Plastic Containers
Plastic containers are commonly used for packaging various sauces. These containers come in a variety of sizes, colors, and shapes such as bear-shaped, rocket-shaped, cartoon-shaped, and simple designs.
Materials such as PP, PET, and both light and heavy polyethylene are used to manufacture these containers. These containers must meet high quality standards since they are in direct contact with food.
Plastic containers are typically used for packaging sauces like ketchup, French, thousand island, and soy sauce.
To fill these plastic containers with sauce, a specialized sauce filling machine is required. There are various filling machines available in the market, but not all of them are suitable for filling sauce containers. Since sauce is a very thick liquid, a machine specifically designed for such a task must be chosen to avoid unnecessary additional costs.
For filling containers with sauce, the semi-automatic RPF10 (single nozzle) or RPF20 (dual nozzle) piston filling machines are ideal for semi-automatic operations, while the fully automatic RPF40 servo piston filling machine is the best option for fully automated systems.
These machines can significantly reduce the need for manual labor in the production line. Some filling machines require a skilled operator, but with these devices, even a basic operator can manage the process.
In this packaging method, in addition to the sauce filling machines, you will also need lid-sealing machines to securely seal the lids of the sauce containers before sending them to the market.
The 8-head lid-sealing machine has no limitations and can seal the lids of various types of packaging, whether plastic or glass, without needing any parts change. There is also an option for using a 2-head lid-sealing machine for some plastic containers.
You can use this lid-sealing machine to seal screw caps, two-stage caps, flip-flop caps, and pump caps onto various packaging types. The machine operates continuously without interruption.
After sealing, a labeling machine is used to display product details. There are three types of labelers:
- Full-body and lid labeler: Covers both the body and the lid of the product.
- Full-body labeler: Covers only the body of the product.
- Lid labeler: Only seals the lid.
These labelers are available at Radan Machine. Typically, label application for sauces is done on the body of the containers. For packaging sauces in rectangular or round containers, using adhesive-backed labels is recommended. Finally, the product is packaged in bundles using shrink wrapping or carton sealing machines.
Glass Containers
Glass containers are used for packaging products like mayonnaise, barbecue sauce, salsa, olive oil, argan oil, and vinegar.
To package these glass containers, a sauce filling machine is required for easy filling and sending products to the market.
For semi-automatic filling, we recommend the semi-automatic RPF20 piston filling machine (single nozzle or dual nozzle), and for fully automatic needs, the RPF40 servo piston filling machine is the best choice.
There are no limitations with Radan Machine filling machines for either glass or plastic packaging. The flexibility of our machines allows you to fill different sizes and shapes of packaging.
These filling machines are designed for thick liquids, so you can fill any type of packaging with sauce without limitations.
One important feature of these machines is their spare parts availability. Fortunately, the spare parts for these products are readily available and reasonably priced, making repairs and maintenance easy. Therefore, even if a machine malfunctions, your production line will not come to a complete halt.
After filling the product, you will need a lid-sealing machine to ensure the product is sealed properly and remains uncontaminated.
The 8-head automatic lid-sealing machine can easily seal lids ranging from 8 to 120 mm, making it the ideal choice for glass jars with twist-off metal caps.
After the filling and sealing process, you will need a labeling machine to brand your product. Labeling is essential for branding and sales. These machines can easily apply 30 to 100 labels per minute, depending on your settings. The container changeover time in these machines is also very fast.
Finally, depending on the type of container, you can enhance the product’s appearance and improve its transportability by shrink-wrapping or cartonizing the packaged items.
Price of Sauce Production Line Machines
The prices of sauce production line machines fluctuate constantly due to the volatility of the currency market. Therefore, it’s recommended to contact Radan Machine directly for the most accurate and up-to-date price quotes.
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Final Words:
In recent years, producing each type of packaging required separate machines. Therefore, business owners had to purchase different machines for different packaging styles. However, with the design and manufacture of multifunctional packaging machines by Radan Machine, there is no longer a need to buy multiple machines for various packaging types. A single machine can now handle all your packaging needs easily.
Radan Machine Industrial Group manufactures products with high diversity, efficiency, genuine warranties, and excellent after-sales service. Despite economic instability, this company has made significant progress in advancing the production lines for packaging products.
Asked Questions (FAQ)
After production, you need to package your product for sale. To set up a sauce packaging production line, it is essential to use a suitable and high-quality sauce filling machine.
Each of these packaging types is designed for a specific purpose and is used accordingly; you can choose any of them based on your needs.
A labeling machine introduces your product and displays all the necessary information for the customer, which is why it plays an important role in the product distribution process.