Sauce Cup Filling Machines

Our automatic sauce cup filling machines are designed for filling a wide range of portion sauces into pre-made plastic cups and containers. Typical applications include ketchup, tomato sauces, mayonnaise, mustard, barbecue sauce, sweet chilli, aioli, garlic sauce, burger sauce, taco sauce, cheese sauce and other dipping sauces. Machines can handle both smooth products and recipes containing vegetable or spice inclusions.

Depending on the packaging format and production requirements, machines can be configured with either pre-cut lid placement or roll-fed film sealing. Optional descending filling nozzles are also available where required.

Available in both rotary and linear configurations, our sauce cup filling machines can be supplied as standalone units or as fully integrated filling and sealing lines with date coding, product handling and end-of-line automation.

Engineering insights

Considerations for Filling Sauces

Product Formulation

Most portion sauces can be filled using standard volumetric piston technology, making it suitable for products such as ketchup, tomato sauces, mayonnaise, mustard, sweet chilli and aioli. Recipes containing vegetable pieces or other inclusions generally require no special modifications unless particle size exceeds approximately 5 mm. In these cases, enlarged product valves and filling nozzles help maintain unrestricted product flow while preserving filling accuracy.

Standard piston fillers are suitable for most sauce applications
Enlarged product passages may be required for inclusions exceeding approximately 5 mm
The filling system should be matched to the product formulation

Portion Packaging

Unlike many other cup-filled products, sauces are most commonly packed in small single-serve cups intended for HoReCa and foodservice applications. Typical pack sizes range from approximately 20–100 ml and often use cup diameters smaller than those found in yoghurt packaging. Depending on the packaging specification, cups can be sealed using either pre-cut foil or film lids or roll-fed film. Optional descending filling nozzles can also be incorporated where required to suit the product characteristics and packaging format.

Single-serve cups of approximately 20–100 ml are the most common packaging format
Both pre-cut lids and roll-fed film are widely used for sealing
Optional descending filling nozzles are available where required

Machine Range

Our Portion Sauce Cup Filling Machines

Semi-automatic cup filling and sealing machine for pre-made plastic cups and containers, ensuring accurate filling and secure sealing for dairy and food applications.

Equipment Selection

Recommended Machine Configuration

Standard Machine Configuration

Most portion sauce applications can be handled using a standard cup filling machine. The final machine configuration should be selected according to the product characteristics, production capacity and hygiene requirements, while maintaining reliable filling performance across a wide range of sauce formulations.

Automatic cup feeding
Automatic lid placement and heat sealing
Automatic finished cup discharge to an outfeed conveyor

Recommended Machine Modules

The packaging specification determines which optional machine modules are required. Depending on the packaging format, the machine can be configured with either a pre-cut lid placement and heat sealing system or a roll-fed film sealing system. UV-C treatment and integrated date coding systems are also available where improved hygiene control or product traceability is required.

Roll-fed film sealing system (optional)
UV-C treatment of the inner cup surface
Integrated date coding systems for batch and expiry information

Dosing System Selection

A volumetric piston filling system is suitable for most sauce applications, providing accurate and consistent filling of both smooth products and recipes containing small inclusions. Where larger particles are present, enlarged product valves and filling nozzles help maintain unrestricted product flow without compromising filling accuracy. Optional descending filling nozzles can also be specified where improved filling control or product presentation is required.

Suitable for both smooth sauces and products containing small inclusions
Enlarged product passages for sauces with larger particles
Optional cup lifting or descending filling nozzles to improve filling control

Ultra-Clean Design

The required hygiene level should be determined by the product formulation rather than the product category. While many sauces can be filled using a standard hygienic machine design, products containing dairy ingredients, yoghurt or other chilled components may require an Ultra-Clean configuration to support the intended shelf life and production process. It may also be appropriate where the sauce is not pasteurised or has not undergone sufficient processing prior to filling.

UV-C treatment of containers and lids
Laminar flow box with HEPA filtration
Aseptic diaphragm valves
Optional inert gas flushing (e.g. nitrogen)
Optional dual-sided piston cleaning during CIP

Packaging Examples

Typical Portion Sauce Packaging

Portion sauces are typically packed in small plastic cups for single-use applications in foodservice, takeaway and retail. Individual pack sizes generally range from approximately 20 to 100 ml. Depending on the packaging specification, cups may be sealed with either pre-cut foil or film lids, or roll-fed film. The examples below illustrate some of the packaging formats commonly used for portion sauce products.

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Planning a Sauce Cup Filling Project?

Whether filling ketchup, mayonnaise, barbecue sauce or other portion sauces, selecting the right cup filling machine begins with understanding your product characteristics and packaging requirements. Product formulation, particle size, packaging format and required production capacity all influence the final machine configuration. Tell us about your product and production requirements, and we’ll help configure the most suitable cup filling solution for your application.