Customer Packaging Requirement

The customer needed to pack two viscous sauce products:

• Ketchup

• Mayonnaise

Both products are filled under a cold-filling process.

The required individual sachet weight is:

20g per sachet

The customer selected a 10-lane four-side-seal packaging format to obtain higher output from a compact production footprint.

For liquid and semi-viscous sauce dosing, the machine uses a 10-lane servo-driven ceramic pump filling system, allowing each lane to perform independent and stable metering during high-speed production.

Main Machine: SF-960 10-Lane Four-Side-Seal Packing Machine

The core machine of the line is the SF-960 10-lane sachet packing machine.

It is designed for multi-lane liquid and viscous product packaging and forms multiple sachets simultaneously from roll film.

Main Specifications

Why Use a 10-Lane Servo Ceramic Pump Filling System?

For products such as ketchup and mayonnaise, filling accuracy and stability are especially important because product viscosity can create inconsistent flow when conventional gravity filling methods are used.

This project therefore uses a servo ceramic pump dosing system across all 10 lanes.

The system allows the machine to control the filling movement more precisely while handling viscous sauces.

Compared with a single-lane or low-lane-count machine, the 10-lane configuration also greatly increases production capacity without requiring ten independent packaging machines.

At the specified production speed of 30–35 sachets per minute per lane, total nominal output can reach approximately:

300–350 sachets per minute

under suitable production conditions.

Automatic Sachet Counting Conveyor

One of the key features of this project is the downstream blue cleated counting conveyor.

After the 10-lane machine cuts and discharges the sachets, the sachets fall onto the conveyor.

The conveyor uses separated cleats together with the control system to organize and count the sachets before they enter the secondary packaging section.

The operator can set the required quantity through the control interface. For example, the system can collect a preset batch such as 100 sachets before automatically releasing them into the carton-loading section.

This is particularly useful for customers who previously relied on workers to:

count sachets → group sachets → fill cartons → transfer cartons manually.

Automating this part of the process reduces repetitive manual work and makes the quantity inside each shipping carton easier to standardize.

Conveyor Between Carton Loading and Carton Sealing

The production order also specifies three conveyor sections between the carton-loading and carton-sealing equipment.

These conveyors provide automatic carton transfer between the secondary packaging machines.

Conveyor Configuration

This enables cartons to move continuously through the downstream packaging process rather than being manually transferred between stations.

Automatic Carton Loading & Sealing

The secondary packaging section is designed for standard corrugated cartons.

According to the production specification:

• Carton type: Standard shipping carton

• Top sealing: Tape

• Bottom sealing: Tape

• Packing quantity: 100 sachets per carton

• Sachet: 20g, 45 × 135 mm

• Carton size: To be confirmed according to final customer carton design

The line uses a bag-first loading arrangement, allowing counted sachets to enter the carton automatically before the carton proceeds to the sealing section.

This configuration is especially suitable for high-volume sachet production because the downstream system can handle the large number of individual small packs generated by a multi-lane packaging machine.

Complete Packaging Process

The working sequence of the line is:

1. Sauce feeding

Ketchup or mayonnaise is supplied to the filling system.

2. Servo pump dosing

Ten servo-controlled ceramic pumps meter the product simultaneously.

3. Multi-lane sachet forming

The laminated film is divided into 10 lanes.

4. Four-side sealing

Each 20g sachet is formed with four sealed edges.

5. Cutting and discharge

Finished sachets are separated and discharged from the machine.

6. Cleated conveyor transfer

The sachets enter the blue cleated conveyor.

7. Automatic counting

The control system counts sachets according to the preset carton quantity.

8. Carton loading

The grouped sachets are discharged into the carton.

9. Carton conveying

The filled carton moves automatically through the connecting conveyor sections.

10. Carton sealing

The carton is sealed and prepared for final handling or shipment.

Why the Customer Chose a Multi-Lane Packaging Line

For single-serve sauce products such as ketchup and mayonnaise, production volume can become extremely high because each finished package contains only a small amount of product.

For example, at approximately 300–350 sachets/minute, even one hour of production can generate tens of thousands of individual sachets.

This means the challenge is not only filling and sealing.

The manufacturer must also solve:

How will the finished sachets be counted, collected, loaded into cartons and sealed efficiently?

That is why this Lebanon project was designed as a complete packaging line rather than simply supplying a standalone sachet machine.

Suitable Applications

This 10-lane liquid sachet packaging system can be configured for products such as:

• Ketchup

• Mayonnaise

• Salad dressing

• Chili sauce

• Tomato sauce

• Mustard

• Barbecue sauce

• Soy sauce

• Vinegar

• Liquid seasoning

• Syrup

• Honey

• Other liquid or semi-viscous products

Different pump and product-contact configurations should be selected according to the actual viscosity, formulation and filling requirements of each product.

Multi-Lane Packaging Solution for Food Manufacturers and Co-Packers

This type of multiline vertical fill-seal packaging machine is suitable not only for brand owners but also for co-packers, contract packers and private-label food manufacturers handling high-volume sachet orders.

For co-packing operations, the main advantage is the ability to process different sauce recipes and filling settings while maintaining high multi-lane productivity.

Parameters such as:

filling quantity, bag length, production recipe and operating settings

can be adjusted according to different customer products.

For this type of multi-lane machine, however, bag width is determined by the lane layout and forming structure and is not intended for frequent changeover. Therefore, customers handling multiple SKUs should normally standardize the sachet width where possible and adjust bag length and filling parameters for different products.

Project Summary

This Lebanon project combines a:

10-lane ketchup and mayonnaise sachet packing machine

with:

automatic counting conveyor + carton loading + conveying + carton sealing

to create a more integrated end-of-line packaging solution.

The core SF-960 system uses 10 servo ceramic pumps, a Siemens control system, SUS304 construction, and SUS316 product-contact components, and is designed to produce 20g, 45 × 135 mm four-side-seal sachets at 30–35 sachets/minute per lane.

For manufacturers producing large quantities of small sauce sachets, integrating secondary packaging directly behind the multi-lane machine can significantly simplify sachet handling and reduce the amount of manual counting and carton loading required.

FAQ

What machine is suitable for packing 20g ketchup sachets at high speed?

A 10-lane servo pump sachet packing machine can be used for high-output 20g ketchup packaging. In this Lebanon project, the SF-960 uses 10 servo ceramic pumps and operates at approximately 30–35 sachets per minute per lane, corresponding to a nominal combined output of about 300–350 sachets per minute.

Can one machine pack both ketchup and mayonnaise?

Yes, a properly configured liquid or viscous-product multi-lane sachet machine can handle products such as ketchup and mayonnaise. Filling parameters should be adjusted according to the viscosity and formulation of each product.

Can a multi-lane sachet machine connect to automatic cartoning equipment?

Yes. In this project, finished sachets are discharged onto a cleated counting conveyor, automatically counted according to a preset quantity, transferred into cartons and then conveyed to carton-sealing equipment.

What is the advantage of a 10-lane ketchup packing machine?

A 10-lane machine forms and fills ten sachets simultaneously, providing much higher output than a single-lane machine while using one integrated packaging platform. It is particularly suitable for high-volume single-serve sauce production.

Can the bag size be changed?

Bag length and filling parameters can normally be adjusted within the machine's designed range. Bag width on a multi-lane machine is much less convenient to change because it is determined by the lane configuration and sealing structure, so the sachet width should normally be confirmed before machine production.