On the filling line of Pixian Doubanjiang, the chili powder and broad bean particles mixed in the sticky sauce have been a technical problem that has plagued the industry for many years. Traditional filling equipment often leads to an imbalance in the ratio due to material residues, while the sauce packaging solution developed by ply-pack, with the pulse constant temperature filling system, controls the error within ±0.3%, completely rewriting the filling standard of sauces containing solids.
In response to the common problems of low filling accuracy, large material loss, and time-consuming equipment cleaning in the seasoning industry, ply-pack has launched a full-scenario intelligent production system. The core of this solution is equipped with three patented technologies:
.Pulse constant temperature filling: By dynamically adjusting the temperature of the filling head (35-45¡æ range), the fluidity of high-viscosity materials such as bean paste and hot pot base is ensured to be stable, avoiding filling volume fluctuations caused by temperature differences.
.Nano-level adaptive cleaning module: With 64 built-in rotatable nozzles, it can complete 360° cleaning of the inner wall of the equipment within 5 minutes, which is 80% more efficient than traditional manual cleaning and reduces 3% of raw material waste.
.AI production data tracking platform: Real-time monitoring of 12 core indicators such as filling accuracy and equipment energy consumption, and automatically generating production reports that meet HACCP certification, helping enterprises pass authoritative audits such as the Sichuan Sauce Food Association Certification.
In the workshop of a leading hot pot base company in Meishan, six production lines using ply-pack sauce packaging solutions have been running continuously for 2,000 hours. The company's production director did some calculations: "In the past, every time a product category was switched, the equipment had to be stopped for 4 hours to clean. Now the system automatically identifies the residue and starts the cleaning program, and a new batch of production can be put into production in 30 minutes, saving more than 500,000 yuan in labor costs per year."
What surprised customers even more was the "filling pressure compensation algorithm" incorporated into the solution. When the size deviation of the bottle mouth of a glass bottle or plastic bottle is detected, the equipment can automatically adjust the filling flow rate and angle to avoid sauce splashing. This design has increased the filling qualification rate from 92% to 99.6%, and this alone has reduced the loss of 200 tons of raw materials for the company each year.
With the acceleration of the upgrading of the condiment industry, new categories such as pre-prepared dishes and compound seasonings have put forward higher requirements for packaging equipment. ply-pack's solutions have been extended to three major scenarios:
·Small batch customized production: Supports rapid switching of multiple specifications from 1L to 20L to meet the trial production needs of emerging brands.
· Cross-border logistics adaptation: After filling, the sauce bottles are automatically injected with nitrogen to keep fresh, and pass the seismic test to adapt to the long-distance shipping environment.
· Carbon neutral path: The power consumption of the equipment is 18% lower than that of similar products, and the solar power supply system optional module is connected.
From the Sichuan pepper oil workshop in southern Sichuan to the smart production line at the international exhibition, ply-pack's sauce packaging solution is becoming the "invisible engine" for Sichuan cuisine to go overseas. As the Secretary-General of the Sichuan Sauce Food Association said at the technical seminar: "Using Chinese smart manufacturing to protect the soul of traditional flavors, this solution has given new standards to the 'old craftsmanship'." In the filling workshop under the setting sun, the golden and red patent certification nameplate and the beating data screen complement each other, silently telling the legend of Sichuan flavor in the new era.
