Chili Sauce Production Line
Turn Fresh Chili into Market-Ready Sauce with Maximum Efficiency
The EasyReal Chili Sauce Production Line delivers a complete solution to handle different chili varieties, including red, green, yellow, bird’s eye, jalapeño, and habanero. The system manages tough skins, seeds, and fiber structures with precision grinding and thermal cooking. It also offers tight control over texture, heat level, and microbial safety.
This line includes:
● Air-blowing + brush washing machine for gentle cleaning
● Destemmer and seed remover to clean raw pods
● Hammer mill or colloid grinder to reduce particle size
● Jacketed cooking kettles or continuous cookers for flavor development
● Tube-in-tube or plate sterilizer to ensure shelf stability
● Automatic filling and capping machines for bottles, jars, or pouches
We build the line in modular sections to fit different capacity needs—starting from 500 kg/h up to 10 tons/h. The materials meet food-grade standards (SUS304/SUS316L), with all pipelines polished and CIP-ready. Combined with our smart control system, users can monitor temperature, flow rate, and filling accuracy in real time.
EasyReal’s global experience in sauce processing helps us deliver machines that fit your chili blend recipe and regional preferences, whether for Asian-style fermented chili sauce, Mexican-style salsa roja, or American Louisiana-style hot sauce.
From Street-Style Heat to Export-Ready Bottles
EasyReal’s chili sauce processing system is ideal for various markets and formulations:
1. Condiment and Sauce Factories
Producers of bottled chili paste, pepper purée, sambal, and sriracha use our line to control heat, acidity, and texture for repeatable quality.
2. Ready-to-Eat and Meal Prep Companies
Use the line to make chili-based flavor bases for noodles, stews, instant food packs, and dipping sauces.
3. Ethnic Food Exporters
Producers of Korean gochujang, Thai chili paste, or Mexican salsa benefit from our flexible ingredient dosing and packaging options (glass bottles, sachets, or spouted pouches).
4. Food Co-Packers and OEM Brands
Need to process different chili varieties on the same line? Our quick CIP, adjustable grinding heads, and multiple cooking kettle options make switching between recipes easy.
5. Small-scale Regional Brands Scaling Up
From artisan batches to larger semi-continuous output, we offer scalable solutions with affordable upgrade paths.
Whether you're sourcing dried chili, fresh chili, or fermented mash, EasyReal tailors the pre-treatment steps to protect flavor compounds, minimize skin residues, and ensure high capsaicin retention.
Match Output, Product Type, and Packaging to the Right Setup
When selecting your chili sauce line, consider the following factors:
1. Output Capacity
● 500–1000 kg/h: Ideal for pilot runs or regional brands
● 1–3 tons/h: Suits medium-scale condiment producers
● 5–10 tons/h: Designed for large factories with high-volume export needs
2. End Product Type
● Chili paste / crushed chili: Coarse grind, minimal cooking, filled hot or aseptically
● Smooth hot sauce: Fine grinding, filtered puree, emulsified texture
● Fermented chili sauce: Requires additional tanks and time-based control for aging
● Green chili sauce: Needs gentle heat, anti-oxidative steps, and color preservation
● Multi-flavor blends: Supports garlic, vinegar, sugar, oil dosing for regional formulas
3. Packaging Format
● Glass bottles / PET bottles: Needs bottle rinser, hot filling, capping
● Sachets / pouches: Requires pouch filler + sealing station
● Drum or bag-in-box: Suitable for bulk chili mash storage
Our engineers can recommend layouts based on your recipe viscosity, sterilization temperature, and packaging speed. We offer both semi-automatic and fully automatic setups.
From Fresh Chili to Sealed Bottle – Step-by-Step Process
Here’s a typical production flow for hot chili sauce:
1.Raw Chili Receiving
Sort by type (fresh, frozen, fermented mash)
2.Washing & Cleaning
Air blower + bubble washer → brush washer
3.Destemming & De-seeding
Separate stalks and seeds (if needed)
4.Crushing / Grinding
Chili hammer mill or colloid mill for particle reduction
5.Cooking & Emulsifying
Kettle cooker or continuous heating mixer for flavor, color control
6.Add Ingredients
Garlic, salt, sugar, oil, vinegar, etc.
7.Homogenization / Refining
Optional, for smoother sauces
8.Sterilization
Tube-in-tube or plate sterilizer at 95–121°C
9.Filling & Capping
Hot filling or aseptic filling for jars, bottles, pouches
10.Cooling & Labeling
Tunnel cooler → labeling → packaging
This flow can be adjusted based on chili source and product format.
Powerful, Reliable Machines Built for Spicy Workflows
Each machine in the line plays a crucial role. Here are key highlights:
Chili Washing and Sorting Machine
This system uses bubble washing + air blowers + soft brushes to remove soil, dust, and pesticide residues. The airflow keeps delicate chili skins from bruising. The structure includes an inclined bed for water drainage and overflow for floating stems. Compared with manual washing, it reduces labor and improves sanitation.
Chili Destemmer & Seed Separator
Built with rotary blades and perforated drums, this unit removes stalks and large seeds from fresh or fermented chili. It adjusts speed to match chili type (e.g., thicker Mexican chili vs. slim bird’s eye). Stainless steel design ensures food contact safety and easy cleaning. This step is critical for smooth sauces.
Chili Hammer Crusher / Colloid Grinder
The chili crusher features a high-speed rotating hammerhead for coarse grinding. For finer texture, the colloid mill uses a rotor-stator gap to emulsify particles. The rotor speed reaches up to 2800 rpm. The grinder supports stepless gap adjustment, making it easy to switch between chunky and smooth sauce textures.
Jacketed Cooking Kettle / Continuous Cooker
The jacketed kettle uses steam or electric heating for slow cooking and flavor infusion. It supports agitation and temperature control. For high-output lines, we offer a continuous screw-type or tube heating cooker, which boosts throughput while maintaining consistency. Cooking helps break cell walls and enhance chili aroma.
Tube-in-Tube Sterilizer
Our tube-in-tube sterilizer applies Indirect heat exchanger: Use hot water to exchange heat with the product to avoid direct steam heating of the product and ensures higher protection of flavors with no contamination or product dilution and sterilize the chili sauce at 95–121°C. It ensures microbial safety without burning the product. The unit includes a holding tube, balance tank, and automatic back-pressure control. Compared to steam injection, it protects the flavor and color better.
Chili Sauce Filling & Capping Machine
We offer piston fillers for thick pastes and gravity or hot-fill machines for smooth sauces. Bottle/jar positioning, nitrogen dosing (optional), and quick-change filling heads ensure efficient packaging. The integrated capping station handles twist caps or flip-tops. Servo-driven motion boosts precision and speed.
Process Any Chili Type – From Bird’s Eye to Bell Pepper
EasyReal’s chili sauce line handles a wide range of chili types and blends. Whether you're using fresh chili, fermented mash, or frozen raw pods, the machines adapt easily with modular upgrades. The destemmer and grinder accept both small and large chili pods, including:
● Red chili (e.g., cayenne, serrano)
● Green chili (e.g., jalapeño, Anaheim)
● Fermented chili mash
● Yellow chili / bell peppers
● Bird’s eye chili / Thai chili
● Smoked or sun-dried chili (after rehydration)
Our grinding units support fine and coarse textures, from chunky Mexican-style salsa to smooth Louisiana hot sauce. You can also add onion, garlic, vinegar, oil, sugar, starch, or thickeners mid-process. For high-viscosity sauces (e.g., chili-garlic paste), we provide vacuum mixers or double-layer agitators to avoid air pockets.
Output formats can be switched easily:
● Switch from glass bottle hot sauce to spouted pouch chili paste by changing the filling machine.
● Use different sterilization modules (tube-in-tube or tubular) depending on viscosity and temperature hold.
● Process multi-flavor blends (sweet chili sauce, sambal, or Sichuan-style spicy oil) with recipe-specific dosing tanks.
Whether you run seasonal batches or year-round production, the line offers high changeover speed and recipe memory storage in the PLC system.
See Every Chili Move – Track, Control, and Adjust
EasyReal equips the chili sauce line with a Germany Siemens PLC + HMI control system for real-time process visibility. You get intuitive control screens with alarms, trend curves, and parameter settings tailored for each module.
Key Features:
● One-touch recipe switch: Store settings for each chili blend (temperature, flow rate, viscosity range)
● Temperature and pressure logging: Track sterilization and cooking data to ensure HACCP compliance
● Automatic level sensors: Monitor feed tanks to avoid overflows or dry runs
● Remote diagnostics: Get support from EasyReal’s engineers via Ethernet connection
● CIP (Clean-in-Place) control: Set cleaning cycles for pipelines, tanks, and fillers
The system simplifies training, reduces errors, and improves consistency. You can set filling volume, bottle count, and cooking time in a few taps. For medium and large lines, we provide multi-screen systems to monitor cooking, sterilization, and filling areas separately.
By using brands like Siemens, Schneider, and Omron, EasyReal ensures stable performance and global spare parts availability. You can also integrate barcode systems or batch record printers for production traceability.
Let EasyReal Help You Bring the Heat to Market
With over 25 years of experience in fruit and vegetable processing, Shanghai EasyReal Machinery Co., Ltd. offers turnkey chili sauce solutions trusted by factories in Asia, Latin America, Africa, and Eastern Europe.
We support:
● Custom process layout and factory planning
● Lab-scale tests and formula trials for chili mash or raw pods
● Installation, commissioning, and local operator training
● After-sales spare parts and online technical support
● OEM/ODM partnerships for branded equipment exports
No matter your chili type, sauce style, or packaging goal, EasyReal can configure the right machines for smooth, spicy, and shelf-stable results.
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