Aioli Filling Machine
A servo-driven aioli filling machine that doses emulsified sauces as a gentle plug into 2-32 oz cups at up to 30 cups per minute, with tamper-evident membrane sealing.
The SDH-R is a fully automatic aioli filling machine designed around the one thing emulsions cannot tolerate: shear. Instead of a pump that recirculates and over-works the product, a servo-driven volumetric piston draws and discharges each 50 g to 500 g shot as a single gentle plug at ±0.5% accuracy, so garlic aioli, chipotle mayo and remoulade reach the cup unbroken. Optional MAP nitrogen flush protects oil-rich sauces from oxidation, and roll-film membrane sealing gives a tamper-evident weld. Built in Calgary, Alberta by Alter Pack and CE, FDA and UL certified - see the full SDH-R specification.
Why the SDH-R Excels at Aioli
Gentle Piston Dosing, Intact Emulsions
Aioli and mayonnaise split when over-pumped or sheared. The servo piston moves each shot as a plug with no recirculation, holding ±0.5% fill weights from 50 g to 500 g without thinning the emulsion.
Clean Cut-Off Keeps Flanges Sealable
Oil-rich sauce on the sealing flange stops the film bonding and creates leakers. Controlled nozzle cut-off and piston retract break the shot cleanly, and seal temperature, pressure and dwell are each tuned independently.
MAP Nitrogen Against Oil Oxidation
Vegetable and olive oils oxidise into rancid, cardboard notes long before microbiology becomes the limit. Optional nitrogen flush displaces headspace oxygen and lifts refrigerated shelf life from 7-10 days to 30-45+ days.
Allergen Control for Egg & Garlic
Egg-based emulsions and heavy garlic loads carry over aggressively between recipes. Food-grade 304 stainless surfaces, CIP clean-in-place circuits and tool-free strip-down let crews verify the product path before switching to a non-allergen sauce.
Why Emulsified Sauces Need a Purpose-Built Aioli Filling Machine
Aioli is an emulsion held together by mechanical balance as much as by chemistry. Push it through a lobe pump too many times, force it around tight bends, or let it recirculate in a hopper loop, and the oil phase begins to separate - the product thins, weeps and looks broken on shelf. That is why an aioli filling machine should be judged first on how it moves product, not on its headline speed.
The SDH-R uses a servo-driven volumetric piston. Each shot is drawn once and discharged once, as a plug, straight into the cup. There is no continuous recirculation, and the servo profile lets you slow the discharge stroke for a thick garlic aioli or speed it up for a thinner ranch or Caesar dressing, with every setting stored per recipe on the PLC and HMI. Viscosity, temperature and target weight therefore travel together as one stored profile rather than as a technician's memory.
Accuracy at foodservice portion sizes
Dipping-sauce economics live in the 2-4 oz range, where a few grams of overfill repeated across a shift becomes real money. A fill range of 50 g to 500 g at ±0.5% fill-weight accuracy keeps giveaway predictable and keeps declared net weights defensible.
- Fill range: 50 g to 500 g at ±0.5% accuracy
- Throughput: up to 30 cups/min dry cycle; 18-25 CPM in normal production
- Cups: 4, 8, 10 and 16 oz standard, 2-32 oz custom, round, square or rectangular
- Sealing: roll-film membrane tamper-evident seal, optional pre-cut and snap-on lids
The same dosing platform handles thicker, chunkier products as well - see our salsa filling application page - and every machine is designed and built in Calgary, Alberta by Alter Pack to CE, FDA and UL standards.
Inside the Automatic Aioli Filling Machine: Denest, Fill, Flush, Seal
As a rotary machine, the SDH-R indexes each cup through dedicated stations rather than asking one head to do everything. For an automatic aioli filling machine that separation matters, because the filling step and the sealing step have completely different failure modes.
The cycle
A pneumatic cup denester singulates cups from the stack, including the shallow 2 and 3 oz dipping cups that foodservice programmes live on. The cup indexes to filling, where up to three stations can run in a single pass: a base of garlic aioli, a drizzle of chilli oil or herb emulsion, and a garnish such as cracked pepper or toasted garlic. Because each station has its own dwell, a three-layer sauce cup is built in one pass instead of two separate handling steps. The optional MAP nitrogen flush then displaces headspace oxygen, and roll-film membrane sealing applies a tamper-evident weld with independently controlled temperature, pressure and dwell.
The flange is where aioli lines fail
Oil-rich sauce is slippery and it creeps. If any product reaches the sealing flange, the film will not bond and you get slow leakers that only reveal themselves days later in the cold chain. Commissioning therefore focuses on nozzle diameter, cut-off geometry and piston retract so the shot separates cleanly above the cup, and that setting is saved with the recipe alongside the seal parameters.
Expect up to 30 cups per minute on a dry cycle and a realistic 18-25 CPM in production, depending on viscosity, fill weight and whether nitrogen flushing is active. The same servo dosing core powers our dip filling and sealing machine and our hummus filling machine, so a plant running several sauce and dip categories keeps one operator skill set, one HMI and one spare-parts list.
Dipping Sauce Cup Formats, Shelf Life & MAP for Mayonnaise Filling
Most aioli volume moves as foodservice portion cups. A 2 oz garlic aioli beside a basket of fries, a 3 oz chipotle mayo in a chicken-tender clamshell, a 4 oz burger sauce in a delivery bag - these are high-count, low-weight formats, and a dipping sauce cup filling machine has to denest and seal them without crushing the rim. The SDH-R covers 4, 8, 10 and 16 oz on standard tooling and 2-32 oz as a custom option, in round, square or rectangular formats.
- 2-4 oz: single-serve dipping sauce and condiment cups for foodservice
- 8-10 oz: retail aioli and speciality mayonnaise cups
- 16 oz: deli and club-store tubs
- Up to 32 oz: commissary, catering and bulk kitchen packs
Oxidation is the shelf-life clock
In a mayonnaise filling machine application the limiting factor is usually flavour rather than safety. Oils pick up oxygen at the headspace and drift toward cardboard and rancid notes, while garlic and fresh herbs fade in parallel. The optional MAP nitrogen flush displaces that oxygen at the seal station, taking refrigerated shelf life from roughly 7-10 days to 30-45+ days and holding colour and aroma far closer to day one. Aioli filled at ±0.5% accuracy also loses less product to overfill across those high-count runs.
Presentation matters as much for a premium aioli as it does for a dip. The tamper-evident membrane seal reassures the end customer, an optional pre-cut lid adds a printable branded face, and an optional snap-on lid supports reclose on larger tubs. All three can be specified on the same machine and recalled by recipe, so a single line covers foodservice portion packs and retail SKUs. Format options, tooling and the 44 x 52 in footprint are detailed on the SDH-R machine page.
Sanitation, Allergen Changeover & Support for Your Aioli Packaging Machine
Egg yolk, garlic, mustard and dairy make aioli a heavy allergen and flavour carry-over risk. A trace of garlic emulsion left in a manifold will announce itself in the next batch of lemon-herb sauce, and undeclared egg is a recall exposure. Sanitation on an aioli packaging machine is therefore a design question, not a housekeeping one. Every product-contact surface is specified for wash-down rather than for appearance.
- Food-grade 304 stainless steel across all product-contact surfaces
- CIP clean-in-place circuits for hoppers, pistons and manifolds
- Tool-free strip-down so crews can physically inspect and swab the product path
- PLC and HMI recipe storage with changeover in under roughly 15 minutes
- Compact 44 x 52 in footprint for tight sauce-room and co-pack layouts
Running several sauces on one line
Fat-heavy emulsions need a genuine degreasing wash, not a rinse - oil films resist water and hide in dead legs. Once the line is cleaned and verified, stored recipes bring back fill volume, piston speed, seal temperature, pressure and dwell in seconds, so a co-packer can move from garlic aioli to tartar sauce to a vegan cashew emulsion within one shift. Cup tooling and film width change over mechanically in the same window, so the schedule is limited by sanitation, not by the machine.
Certification, warranty and lead time
The SDH-R is CE, FDA and UL certified, designed and built in Calgary, Alberta by Alter Pack, and backed by a 12-month warranty with service centres in Alberta, New Jersey and California. Pricing starts at $45,000 USD with delivery in 8-12 weeks. We will also confirm cup, film and lid compatibility before quoting. Send us your sauce viscosity, cup format and target cups per minute, and our engineers will size an aioli filling machine for your line.
Certified, Food-Grade Engineering Behind Every Aioli Filling Machine
CE, FDA & UL Certified
Every SDH-R ships with CE (European conformity), FDA (US food-contact) and UL (electrical safety) documentation - the paperwork your auditor, insurer and electrical authority ask to see.
Food-Grade 304 Stainless Steel
All product-contact surfaces are food-grade 304 stainless with CIP clean-in-place and tool-free strip-down, built for HACCP and BRCGS-audited facilities.
Servo-Driven Precision
A closed-loop servo volumetric piston holds +/-0.5% fill-weight accuracy across the full 50-500 g range, protecting net-content compliance and cutting product give-away.
Made in Calgary by Alter Pack
Designed and built in Calgary, Alberta, Canada by Alter Pack, with a 12-month warranty and North American service centres in Alberta, New Jersey and California.
SDH-R Aioli Filling Machine - Full Specifications
Complete specification for the SDH-R automatic rotary cup filling, sealing and cupping machine.
| Specification | SDH-R |
|---|---|
| Throughput | Up to 30 cups per minute (dry cycle) |
| Real-world output | 18-25 cups/min depending on product, cup size & options |
| Fill range | 50 g - 500 g (2 oz - 17 oz) |
| Fill-weight accuracy | +/-0.5% (servo-driven volumetric piston) |
| Standard cup sizes | 4 oz, 8 oz, 10 oz, 16 oz |
| Custom cup sizes | 2 oz - 32 oz with matching tooling |
| Cup shapes | Round, square, rectangular |
| Sealing | Roll-film membrane heat seal (tamper-evident) |
| Lidding options | Pre-cut lid | snap-on lid (pick-and-place) |
| Shelf-life option | MAP nitrogen flush - 7-10 days to 30-45+ days refrigerated |
| Filler stations | Up to 3 (base + drizzle + garnish in one pass) |
| Construction | Food-grade 304 stainless steel |
| Cleaning | CIP clean-in-place + tool-free strip-down |
| Controls | PLC + HMI with recipe storage & diagnostics |
| Changeover | Under ~15 minutes between SKUs |
| Certifications | CE, FDA, UL |
| Footprint | 44 x 52 in (1,100.5 x 1,315.5 mm) |
| Height | 65.6 in |
| Origin | Made in Calgary, Alberta, Canada by Alter Pack |
| Warranty | 12 months |
| Delivery | 8-12 weeks from order confirmation |
| Starting price | From $45,000 USD |
The SDH-R Aioli Filling Machine
Products It Fills
Available In These Markets
How the SDH-R Fills & Seals Aioli
Fully automatic from empty cup to sealed, retail-ready product - no manual labour
Cup Denesting
Empty cups are automatically separated from a nested stack and placed into the rotary table carriers. The pneumatic denester handles round, square, and rectangular cups from 2oz to 32oz.
Servo-Driven Filling
The volumetric piston filler draws a precise dose and dispenses it into the cup. Servo control adjusts stroke length and speed per recipe, maintaining plus/minus 0.5% fill-weight accuracy. The PLC stores recipes for quick changeovers.
Membrane Heat Sealing
Roll-stock film is drawn across the filled cup and heat-sealed to create a tamper-evident, airtight membrane. Sealing temperature, pressure, and dwell time are individually controlled to match your film and cup materials.
Snap-On Lid (Optional)
A pick-and-place mechanism applies a consumer-friendly snap-on lid over the membrane seal - a two-barrier system providing tamper evidence and reclosability for grocery retail and foodservice.
MAP Nitrogen Flush (Optional)
Modified Atmosphere Packaging replaces headspace oxygen with food-grade nitrogen immediately before sealing, typically extending refrigerated shelf life from 7-10 days to 30-45+ days.
Aioli Filling Machine - Frequently Asked Questions
The SDH-R starts at $45,000 USD. Where you land above that depends on cup tooling, the number of filler stations, MAP nitrogen flush and lidding choices. Lead time is 8-12 weeks from order, and every machine is CE, FDA and UL certified and covered by a 12-month warranty.
Up to 30 cups per minute on a dry cycle. In production, aioli lines usually run 18-25 cups per minute depending on viscosity, fill weight, cup diameter and whether MAP nitrogen flushing is active. We confirm realistic output against a sample of your own sauce before quoting.
No. Emulsions break under shear and repeated pumping. The servo-driven volumetric piston draws each shot once and discharges it as a gentle plug, with no recirculation loop, and the discharge stroke speed is adjustable per recipe. Thick garlic aioli and thinner dressings each get their own tuned profile.
Oil-rich sauces oxidise at the headspace before microbiology becomes limiting. Sealed conventionally, refrigerated aioli typically holds 7-10 days; with the optional nitrogen flush displacing headspace oxygen, that extends to 30-45+ days. Your validated figure still depends on formulation, acidity, cold chain and your own shelf-life testing.
Oil films resist plain rinsing, so the SDH-R combines food-grade 304 stainless contact surfaces with CIP clean-in-place circuits and a tool-free strip-down for inspection and swabbing. That matters most when egg and garlic allergen carry-over is the risk, and when the same line also runs hummus or salsa.
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