Choosing a Cup Filling and Sealing Machine for Fresh Food Cups
Compare manual, semi-automatic, rotary and inline cup fillers, then see how our SDH-R denests, fills up to three components, seals and lids pre-formed cups at up to 30 cups per minute with ±0.5% fill accuracy.
A cup filling and sealing machine is packaging equipment that places pre-formed cups, doses a measured portion of product into each one and heat-seals a lidding film across the rim, often adding a snap-on over-cap. Our SDH-R is a fully automatic rotary cup filling and sealing machine that runs up to 30 cups per minute (18-25 real-world), fills 50-500 g at ±0.5% accuracy and starts from $45,000 USD.
- Machine type
- Fully automatic rotary fill-seal-lid (SDH-R)
- Output
- Up to 30 CPM dry cycle (18-25 CPM real-world)
- Fill range & accuracy
- 50-500 g at ±0.5% (servo-driven volumetric piston)
- Cup formats
- 4, 8, 10, 16 oz standard; 2-32 oz custom; round, square, rectangular
- Closing
- Roll-film heat seal, pre-die-cut lids, snap-on plastic lids
- MAP
- Optional nitrogen flush to 0.3-0.4% residual oxygen
- Price
- From $45,000 USD (single-filler configuration)
What Is a Cup Filling and Sealing Machine?
A cup filling and sealing machine is packaging equipment that takes empty pre-formed cups, doses an exact portion of product into each one and closes the cup with a heat-sealed lidding film, often followed by a snap-on plastic over-cap. It replaces hand-scooping, hand-weighing and tabletop sealing with one controlled, repeatable step. For refrigerated dips, spreads, dairy and desserts, this is where portion accuracy, seal integrity and shelf life are won or lost.
Every fill-seal cycle follows the same physics. The cup sits in a fixed nest, a measured dose drops in without stringing or drips, and the flange (the flat rim) must stay clean, because product on the flange is the most common cause of weak or leaking seals. A heated sealing head then presses film onto the flange for a set combination of temperature, pressure and dwell time. Match those to the cup and film and you get a clean, tamper-evident seal; miss them and you see channel leaks, wrinkles or film that will not peel.
We design and build the SDH-R automatic cup filling and sealing machine in Calgary, Alberta, for exactly this job. This guide covers every type of cup filler and sealer so you can judge where the SDH-R fits and where it does not.
How a Cup Fill Seal Machine Works, Station by Station
On a fully automatic cup fill seal machine, the cups move between stations instead of an operator moving between tasks. On the SDH-R, an indexing turret carries each cup through these stations in one pass:
- Cup loading and denesting. A pneumatic denester drops one pre-formed cup into a turret nest.
- Base filling. A servo-driven volumetric piston doses 50 g to 500 g at ±0.5% fill-weight accuracy.
- Secondary or third filling (optional). Extra fillers add paste, spices, nuts, oil or a liquid garnish.
- Membrane sealing. Film cut from a roll is heat-sealed to the flange for a tamper-evident closure.
- Nitrogen MAP flushing (optional). Nitrogen flushing reduces residual oxygen to 0.3-0.4%.
- Lidding (optional) and discharge. A plastic lid is placed and snapped on, and the cup discharges to the conveyor.
Dosing is where most of the engineering lives. Our volumetric cup filler uses a piston filling system driven by a servo motor, so stroke length and speed are tuned per recipe on the HMI rather than by swapping mechanical parts. The sealing station is covered in depth on our automatic cup sealing page, and nitrogen flushing on the MAP cup filler page.
Types of Cup Filling and Sealing Machines Compared
Cup packaging machines fall into five families. Volume, SKU count and product matter more than headline speed.
Cup filling and sealing machine types at a glance
| Type | How it works | Output | Best fit | Main trade-off |
|---|---|---|---|---|
| Manual fill + tabletop sealer | Hand deposit, then one cup at a time on a bench sealer | Operator-paced | Start-ups and pilot batches | Fill variation, giveaway and labor climb with volume |
| Semi-automatic filler and sealer | Operator places cups; machine doses and seals | Operator-paced, faster than manual | Small plants with a few SKUs | Cup handling stays manual |
| Automatic rotary (SDH-R) | Indexing turret carries cups through denest, fill, seal, flush and lid stations | Up to 30 CPM dry; 18-25 CPM real-world | Multi-SKU fresh-food plants, one to three components per cup | Single cup path, so output tops out around 30 CPM |
| Automatic inline / multi-lane | Cups travel in straight lanes under fill and seal stations | Scales with the number of lanes | Long runs of one or two SKUs | Typically larger footprint, higher price, longer changeovers |
| Form-fill-seal (thermoforming) | Forms cups from roll stock, then fills and seals them | High, continuous | Very large single-format volumes | Cup shape tied to forming tooling; not an SDH-R function |
A rotary cup filler arranges every station around a compact turret, which is why the SDH-R fits in 44 × 52 in. An inline cup filling machine spreads the same steps along a straight frame and adds lanes for volume. For layered or multi-component products, read our multi-head cup filling overview; for shallow trays rather than cups, see tray sealing. For a deeper side-by-side, see rotary vs inline filling machines.
How to Choose a Cup Filling and Sealing Machine: 8 Criteria
We ask every buyer the same eight questions before we quote. Answer them honestly and the right type of automatic cup filling and sealing machine usually becomes obvious.
- Throughput. Work from cases per shift, not brochure speed. A 30 CPM dry-cycle rating falls to 18-25 CPM real-world with a real product, fill weight and options. Above 30 CPM sustained on one SKU, an inline line is the better buy.
- Product behavior. Viscosity, particulates, oil separation and fill temperature decide the filler and nozzle. A servo cup filler tunes piston speed for thick pastes and runny sauces without mechanical changes.
- Cup format. List every cup size, shape and material you run now and plan to run; each format needs matching change parts.
- Shelf life and MAP. If retailers ask for longer code dates, specify nitrogen flushing at the time of order.
- Lidding. Choose a film-only seal, a pre-die-cut lid, or a film seal plus a snap-on over-cap that lets consumers reclose the cup.
- Sanitation and allergens. Look for food-grade 304 stainless steel, tool-free strip-down and optional CIP, and count your weekly allergen changeovers.
- Footprint and utilities. Measure the room, doorways and the path to labeling and cold storage, and confirm compressed air and power. Our guide to optimizing production footprint covers layout.
- Budget and total cost. Weigh the purchase price against labor saved, giveaway eliminated and shrink avoided from leaking cups.
Get a configured SDH-R quote for your productSend your product, cup size and target cups per minute — we reply within 24 hours.
Request a quoteSDH-R Automatic Cup Filling and Sealing Machine Specifications
The SDH-R is our fully automatic rotary cup filling, sealing and lidding machine. It is built for fresh and refrigerated food producers that run several products on one line and need consistent weights, clean seals and fast changeovers.
SDH-R cup filler and sealer specifications
| Specification | SDH-R |
|---|---|
| Machine type | Fully automatic rotary (indexing turret) |
| Output | Up to 30 CPM dry cycle; 18-25 CPM real-world |
| Fill range | 50-500 g (approx. 2-17 oz) |
| Fill accuracy | ±0.5% (servo-driven volumetric piston) |
| Cups | 4, 8, 10, 16 oz standard; 2-32 oz custom; round, square, rectangular |
| Filling stations | Up to 3: piston, vibration, garnish or peristaltic pump |
| Closing | Roll-film seal, pre-die-cut lids, snap-on plastic lids |
| MAP | Optional nitrogen flush to 0.3-0.4% residual oxygen |
| Controls | PLC, HMI recipe storage; changeover under ~15 minutes |
| Construction | Food-grade 304 stainless steel; CE, UL, FDA compliant |
| Footprint | 44 × 52 in (1,100.5 × 1,315.5 mm); 65.6 in (1,666 mm) high |
Options include a conveyor extension, labeling integration, variable data coding and a weight checker with feedback to the filler. The full engineering story is on our filling and sealing technology page.
How Product Behavior Shapes a Cup Filler and Sealer Setup
Two products with the same fill weight can need completely different setups. Our engineering team checks these first:
- Viscosity and stringing. Thick pastes such as hummus and cream cheese string off the nozzle and smear the flange. A suck-back nozzle pulls product back after each dose.
- Particulates. Salsa, chunky guacamole and tzatziki can bridge a narrow valve. Large-bore valving passes herbs, shredded cucumber and nut pieces.
- Syneresis and weeping. Yogurt, sour cream and cottage cheese can release whey when sheared hard. Gentler piston speeds, stored per recipe, help limit shear in the filler.
- Oil separation. Pesto and tahini separate if they sit, so keep hopper product consistent and add finishing oil as a separate peristaltic-pump dose.
- Aeration. Whipped spreads change density as they are pumped, so volumetric doses should be verified by weight.
- Fill temperature. The SDH-R targets fresh and refrigerated cups filled at a pumpable temperature. Warm fills, viscosity extremes and unusual particulates are confirmed with our engineering team before we quote.
Products You Can Run on a Cup Filling and Sealing Machine
The SDH-R is used across dips, dairy, spreads and desserts. Each product page below explains the filler, nozzle and closing setup we recommend for that product:
- Mediterranean dips: hummus, baba ganoush, tahini and tzatziki
- Mexican and chunky dips: salsa, guacamole and queso and cheese dips
- Sauces and condiments: pesto, aioli and other dips and sauces
- Cultured dairy: sour cream, cream cheese, cottage cheese, ricotta and yogurt
- Spreads and fats: spreads, butter and margarine and nut butters
- Desserts and layered cups: dessert cups, pudding, custard and parfaits
- Small formats: 2 oz portion cups for sauces and dips, at the low end of the 50 g standard fill range
Plant-based dips, baby food purees, salads and sauces also run on the machine; browse all cup filling applications for product-specific notes.
Cup Filling and Sealing Machine Price and What Drives Cost
The SDH-R starts from $45,000 USD for the single-filler configuration: denesting, servo piston filling and roll-film sealing. Price then scales with what you add:
- Second and third fillers (vibration, garnish or peristaltic pump) for multi-component cups
- Nitrogen MAP flushing for extended refrigerated shelf life
- Plastic lid pick-and-place and snapping device for over-caps
- Custom tooling for each additional cup size or shape
- Labeling integration, variable data coding, a weight checker with feedback and a conveyor extension
- A CIP (clean-in-place) system
Our cup filling and sealing machine cost guide breaks down each driver and how to weigh it against manual labor and product giveaway. Lead time is 8-12 weeks from order confirmation, and every machine carries a 12-month warranty with support from our Alberta, New Jersey and California service centres.
For an accurate number, send us your product, cup size, target cups per minute and options. Our team may ask a few questions about the application first and typically replies within about 24 hours.
Sanitation, Allergens and Food-Safety Compliance
Product is exposed until the film goes on, so the filler and sealer sit in the highest-risk zone of a fresh-food plant. The SDH-R is built from food-grade 304 stainless steel, strips down without tools and can be specified with CIP, supporting the sanitation controls plants document under FDA FSMA Preventive Controls (21 CFR Part 117), HACCP plans and schemes such as BRCGS and SQF. It is CE and UL listed with FDA compliant food-contact materials, and it is designed to support plants operating under these programs, not certified to them itself.
Allergen changeovers deserve their own plan. Sesame became the ninth major US allergen under FALCPA on January 1, 2023 through the FASTER Act, which matters on any line running hummus or tahini beside sesame-free products. Canadian plants operate under the Safe Food for Canadians Regulations (SFCR) enforced by the CFIA, and EU exporters must meet Regulation (EC) 1935/2004 for food-contact materials. Recipe changeovers take under about 15 minutes; a validated allergen clean takes longer and should be scheduled separately.
When the SDH-R Is Not the Right Cup Packaging Machine
We would rather lose a sale than sell the wrong machine. The SDH-R is not the right choice if:
- You need sustained output above 30 CPM on a single SKU; a multi-lane inline line will cost more but deliver the volume.
- Your product must be shelf-stable at ambient temperature. The SDH-R is not aseptic or retort; MAP extends refrigerated shelf life only.
- You fill frozen products such as ice cream, or need cups thermoformed on the machine.
- Your portions are below 50 g, such as 1 oz cups.
- You pack meat or poultry in shallow trays, which calls for a dedicated tray sealer.
If you are unsure, talk to our engineering team about your product and volumes, and we will tell you plainly which machine fits. Common buyer questions are also answered on our cup filler FAQ page.
Cup Filling and Sealing Machine — Frequently Asked Questions
Our SDH-R automatic cup filling and sealing machine starts from $45,000 USD for the single-filler configuration, which denests, fills with a servo piston and roll-film seals pre-formed cups. Price rises with extra fillers, nitrogen MAP flushing, plastic lid pick-and-place, custom cup tooling, labeling and CIP. Our cost guide explains each driver, and we usually reply to quote requests within about 24 hours.
The SDH-R rotary cup filling and sealing machine runs up to 30 cups per minute on a dry cycle and typically 18-25 cups per minute in real production, depending on product, cup size, fill weight and options such as MAP or lidding. Producers who need sustained output above 30 cups per minute on a single SKU are usually better served by a multi-lane inline line.
The SDH-R fills 50 g to 500 g (about 2 oz to 17 oz) as standard and runs 4 oz, 8 oz, 10 oz and 16 oz cups. Custom cup sizes from 2 oz to 32 oz are available with matching change parts, in round, square or rectangular shapes. It runs pre-formed cups and tubs only; fills below 50 g, such as 1 oz cups, are outside the standard range.
The SDH-R holds fill-weight accuracy of ±0.5% using a servo-driven volumetric piston, so an 8 oz (227 g) fill stays within roughly ±1.1 g. Tight accuracy lets producers set target weights closer to the label declaration and cut product giveaway. An optional weight checker with a feedback loop to the filler helps hold weights steady when product density drifts during a run.
Yes, with modified atmosphere packaging. The SDH-R's optional nitrogen flush reduces residual oxygen in the cup to 0.3-0.4%, which typically extends refrigerated shelf life from roughly 7-10 days to 30-45 days or more, depending on the product. MAP does not make a product shelf-stable: cups still need refrigeration, and the SDH-R is not an aseptic or retort system. See our MAP shelf-life guide.
The SDH-R cup filling and sealing machine is built from food-grade 304 stainless steel with tool-free strip-down and an optional CIP (clean-in-place) system. Recipe changeovers between SKUs take under about 15 minutes using stored HMI recipes. Allergen changeovers, such as sesame-based hummus to a sesame-free dip, need a full validated clean under your HACCP or preventive controls plan.
Yes, with the right nozzle and valve fitted for each product at changeover. The SDH-R's servo piston is tuned per recipe on the HMI, large-bore valving passes herbs, shredded cucumber and nut pieces, and a suck-back nozzle stops drips on stringy pastes. Very large chunks or warm fill temperatures are confirmed with our engineering team before we quote.
A combined machine such as the SDH-R denests, fills, seals and lids in one pass, so open cups are never carried between machines and one operator can supervise the process. Separate fillers and sealers can suit very low volumes or plants that already own one half of the process, but they add handling, floor space and an exposure point between dosing and sealing.
The SDH-R is designed and built in Calgary, Alberta, with a delivery lead time of 8-12 weeks from order confirmation and a 12-month warranty. Service is supported from our Alberta, New Jersey and California service centres for producers in the USA, Canada and overseas markets. Contact our team to confirm current lead times for your configuration.
Related machines & guides
Explore the pages most relevant to this application.
Why producers buy from Hummus Pack
Ready to Quote Your Cup Filling and Sealing Machine?
Get a personalized SDH-R configuration and price for your product, cup sizes, and production volume.