Precision, Flexibility, and Washdown Design by AMS Filling Systems
Filling very small quantities of spices into large pickle jars presents a unique set of challenges—especially when accuracy, sanitation, and line integration are non-negotiable. When a food processor needed a better way to dose complex spice blends into pickle jars, they turned to AMS Filling Systems to engineer a purpose-built solution.
The Challenge: Inconsistent Blends and Limited Control
The customer’s existing process relied on a volumetric cup filler feeding a pre-blended spice mix into pickle jars. While workable in theory, the process consistently failed in practice.
Key issues included:
- Extremely small target weights
Individual spice components ranged from 0.1 to 3.5 grams, pushing the limits of volumetric accuracy. - Wide variation in spice characteristics
Fine spices such as mustard seed and celery seed settled to the bottom of the blend, while lighter, larger components like red bell pepper flakes migrated to the top. - No ability to control ratios during filling
Because the spices were pre-blended, operators had no way to adjust individual spice percentages once production started. - Existing line constraints
The filler had to integrate into an active packaging line with limited available footprint. - Harsh operating environment
Constant exposure to pickle brine required 100% washdown capability and corrosion-resistant construction.
The result was inconsistent flavor profiles, higher scrap rates, and unnecessary process complexity.
The AMS Solution: Individual Spice Filling at Production Speed
AMS Filling Systems engineered a custom multi-component spice filling system designed specifically for this application. Rather than filling a blended mix, the system fills each spice independently into every pickle jar.
Key Performance Capabilities
- Throughput: Up to 350 containers per minute (CPM)
- Independent control: Each spice metered separately
- On-the-fly adjustment: Operators can fine-tune individual spice weights during production
- No container, no fill: Eliminates waste and improves line efficiency
By eliminating pre-blending altogether, the customer gained complete control over recipe consistency while improving yield and repeatability.
Hygienic, Washdown-Ready Design
Given the corrosive nature of pickle processing, AMS designed the system from the ground up for sanitation and durability:
- 100% 316 stainless steel construction
- Open-base design for easy washdown, inspection, and sanitation
- Full washdown compliance for food safety and uptime
- Custom base and safety doors engineered to integrate seamlessly into the existing packaging line
Every design decision prioritized cleanability, operator safety, and long-term reliability.
Precision Ingredient Delivery
To ensure consistent dosing of each spice, the system utilizes:
- Four independent pneumatic conveyor systems, each dedicated to a specific spice
- Direct delivery to individual fill heads, eliminating cross-contamination
- Stable, repeatable flow regardless of spice density or particle size
This architecture ensures every pickle jar receives the correct spice composition—every time.
Results: Better Control, Less Waste, Higher Efficiency
By partnering with AMS Filling Systems, the customer achieved:
- Elimination of pre-blending and segregation issues
- Accurate filling of ultra-low-weight ingredients
- Reduced waste through no-container-no-fill logic
- Improved sanitation and faster washdown cycles
- A scalable, future-proof solution tailored to their exact process
Designed and Manufactured by AMS Filling Systems
This project exemplifies AMS Filling Systems’ core strength: engineering custom filling equipment that solves real-world production problems. From ultra-low-weight ingredient handling to full washdown environments, AMS delivers systems that integrate seamlessly, run reliably, and give operators control where it matters most.
If your application involves difficult products, tight tolerances, or challenging environments, AMS Filling Systems can design the solution.