Hot fill technology is growing at a steady pace, standing out in the world of plastic packaging.
Gualapack was recently featured among other leading packaging suppliers such as Amcor, Greiner Packaging, Sidel, and KP Films in an in-depth article by the industry publication Eco-Plastics in Packaging.
The company's primary technologies include multilayer laminate structures that withstand high temperatures while preserving product integrity and extending shelf life.
Hot fill is a packaging process where products are filled into containers at elevated temperatures, typically between 85°C and 95°C, and then immediately sealed. This thermal treatment effectively eliminates harmful microorganisms without the need for chemical preservatives, extending shelf life naturally while maintaining product freshness and nutritional value. The process is particularly suitable for acidic products with low pH levels, such as fruit juices, purees, sauces, and certain beverages. Compared to cold fill or aseptic filling, hot fill technology offers significant advantages: it requires simpler equipment, reduces production costs, ensures food safety through natural thermal processing, and allows brands to create clean-label products that appeal to health-conscious consumers seeking preservative-free options.
Our range of premade pouches and spouted pouch systems are suitable for various applications, including baby food, fruit purees, sauces, and functional drinks.
Gualapack's largest segments include fruit purees, baby food, sauces, and ready-to-drink beverages such as iced teas and sports drinks. These products typically have low pH levels, making them ideal for hot fill applications, as they ensure quality and shelf stability without preservatives. The pouch format is particularly popular in these categories due to its convenience and resealability.
The hot fill industry is addressing the need for natural, preservative-free, and shelf-stable products - especially in baby food, functional beverages, and fruit-based snacks. Consumers seek convenience, lightweight, flexible, and on-the-go formats.
Gualapack has been a pioneer in the development of recyclable hot fill packaging, led by its Pouch5, a mono-material spouted pouch that meets recyclability requirements without sacrificing thermal resistance, barrier properties, or sealing strength. Pouch5 is specifically engineered to perform under hot fill conditions and be compatible with existing recycling streams.
In addition, the company has developed recyclable caps and spouts to support full-pack recyclability and continue collaborating with industry stakeholders to promote circular packaging solutions.
Gualapack also manufactures proprietary filling machines - from compact models like the CHP-1H to high-output versions like the CHP-8H - designed to pack liquid or viscous products into various pouch sizes at filling temperatures of up to 95°C. These units boast quick format changes, clean-in-place systems, and high flexibility in cap types. They reach speeds of up to 260 pouches per minute, accommodating production volumes from 10 to 65 million units per year.
Also offered are two tailored pasteurization solutions: the Pasteurization Tunnel, a compact system running a hot water shower and hot bath, processes between 100 pouches per minute; and the TT System, a linear tunnel with hot/cold water showers and turbine drying, offering 260 pouches per minute throughput, making it ideal for automatic cartoning.
Ready to explore hot fill packaging solutions?
Whether you're looking for recyclable pouches, high-speed filling equipment, or sustainable packaging that meets the latest industry standards, Gualapack has the expertise and technology crossover to support your needs. Contact us today to discuss how our hot fill solutions can help your brand achieve its sustainability goals while maintaining product quality and shelf life.