Hot fill packaging is the practice of filling and sealing the hot sterilized product in containers, then tipping the packaging on its head to sterilize the cap. While the product is tipped on its head, the packaging is rapidly cooled to complete sterilization. Some benefits of hot fill packaging methods are:

• Most products have an average 6-12 month shelf-life (several factors can cause variations in product shelf-life)
• Hot-fillable packaging is easy to obtain and available in glass and plastic options
• Using preservatives in products is optional with hot fill containers
• PET, PP, and glass packaging are sustainable resources
• Removes harmful bacteria and microorganisms for a safer product
• Allows manufacturers to offer a more natural product

Popular Uses for Hot Fill Packaging

The most popular and practical uses for hot fill processing techniques are found in the food and beverage packaging industry. Hot fill packaging like heat-set PET and clear PP plastic hot fill bottles, help reduce or eliminate the need for preservatives in products. Heat-set PET bottles are also shatter-resistant, unlike glass options, so they work well for on the go beverages. Glass hot fill bottles are still popular for many fruit juices and cold teas because they help preserve flavors longer. Other items popularly packaged using hot filling include:

• Liquid pharmaceutical products
• Vitamin or mineral enhanced water products
• Fruit and vegetable juices
• Cold teas and coffees
• Soups, stews, etc
• Bulk liquid and semi-viscous pharmaceutical, beverage, and food products

Disadvantages of Hot Fill Packaging

Hot fill packaging is useful for packaging a variety of products, but it does have disadvantages. In order to be properly sterilized using this method, the finished product must be rapidly cooled at specific temperatures. Cooling product and packaging too rapidly can cause damage to your packaging and product or worse--inadequate sterilization. Additional disadvantages to hot fill packaging are listed below.

• It doesn't work for carbonated products like soda or ginger ale
• Over-processing can affect the color, taste, and nutrient value of products
• Using glass can become costly for companies that don't want to use heat-resistant plastic packaging
• Manufacturers are unable to package solid products using hot filling techniques