How to Select the Right Container for Hot Fill Applications

Hot fill processing is a widely used method to improve food safety and extend shelf life—especially for sauces, soups, beverages, and certain ready-to-eat items. But selecting the wrong container for hot fill can lead to deformation, seal failure, or material migration. At Teinnovations, we help food brands choose container and film systems that are fully compatible with the demands of hot fill packaging.

What Is Hot Fill?

Hot fill involves filling a container with food while it’s still at an elevated temperature—typically between 180°F and 205°F. The heat helps kill microorganisms before sealing, creating a vacuum effect as the product cools. For this process to be effective and safe, the packaging must withstand:

High thermal stress
Moisture and fat exposure
Vacuum pressure during cooling

Key Container Attributes for Hot Fill

We evaluate multiple performance criteria to recommend suitable containers, including:

Thermal stability – Must maintain rigidity and shape at high temps
Seal surface integrity – Smooth, uniform rims that allow clean bonding under heat
Food-contact safety – Materials must not leach or deform under processing conditions
Vacuum tolerance – Containers must resist collapsing as they cool

Common Material Options

Based on product type and process conditions, we often recommend:

CPET trays – Dual ovenable, high heat-tolerant, and ideal for meal kits and entrees
PP containers – Microwave-safe, widely available, and effective for sauces, dips, and deli-style items
Glass or semi-rigid PET – Occasionally used in beverage or pourable applications

We guide material selection based on food chemistry, fill temperature, and your sealing equipment capabilities.

Pairing the Right Lidding Film

Just as important as the container is the lidding film. For hot fill, we recommend films that:

Are heat-sealable at elevated temperatures
Maintain adhesion during product expansion and cooling
Offer tamper evidence or peelable options depending on your use case
Meet FDA compliance for direct food contact under hot fill conditions

System-Wide Optimization

Choosing a hot fill container isn’t just about one material—it’s about ensuring that every component in your packaging system works together. That includes container material, lidding film, sealing machine settings, and fill-to-seal timing.

Not sure if your current packaging is compatible with hot fill?

Contact us today and let Teinnovations help you select and validate the ideal container system for your hot fill food product.