Portable cap sealer helps this homemade sauce ship securely

Steve Knackstedt took up serious cooking when he had to leave his physically-demanding regular job for health reasons. "Knackies"--a small, hometown restaurant in Inman, Kansas--was born as a result. When Steve's barbecue sauce became a hit not only with locals but with mail-order customers, he and his wife Kay sought help in packaging their Bear-B-Cue Sauce[TM] securely for mailing.

Steve's wife Kay discovered a nearby honey producer who was shipping product in squeezable plastic bottles. Kay contacted the local bottle maker, Container Services Inc., and discovered the plastic bottles were less expensive than glass, weighed less, would withstand pasteurization and would hold up well in shipping. But the bottles were shaped like bears--suitable for honey, but barbecue sauce?

The Knackstedts renamed their sauce "Bear-B-Cue Sauce" and went right ahead.

They also chose a TabTop[TM] flip-top dispensing closure from Seaquist Closures that is easy to open and has a directional spout for convenient pouring. For a larger container there is a 48 millimeter (mm) flat cap provided by Rexam Closures. All caps are lined with an easy-peel inserted foil inner seal from Unipac Corp.

Packaging takes place in the restaurant kitchen. The bottles are available in three sizes, named (appropriately) Papa Bear (16 ounces), Momma Bear (8 ounces) and Baby Bear (5 ounces). Knackies also produces a half-gallon jug.

Bottles are filled by hand, and lined caps are applied. But what makes the bottles really secure enough for mailing is the induction cap sealing, which is performed by an Enercon Industries Corp. Compak Jr. induction sealing unit. A handheld coil is placed over the cap and the unit's trigger pressed. The sealing cycle begins, applying heat to the cap to form the seal. The Compak Jr. was designed specifically for small runs such as that at Knackies, and can seal all three bear sizes as well as the 48 mm jar cap. To accommodate the TabTop closure's unique shape, the center of the induction sealing head unscrews to ensure complete contact and a tight seal.

Pasteurization follows, then the placing of a heart-shaped hang tag around each neck, and the sauce is off to its enthusiastic customer.

"And we haven't had a leaker yet since we started using the inner seal," he says. And, because the seal is airtight, Knackies Bear-B-Cue Sauce also has a longer shelf life--an important plus for an all-natural, preservative-free product.

For more information from Container Services Inc., call (316) 947-2664 or Circle 581. For information from Enercon Industries Corp., call (414) 255-6070 or Circle 582. For information from Rexam Closures, call (812) 867-6671 or Circle 583. For information from Seaquist Closures, call (414) 363-7191 or Circle 584. For information from Unipac Corp., call (905) 727-0114 or Circle 585.

In a nutshell

Goal: Package handmade sauces securely for shipping

How: Use a portable induction sealer

Result: Sales grow through mail-order and gift shops

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