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Making a batch

Blending and texture

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Texture is the first thing a customer notices and the last thing producers often control deliberately.

What texture you are aiming at

Decide before you blend, because it drives the closure, the bottle and the customer's experience. A thin pourable sauce wants a narrow neck and an orifice reducer. A thick one wants a wider opening and will not go through a reducer at all.

Getting that backwards is a common packaging mistake in this category: a thick sauce in a woozy bottle with a small orifice is a bottle people give up on.

The machine matters

A domestic blender makes a coarse sauce with visible particle. A high-shear blender makes a smooth emulsion-like body that resists separation. Those are different products, not different qualities.

Blending longer in a weak machine mostly adds heat and air rather than fineness. If you want smooth, the answer is a better machine or a strainer, not more time.

Air is the enemy

Blending whips air in. Air lightens the color, makes filling inaccurate because the volume is inflated, and gives you a foam head in the bottle that looks like spoilage to a customer.

Let a blended batch settle before filling, or return it briefly to heat to drive the air out. Filling straight from the blender is fast and it is why bottles come out underweight and foamy.

Hot or cold

Blending hot is easier, smoother and drives off some air on its own. It also carries capsaicin into the room, which is a real consideration at any scale and a serious one with superhots.

Blending cold is kinder to aromatics and harder on the machine. If your sauce sells on the fruity top of a habanero, cold blending and a short heat afterwards keeps more of it than a long hot blend.

References

No published source. This page is written from practice rather than from published guidance. No extension service or agency publishes on this question for hot sauce, so nothing here is cited, and it should be weighed as experience and not as a standard.
Written from published extension guidance and federal publications, not from a laboratory. Your state's requirements and your own process govern anything general said here.