Description

The tomato processing line is highly effective in converting fresh tomatoes into a wide array of final products. One of the most popular processes is the Tomato Sauce Production Line, which transforms fresh tomatoes into tomato paste that is aseptically packaged in drums using aseptic bags. This comprehensive process involves crucial stages including receiving fresh tomatoes, washing, sorting, pulp extraction, concentration, sterilization, and finally, filling the product into aseptic bags within drums, resulting in premium-quality tomato paste ready for distribution.

Moreover, the tomato paste stored in aseptic bags within drums can undergo additional processing to create a variety of products such as tomato ketchup, sauces, and juice. These products can be conveniently packaged in sachets, stand-up pouches, metal cans, PP containers, bottles, gable top cartons, and various other packaging formats.

• The processing capacity for fresh tomatoes is customizable, ranging from 60 tons per day to 4000 tons per day to meet varying production needs.
• Customers can choose between hot crushing or cold crushing processes for the tomatoes, depending on their preferences and specific requirements.
• The brix level of the final tomato paste can be adjusted to align with customer specifications, typically falling within the ranges of 28-30% or 36-38% for optimal taste and consistency.
• The tomato paste is carefully packaged in aseptic bags within drums, ensuring a shelf life of up to two years when stored at regular temperatures, guaranteeing product freshness and quality.
• All materials used in the production process are food-grade, with the primary materials being either SUS 304 or SUS 316, carefully selected based on the unique demands of the operation to maintain hygiene and safety standards.
• In addition to aseptic bag filling, we provide diverse packaging options such as metal cans, small sachets, stand-up pouches, and PET/PP containers for added convenience and versatility.
• Furthermore, any waste fruit or vegetables generated during the production process can be repurposed into fertilizer, promoting sustainable practices and minimizing environmental impact through efficient resource utilization.

Advantages

The Tomato Sauce Production Line from Shanghai Gofun machinery company is running with high effective, water saving, high extracting rate, safety quality control for final product, safety control for operators, etc.

Flowchart

FRESH TOMATO ⇒ CONVEYOR ⇒ WASHING ⇒ SORTING ⇒ CRUSHING ⇒ PREHEATING ⇒ PULPER & REFINER ⇒ EVAPORATING ⇒ STERILIZING ⇒ ASEPTIC FILLING ⇒ STORAGE OR BLENDING

The Tomato Production Line has been improved with a primary emphasis on streamlining the labor-intensive process of unloading fresh tomatoes from delivery trucks. An innovative discharge platform has been custom-designed for this specific task. This platform, featuring water guns, effectively unloads tomatoes from trucks, transports them to the processing line, and conducts preliminary washing of the fresh tomatoes, enhancing the efficiency of the initial production stages.

Key Components of the Tomato Sauce Production Line:

Discharge Platform with Water Guns:
The discharge platform, featuring water guns, effectively unloads and conveys fresh tomatoes from trucks to the processing line while facilitating pre-washing.
Elevator/Conveyor System:
This system is pivotal in transferring fresh tomatoes from external delivery points into the processing facility.
Washing:
Comprehensive washing of fresh tomatoes pre-crushing is vital. Bubble washing and spray washing machines are employed for this purpose. Additional washing phases can be integrated for stringent cleanliness standards, utilizing techniques like ultrasonic and ozone cleaning for enhanced effectiveness.
Sorting:
After washing, manual visual inspection is conducted to remove any substandard tomatoes.
Crushing:
The crusher operates at 1470 r/min to ensure thorough crushing of fresh tomatoes.
Preheating:
The pre-heater elevates the product's temperature post-crushing, typically adjustable between 45°C to 85°C. This step enhances juice extraction rates and preserves the color and flavor of the final tomato paste.
Pulper and Refiner:
These machines operate at 1470 r/min, utilizing centrifugal force and screens for refining. A dual-stage configuration with varying screen sizes is commonly utilized.
Evaporation:
A Forced Circulation Vacuum Evaporator concentrates the tomato paste under vacuum and low temperatures, retaining taste and nutrients and achieving paste with brix levels of 28-30 and 36-38.
Sterilization:
Tube-in-tube type sterilizers are employed for paste sterilization. The temperature and holding time are adjustable, typically heating the paste to around 115°C for 30 seconds before rapid cooling to preserve taste and nutrients.
Aseptic Filling:
An aseptic filling machine functions within a closed cycle system with the sterilizer, ensuring an aseptic environment through steam for cavity sterilization.
Storage or Blending:
The processed tomato paste can either be stored for later use or directed to blending processes as needed.

In an industrial ketchup production line, in addition to the primary tomato processing machinery, the following auxiliary equipment plays a vital role:

Steam Boiler: Supplies heating steam for tomato steamers and other steam-dependent equipment.
Cooling Equipment: Quickly cools tomato products or machinery to control processing temperatures.
Pumps and Conveyors: Transport tomato pulp, juice, etc., between processing machines.
Steam Sterilizers: Steam sterilize containers, pipes, etc., ensuring product cleanliness before filling.
Packaging Machinery: Includes automated packaging and sealing devices for packaging finished tomato products.
Water Treatment Systems: Treat processing wastewater to adhere to environmental standards.
Odor Control Systems: Manage odors produced during processing to uphold plant air quality.
These auxiliary components are essential for the smooth operation and quality maintenance of tomato product processing lines. The specific auxiliary equipment required will vary depending on production scale, product diversity, and processing technology needs.