Description

The tomato processing line is adept at converting fresh tomatoes into a variety of final products. One of the most sought-after processes is the Tomato Sauce Production Line, which transforms fresh tomatoes into tomato paste, aseptically packaged in drums within aseptic bags. This comprehensive process encompasses key stages including receiving fresh tomatoes, washing, sorting, pulp extraction, mixture concentration, sterilization, and ultimately filling the product into aseptic bags within drums. The result is premium-quality tomato paste primed for distribution.

Additionally, the tomato paste in aseptic bags within drums can undergo additional processing to yield an array of products like tomato ketchup, sauces, and juice, which 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 enhanced with a focus on optimizing the labor-intensive task of unloading fresh tomatoes from trucks upon delivery. An innovative discharge platform has been specially designed for this purpose. This platform, equipped with water guns, efficiently unloads tomatoes from trucks, transports them to the processing line, and performs pre-washing of the fresh tomatoes, streamlining the initial stages of production.

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 the industrial ketchup production line, in addition to the main tomato processing equipment, the following are some auxiliary equipment that may be needed:

• Steam boiler: used to provide heating steam to supply tomato steamers and other equipment that requires steam.
• Cooling equipment: used to quickly cool down tomato products or equipment to control the temperature during processing.
• Pumps and conveying equipment: used to transport tomato pulp, juice, etc. from one equipment to another during processing.
• Steam sterilization equipment: used to steam sterilize containers, pipes, etc. to ensure the hygiene of products before filling.
• Packaging equipment: such as automatic packaging machines, sealing machines, etc., used to package processed tomato products into final products.
• Water treatment equipment: used to treat wastewater generated during processing to ensure environmental compliance.
• Odor treatment equipment: used to treat odors generated during processing to maintain air quality in the plant.

These auxiliary equipment play an important role in the processing of tomato products, helping to ensure the smooth operation of the production line and product quality. The specific auxiliary equipment required depends on the production scale, product type and processing technology requirements.